ARL LKW Actros Arocs AeJ2022 2a 202207 en

Actros/Arocs Model
Series 963x/Model
Series 964x
Body/Equipment Mounting
Directives Trucks
Technical Description Edition YoM J2022 2a
Mercedes-Benz Service
Actros/Arocs Model Series 963x/

Model Series 964x
Body/Equipment Mounting
Directives Trucks
Daimler Truck AG - TE/PEX

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Image no. of title image: W00.00-A046-87
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2 Actros/Arocs Model Series 963x/Model Series 964x | Body/Equipment Mounting Directives Trucks
Introduction 11
Preface 11
Concept of these body/equipment mounting directives 13
Vehicle safety 15
Notes on copyright protection 16
Documentation of body data 17
Operator's manual and notes 18
General 19
Body manufacturer consulting 19

Certificate of non-objection 23
Product and vehicle information for body manufacturers 33
Custom Tailored Trucks Code (CTT) 37
Product safety and product liability 38
Accident prevention 39
Trademarks 40
Reuse of component parts - Recycling 42
System for quality assurance 43
Safeguards and traceability 44
Overall vehicle 45
Selection of chassis 45
Dimensions and weight specifications 47
Vehicle modifications 50
Tires 52
Soundproofing 53
Service and maintenance 54
Special equipment 57
Threaded connections and weld joints 58
General operations/modifications 66
Display without fault message 66

Line installation of Bowden cable 67
Warning boards 68
Operations prior to vehicle delivery 69
Transport mode 74
Actros/Arocs Model Series 963x/Model Series 964x | Body/Equipment Mounting Directives Trucks 3
Painting 76
Routing of electric lines, compressed air lines and fue... 84
Routing of hydraulic lines 101
Basic vehicle, general 110
Technical threshold values for planning 111
Vehicle overhang and technical wheelbases 111

Load distribution 113
Steerability 115
Clearance for major assemblies and cab 117
Frame lowering on air-sprung vehicles 118
Permissible roof loads 120
Usage-dependent limit values for total vehicle mass and... 122
Damage prevention 123
Electrical system 123

Battery - Notes on handling batteries 124
Brake hoses or cables and lines 127
Mobile communications systems 128
Electromagnetic compatibility (EMC) 129
Welding 130
Anti-corrosion protection 132
Corrosion protection-compliant welding 135
Threaded connections 136
Engine/transmission 138
Leaf springs 139
Tilt cab 140
Towing 141
Fire hazard 142
Avoiding dirt in system circuit 144
Trailer sockets 145
Non-operational time longer than 4 months 146
Redundant protection 148
Modifications at frame 150
Vehicle frame material 150

Drilling the vehicle frame 151
Welding on vehicle frame 152
Modifications to wheelbase 153
Modifications to frame overhang 159
Crossmembers and retrofitting crossmembers 164
Reinforcements in frame 166
Detachable parts at frame 167
Mounting on vehicle frame 167

Front underride guard 168
Rear underride guard ex factory 169
Rear underride guard 179
Possible locations for bolting on side protection devic... 181
Side underride guard 191
Mount of fender 193
Mounting compressors 195
Front attachments 197
Connecting devices 206
Intake air system 216
Mount of fuel tank 217
Clearance between fuel filler cap and body 219
Tank surface 220
Extension of fuel lines 222
Fuel tapping for additional assemblies 224
Installation of automatic snow chains 227
Chocks 231
Temporary spare wheel mounting for vehicle transfer 232
Hydraulic oil reservoir K6Y/K6W/K2P 233
Code C8B/C8C rear axle fender, vehicle width 2500 mm/25... 238
Code Q9A - Pre-installation, for low coupling system 239
Modifications to basic vehicle 241
Leading/trailing axle 241

Retrofitting an automatic transmission 242
Retarder 243
Hydraulic auxiliary drive (HAD) 244
Installation of propeller shafts 247
Technical weights 250
Engine preheaters 251
Coolant tap for external heat exchanger 252
Tire pressure monitoring system 253
Steering-related modifications 254
Modifications at cab 255
Cab 255
Fastening points for retrofitting the wind deflectors o... 257
Seats and bench seat 262
Exhaust gas aftertreatment system 263
Exhaust gas aftertreatment system for Euro III Standard 263

Exhaust gas aftertreatment system Euro V Standard 265
Exhaust gas aftertreatment system Euro VI Standard 268
Exhaust gas aftertreatment system GATS 2.0, Euro VI Sta... 306
Vertical exhaust system behind cab, Euro VI Standard 348
Code K7W - Exhaust system, vertical tailpipe, rotating ... 351
Remove/install exhaust flex pipe 355
Extension of insulated exhaust gas lines 359
Power take-off 360
Power take-off, general information and exhaust gas aft... 360

Tilt pump 363
Rear engine power take-off for direct flange-mounting o... 365
Rear engine power take-off with propeller shaft flange ... 373
Upper right rear engine power take-off in combination w... 379
Center upper rear engine power take-off with propeller ... 391
Center upper rear engine power take-off for direct flan... 396
Transmission power take-off 401
Transmission-independent power take-off 404
Front engine power take-off 415
Power take-off via externally installed transfer case 416
Driver assistance systems 422
Front sensors 422

Side sensors 431
Electronic Stability Program ESP(R), center of gravity ... 445
Electronic Stability Program (ESP) shutoff 451
Position and relocation of ESP(R) module 452
Driver assistance system 454
Compressed-air system 455
Repair and extension of plastic compressed-air lines of... 455

Relocating compressed-air reservoirs 458
Doubling connections of trailer brake (2 and 3-axle veh... 459
Compressed air external filling 461
Pneumatic auxiliary consumers 463
Checks after work on the brake system 479
Tolerances for dent formation on compressed-air reservo... 482
Change compressed-air line on compressor 484
Vertical compressed-air reservoir 486
Subframe 487
Subframe, general 487

Material for subframe 488
Design of subframe 489
Subframe mounting 493
Mounting of systems with exchangeable body 494
Frictional flexible connection 495
Positive rigid connection 496
Mounting with U-bolts 499
Body mountings available ex factory 500
Code C9S - Omission of attaching parts, on frame 513
Code C5M - Pre-installation, for bodies without subfram... 514
Code C5N - Frame, for refuse vehicle 515
Design of bodies 516
Design of bodies, general 516

Dropside 518
Platform and swap body 521
Self-supporting body 523
Fully integrated body 524
Waste collection vehicle body mounting 525
Tilting body 527
Roll-off container vehicle 537
Concrete mixer bodies 539
Tank vehicles and silo trucks 542
Vehicles for transport of hazardous goods 545
Cargo liftgate/loading platform 546
Loading crane body 549
Loading crane test 563
Fixed and swap bodies on semitrailer trucks 564
Other body 565
Code C7P - Clearance for swap bodies, low frame 566
Code C7Q - Clearance for crane support feet 567
Code C7R - Clearance on frame, right 568
Code C7S - Clearance on frame, left 569
Code C7U - Clearance for swap bodies, ground clearance ... 570
Code E9H - Pre-installation for cargo liftgate control 571
Code K7V - Exhaust system, 80 mm lowered 573
Code P9A - Dumper control, in cab 574
Code P9B - Trailer operation switchover 575
Code P9C - Crane operation switchover 576
Code P9D - Pre-installation, automatic side board switc... 577
Code P9F - Rear panel claw-type lock switchover 578
Electrics/electronics 579
Electrics/electronics - General, wiring diagrams, inter... 579

Work on electrical system 582
Networking 586
Battery line, low voltage 588
Installation of indicator/warning lamps in instrument c... 589
Switches, general information 594
Additional and virtual switches 608
Cable glands on cab walls 611
Extending electric lines 615
Relocating the main battery 618
Code E5A/E5B/E5C - Switch no. 1/2/3, other make body el... 620
Electrics/tap 623
Connection of electrical consumers 623
Electrical consumers up to 10 A in total 626
Electrical consumers up to 250 A in total 629
Installation of relays and fuses in the electrical comp... 640
Installation of a mechanical battery disconnect switch 644
Electrics/interfaces 645
Pre-installations/switches/connections 645
ASAM function pins 647
Standard rpm and vehicle speed signal at plug X2 650
Interfaces on cab-chassis connecting point (FF) 652
SAM with additional functions (XMC) and body/trailer CA... 665
Connection of control units with ISO 11898 671
Trailer Control 673
Communications interfaces and fleet management system 675
German regulation concerning the transport of dangerous... 678
Signal for backward rolling of vehicle 679
Electronic parking brake, request via body 680
Reversing camera 681
ABS/EBS trailer socket, 7-pin, 24 V, in combination wit... 683
Code E3B - Connecting point 12 V/15 A, for auxiliary co... 684
Code E4D - Body interface, behind cab 685
Code E4E - Engine start/stop for ABH, automatic 692
Code E6A - Trailer socket, 24 V, 15-pin 693
Code E9D - Pre-installation, double-pole battery circui... 695
Code E9E - Pre-installation for ADR, without chassis sh... 697
Code E9F Pre-installation, 2nd air suspension operating... 699
Code E9G - Pre-installation for electrical equipment 701
Code E9I - Pre-installation for switches, lift axle, se... 702
Code F8Z - Alarm system with interior sensing 703
Code J9P - Pre-installation and display for up to 4 cam... 704
Lighting 705
Lighting systems according to UN directives and German ... 705

Contour marking 706
Tail lamp installation 713
Pre-installations for installing lamps 718
Code E7B - Pre-installation for electrics/lamps, for sw... 719
Code L9A - Pre-installation for rotating beacons 721
Code L9B - Pre-installation, additional headlamps 724
Code L9C - Pre-installation, additional headlamps, roof 727
Code L9G - Pre-installation, work lamps, cab rear panel 728
Additional information 730
Overview of documents/catalogs/instructions/circuit dia... 730

Calculations 732
Code JALG - Relief control for rear loader 737
List of abbreviations 741
Attachment 742
Preface
Introduction
Certificate of non-objection Page 23
System for quality assurance Page 43
These Body/Equipment Mounting Directives provide When Daimler Truck AG is the general contractor,
body manufacturers (legal entities) and converters recommendations in the body/equipment mounting
(natural entities), hereinafter referred to collectively as directives must also be implemented on a binding basis
"body manufacturers" (ABH), with important technical (see document Certificate of non-objection).
information which must be observed in the planning and Due to the large number of body manufacturers and
production of a safe and roadworthy body. The body types involved, Daimler Truck AG cannot take into
attachments, bodies, equipment or modifications account all the possible modifications to the vehicle,
installed and implemented by the body manufacturer are e.g. driving performance, stability, load distribution,
subsequently referred to as "body mounting work". vehicle center of gravity and handling characteristics that
Daimler Truck AG prohibits all attachments, bodies, may result from body mounting work. For this reason,
equipment and modifications which could cause safety Daimler Truck AG can accept no liability for accidents or
risks, in particular injuries sustained as a result of such modifications to
• if they are not manufactured according to the safety- your vehicles. The body manufacturer undertakes to
relevant specifications of the Mercedes‑Benz body/ ensure that their body modifications are free from
equipment mounting directives, defects, including with regard to the overall vehicle, and
do not cause danger to persons or property. If this
• if they exceed the permissible gross mass, obligation is violated in any way, the body manufacturer
• if they exceed the permissible technical axle loads. shall assume full product liability.
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body/equipment mounting directives is permissible. All
Further requirements resulting from the Body/Equipment body mounting work not described here is prohibited. If,
Mounting Directives for components from other nevertheless, body mounting work that is not described
manufacturers, e.g. loading cranes etc., must also be is performed when required, always contact the relevant
observed in addition to these directives. body manufacturer support team before starting the work
or apply for a certificate of non-objection.
These Body/Equipment Mounting Directives are aimed
at professional body manufacturers. As a result, these The current valid version of all laws, standards and
Body/Equipment Mounting Directives assume that the directives, etc. as specified in these Body/Equipment
body manufacturer has suitable background knowledge. Mounting Directives always applies unless otherwise
stated (in the case of standards and directives). It is
Moreover, the body manufacturer must adhere to the important to note that technical guidelines and standards
operator's manual valid for the respective vehicle. only describe a minimum standard for the purposes of
Please be aware that certain types of work, e.g. welding product liability and product safety. The body
work on load-bearing components, may only be carried manufacturer must, on its own initiative, check whether
out by appropriately qualified personnel. This will avoid there are safety-related risks associated with the use of
the risk of injury and will attain the degree of quality the vehicle with body, which are not contained in
required for the body mounting work. standards and guidelines.
As a body manufacturer, you must always bear in mind
that only the body mounting work described in these
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If, as part of common business relations, a vehicle
These guidelines that Daimler Truck AG, as inspection is performed by a representative of
manufacturer of Mercedes-Benz vehicles, makes Daimler Truck AG, the body manufacturer is obliged to
available to body manufacturers contain important rectify any faults found on the affected vehicle prior to
technical information concerning the execution of work delivery and also to take appropriate measures that will
on the basic vehicle. This information should be permanently prevent any such faults occurring on
observed by the body manufacturer during the subsequent vehicles.
manufacture of attachments, bodies, equipment or Any vehicle inspection carried out by Daimler Truck AG
modification parts intended for Mercedes-Benz vehicles. does not release the body manufacturer from their
These guidelines are mandatory for vehicles statutory obligations such as product liability, liability for
commissioned by Daimler Truck AG as the general material defects, etc.
contractor.
Preface
Introduction
The body manufacturer will undertake to ensure that A quality management system (see Document "System
attachments, bodies, equipment or modification parts are for Quality Assurance") should be applied to ensure
not defective in themselves, nor capable of causing the specified points.
faults or hazards in the overall vehicle. If this obligation
is violated in any way, the body manufacturer shall
assume full product liability.
Concept of these body/equipment mounting directives
Introduction
Body manufacturer consulting Page 19
i
For reasons of standardization, representations,
i descriptions, code scopes and pre-installations of
To ensure the operating and road safety of the other model designations and model series are also
overall vehicles, and to avoid contravention of listed in some cases. Only the information valid for
warranty conditions, the information in all the tabs your model designation/model series is to be used.
must be strictly observed.
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The Mercedes-Benz Body/Equipment Mounting • Power take-off
Directives are organized into tabs in order to ensure • Driver assistance system
optimum clarity.
• Compressed-air system
• Introduction
• Subframe
• General
• Design of bodies
• Overall vehicle
• Electrics/electronics
• Work/modifications in general
• Electrics/power tapping
• Technical limit values for planning
• Electrics/interfaces
• Damage prevention
• Illumination
• Modifications to the basic vehicle
• Additional information
• Exhaust gas aftertreatment system (not for
BM C983x)
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Model 405, 437 The following documents should be made available to
The development and coordination of equipment or the body manufacturers and the companies that attach
attachments and bodies for the Unimog do not, in equipment to the UNIMOG or install bodies:
principle, entitle to legal claims for costs or damages • The current UNIMOG price list or equipment list with
against Daimler Truck AG. The involvement of Daimler the available UNIMOG models and special
Truck AG in solving technical problems is of an advisory equipment
nature only. This also applies for equipment operated in • The applicable Technical Manual with the complete
the Federal Republic of Germany in respect of technical data and important additional information
compliance with the provisions of road traffic legislation
and accident prevention in the context of the German • The applicable UNIMOG body/equipment mounting
Technical Equipment Law (Gesetz über technische directive with the complete information on equipment
Arbeitsmittel). mounting and the requirements of Daimler Truck AG
for equipment mounting
Daimler Truck AG refers here expressly to the fact that
the body manufacturer is responsible for its delivery • The applicable CAD data records
package and for complying with the safety regulations to
be observed with respect to the vehicle/equipment
interface.
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On account of the ongoing technical evolution of the Mercedes-Benz Bodybuilder Portal (http://bb-
Mercedes-Benz truck products, body manufacturers are portal.mercedes-benz-trucks.com) in the same way
notified at points between the regular publication dates as the body/equipment mounting directives. With their
about the latest topics or contents/updates as part of a publication in the Bodybuilder Portal, they become an
"Changes to the Body/Equipment Mounting Directives" integral part of the latest Body/Equipment Mounting
document. Directives and must be complied with.
The "Changes to the Body/Equipment Mounting Illustrations and schematic drawings are examples only
Directives" are freely accessible and can be called up in and serve to explain the texts and tables.
Concept of these body/equipment mounting directives
Introduction
All graphics are for illustrative purposes only and they do EPC can be found in the Mercedes‑Benz Bodybuilder
not depict all the technical details faithfully. Portal.
The parts listed in these Body/Equipment Mounting You can receive further information from any Daimler
Directives can be found under the specified part Truck Service Partner.
numbers in the Electronic Parts Catalog (EPC). The
Vehicle safety
Introduction
i i
Modifications to electronic components, their Body mounting work and modifications can
software or wiring can impair their functioning and/or invalidate the operating permit. Always observe
the functioning of other networked components. national registration regulations, laws and
Safety-relevant systems in particular may also be guidelines. This applies in particular for
affected. Because of this, they may no longer modifications:
function properly and/or compromise the operational which change the vehicle type approved in the
safety of the vehicle. There is a heightened risk of general operating permit,
accident and injury for the user/operator! Never carry
which could endanger road users,
out any modifications to the wiring and electronic
components or their software. Have all work on which adversely affect exhaust gas emissions or
electrical and electronic equipment carried out at a noise levels.
qualified specialist workshop.
i
Avoid potential danger to persons and property
damage due to unfamiliarity. Before starting to install
other make bodies or equipment, please read the
relevant chapters of these Body/Equipment
Mounting Directives, the instructions and information
from the equipment supplier and the detailed
operator's manual for the base model vehicle.
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Vehicle modifications by the body manufacturer The vehicles must still comply with EC and/or UN-R
It is recommended that you use the parts, major regulations and national regulations after modifications
assemblies, conversion parts and accessory parts that have been carried out.
have been tested and found suitable by Daimler Truck The body manufacturer must inform the officially
AG for the model of vehicle concerned. If parts, major recognized approval authority or inspector of any
assemblies, conversion parts or accessory parts are modifications to the basic vehicle. The approval and
used that have not been recommended, have the safety inspection organizations will decide on compliance with
of the vehicle verified without delay. legislation and regulations after any modifications made
Before starting body mounting work, the body to the basic vehicle, and therefore on the registration
manufacturer must check whether: requirements for the complete vehicle.
• the vehicle is suitable for the planned body, Modifications which invalidate the approvals
(construction, system or type-approval certificates) for
• the vehicle model and equipment are suitable for the the base model vehicle, must be reobtained or reverified
operating conditions intended for the body. by the body manufacturer.
Standard production vehicles comply ex factory with EC The body manufacturer, as the manufacturer of the
and UN-R directives and national regulations (vehicles overall vehicle, assumes the responsibility for these new
produced for countries outside of Europe may be approvals.
exceptions). If all of the legislation cannot be satisfied,
the vehicle is to be delivered with an EU data
confirmation instead of a CoC document.
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Cyber Security Direct electronic access to the vehicle networks
Signals can only be picked off or supplied at predefined (e.g. CAN bus, CAN star point) is not permissible.
points, on parameterizable special modules (PSM). The body manufacturer is obliged to notify Daimler
Make sure that there is no unauthorized access to the Trucks about any weak points in the body's electronics
PSM (body CAN and trailer CAN) or that any malicious system and any cyber security attacks on the body.
data are imported into it. If this is neglected, be it knowingly or unknowingly, the
Access to the electronics of the underlying vehicle may vehicle approval shall expire in accordance with UN
only be possible as part of the body's defined ECR R155 as shall the vehicle registration.
functionality.
Notes on copyright protection
Introduction
All the text, illustrations and data contained in this Body/ If you have any questions, please contact
Equipment Mounting Directive are protected by Mercedes‑Benz Customer Assistance.
copyright: Telephone: 00800 97 777‑777
Confidential! All rights reserved. Disclosure or Fax: 069 95 30 7255
reproduction is only permitted with the written
consent of Daimler Truck AG.
Documentation of body data
Introduction
The body manufacturer must ensure compliance with (http://bb-portal.mercedes-benz-trucks.com)
Directive 2001/95/EC concerning general product safety. The body data entered in the Bodybuilder Portal is also
It follows that, among other things, all work and imported into the Mercedes-Benz workshop systems in
modifications performed on the chassis as well as order to make the procurement of replacement parts
mounted bodies/attachments must be documented in the easier for Mercedes-Benz service partners in case of
Mercedes-Benz maintenance booklet and in the repairs/damage and to thus minimize the vehicle's
Mercedes-Benz Bodybuilder Portal. workshop stay.
Operator's manual and notes
Introduction
As a result of mounting major assemblies and bodies on The operator must be informed of any requirements that
Mercedes-Benz chassis, it is necessary to attach result from a certificate of non-objection issued by the
operating, warning and safety information to the vehicle responsible department, e.g. max. axle loads.
and to supplement the accompanying vehicle documents This can be done by means of a note in the operating
with operating instructions and safety information instructions for the body, information labels on or in the
specific to the mounted attachments, equipment, vehicle, or similar.
modification parts and body.
Serial numbers, identification numbers, body
All body work that is subject to the European Machinery designations, major assembly types of the attachments
Directive must be provided with a CE mark and the EC or bodies must be documented in the accompanying
declaration of conformity must be enclosed with the documents.
accompanying vehicle documents.
Body manufacturer consulting
General
The team responsible for vehicle conversion/body
manufacturers and Body/Equipment Mounting Directives i
issue certificates of non-objection and answer technical Please be aware of First and Second Level Support:
and design-engineering questions regarding vehicle
All the contact persons listed here are to be
registration and damage cases.
considered as first points of contact only for vehicles
The Quality Management team carries out acceptance registered in the Federal Republic of Germany (First
inspections in the context of transactions where Daimler Level Support Germany).
Truck AG is the general contractor (single invoice For all other vehicles, please contact the national
transactions). Mercedes‑Benz Sales Germany in Berlin general distributors directly (First Level Support for
is available for matters relating to weight changes, tire country of registration).
changes and towing capacities. The point of contact for
Data and information concerning application for non-
vehicle configurations and special equipment is the
objections and certificates should also be sent to
Technical Consulting team at the Mercedes-Benz plant
these organizations first.
in Wörth am Rhein.
If necessary, these organizations will contact the
contact persons listed here by way of Second Level
Support.
You can find the relevant national contact persons at
the general distributor in the Mercedes-Benz
Bodybuilder Portal.
(http://bb-portal.mercedes-benz-trucks.com)

Quality Management (QM)
Responsibility
Contact person: Stephan Folk Team Manager

Tel.: +49 7271 71 5400 Actros, Arocs, Atego, Zetros, Econic, Unimog
Email: bb-qm@daimlertruck.com
General

Actros, Arocs, Atego
Responsibility
Contact person: Martin Glaser Team Manager

Tel.: +49 160 867 28 35 Actros, eActros, Arocs, Atego
Contact person: Carsten Hirt Technical Weights, Tire Change, ESP®

Tel.: +49 711 8485 3842 Actros, eActros, Arocs, Atego
Marius Marxer Certificates of Non-Objection

Peter Neffle Certificates of Non-Objection

Rafael Scandelari Certificates of Non-Objection

Süleyman Özyer Certificates of Non-Objection

Written Queries: Written queries and applications for certificates of non-objection can be submitted via the
email address: bbe@daimlertruck.com.
Postal address: Daimler Truck AG

Fasanenweg 10
70771 Leinfelden-Echterdingen
Germany
General

Econic, Unimog, Zetros
Responsibility
Contact person: Rainer Thomas Team Manager

rainer.thomas@daimlertruck.com Body Coordination
Tel.: +49 7271 71 7614 Econic, Unimog, Zetros
Contact person: Sascha Pompejus Econic (model series 956.0/.4)

sascha.pompejus@daimlertruck.com
Tel.: +49 7271 71 7774
Thomas Wagenblatt Econic (model series 956.5), Zetros (model

thomas.wagenblatt@daimlertruck.com series 959)
Tel.: +49 7271 71 8479
Volker Jungmann U216 – U530 (UGN and UGE)

volker.jungmann@daimlertruck.com
Tel.: +49 7271 71 7623
Andreas Rödler U4000 - U5023 (UHN and UHE)

andreas.roedler@daimlertruck.com
Tel.: +49 7271 71 7597
Stefan Tauras Offer Drawings, 3D Models

stefan.tauras@daimlertruck.com
Tel.: +49 7271 71 7926
Mario Messina Marketing, Processes and Contracts

mario.messina@daimlertruck.com
Tel.: +49 7271 71 8714
Fax: +49 7271 71 8086
Postal address: Daimler Truck AG

HPC (in-house post code) K 142
Body Manufacturer Management MBS
Daimlerstrasse 1
D-76742 Wörth am Rhein
General

General: Actros, Arocs, Atego

Point of Contact for Weight Mercedes‑Benz Sales Germany

Changes, Tire Changes and Email:
Towing Capacities:
hebeo-truck@daimlertruck.com
Tel.: +49 900 1844 559
(€1.99/min
(applies to calls from Germany))
Postal address: Department: VDS, in-house post code:

HPC V620
10787 Berlin
Point of Contact for Vehicle Technical Advice for Body Manufacturers

Configurations and Special Mercedes‑Benz Trucks
Equipment:
Tel: +49 7271 71 2506
Email: sosbb@daimlertruck.com

General: Econic, Unimog, Zetros

Point of Contact for Weight Daimler Truck AG

Changes, Tire Changes and Department: TE/OR-PP
Towing Capacities:
In-house post code: HPC K141
D-76742 Wörth am Rhein
Email: mbox_060_hebembs@daimlertruck.co
m
Tel.: +49 7271 71 7615
Fax.: +49 7271 71 71 737615
Point of Contact for Vehicle Technical Advice MBS

Configurations and Special Tel: +49 7271 71 2503
Equipment:
Email: sosmbs@daimlertruck.com
• Please have the vehicle identification number ready • Details of the required towing capacity and type
for telephone queries. (pivoted logging frame or rigid drawbar and center-
• For written queries, please use the request form axle trailer operation)
available from the Mercedes-Benz Workshop • For rigid drawbar and center-axle trailer operation,
Information System (WIS). information on tongue weight, Dc and V value (copy
Additional information required: of motor vehicle registration certificate)
• Readable copy of the motor vehicle registration • Information on any rear-heavy implements, e.g.
certificate cargo liftgate, rear loading crane
Certificate of non-objection
General
Roll-off container vehicle Page 537
i
For reasons of standardization, representations,
code scopes and pre-installations of other model
designations and model series are listed in this
chapter. Only the information valid for your model
designation/model series is to be used.
---------------------------------------------------------------------------
Certificate of non-objection (CNO) their effect on the base model vehicle, but does not carry
Daimler Truck AG does not issue any body/equipment out any design-related activities itself, e.g. dimensioning
approvals for other-make bodies. These directives only of a subframe.
supply important information and technical specifications The certificate of non-objection shall not refer to the
to body manufacturers explaining how to handle the overall design of the body, its functions or its intended
product. Daimler Truck AG requires that all work on the application. The certificate of non-objection shall only be
basic vehicle and body is performed in compliance with valid if design, production and assembly are performed
the permissible gross mass and permissible technical by the body manufacturer carrying out the modifications
axle load and in accordance with the current Mercedes- in accordance with the state of the art, and in
Benz body/equipment mounting directives applicable to compliance with the valid Body/Equipment Mounting
the vehicle. Directives of Daimler Truck AG – unless deviations from
Daimler Truck AG issues certificates of non-objection on these directives are endorsed. Nevertheless, the
a voluntary basis in accordance with the following certificate of non-objection does not release the body
criteria: manufacturer carrying out the modifications from its
responsibility for the product or its obligation to perform
Daimler Truck AG's assessment shall be based solely on its own calculations, tests and trials in order to ensure
the documents submitted by the body manufacturer that the overall vehicle produced by the company meets
carrying out the modifications. The assessment and the required specifications for operational safety, road
certification shall only cover the expressly defined safety and handling characteristics.
scopes and their basic compatibility with the designated
chassis and its interfaces or, in the case of chassis Accordingly, it shall be the sole duty and responsibility of
modifications, the basic feasibility of the design for the the body manufacturer to ensure the compatibility of its
designated chassis. body mounting work with the basic vehicle and to
guarantee the operating and road safety of the vehicle
Here, Daimler Truck AG only checks complete and to guarantee that it can be approved.
attachments, bodies, equipment and modifications and
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Application for a certificate of non-objection not refer to the overall design of the body, its function or
A certificate of non-objection becomes necessary when its intended application. A distinction is made between
the modification work goes beyond the requirements of single certificates of non-objection (vehicle identification
the Body/Equipment Mounting Directives. The number-related) and concept certificates of non-
assessment and certification shall only cover the objection (vehicle model designation-related). Apply with
compatibility of the body solution with the basic vehicle a regular e-mail to the contact person (see document
and its interfaces. The certificate of non-objection shall "Advice for body manufacturers").
---------------------------------------------------------------------------
Legal claims from it, even if a similar certificate was issued in the
• No legal claim can be made as to the issuance of a past.
certificate of non-objection. • The certificate of non-objection applies only for the
• Daimler Truck AG reserves the right to revoke the specifically requested body and the specifically
issue of a certificate of non-objection due to ongoing requested vehicle. For further vehicle modifications to
technical development and the knowledge gained the body or for bodies on a different vehicle, a new
certificate of non-objection is required in each case.
General
• The retroactive issue of a certificate of non-objection • Operating and road safety

for vehicles already completed or delivered can be • All body modifications and fitted parts
refused.
• Eligibility for registration in the destination country
• The body manufacturer alone shall be responsible for
compliance with the following requirements:
• The functionality and compatibility with the basic
vehicle of its body modifications
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General contractor of Daimler Truck AG Equipment Mounting Directives must be observed on a
For vehicles where Daimler Truck AG is the main binding basis. A CNO must be requested for any
contractor (known as "single-invoice transactions"), the deviations from the directives.
requirements and recommendations of the Body/
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Information required to request a certificate of non- • Safety (DS)/certification relevance (DZ)
objection • Emissions specifications (FOG/VOC)/
To conduct an assessment as part of a certificate of non- specifications on inflammability as well as all other
objection, the following documents and drawings must certification-relevant scopes.
be submitted before commencing any work on the • Tests and certifications:
vehicle in accordance with the scheduled body mounting
work, e.g. electrical/electronic-related scopes, • Test reports, description of test sequence and test
mechanical modifications: setup
• General information about the body manufacturer • Proof of homologation
(contact persons/contact details/email/telephone • CE mark, seat tensile strength test etc.
number)
Submitting the required documentation in full will make
• Details on base model vehicle (vehicle model queries on our part unnecessary, and it will speed up the
designation/vehicle identification number/order procedure.
number/equipment list)
If complex computations and/or vehicle tests are
• Description of the planned body: necessary for the non-objection check, all costs incurred
• Function description of the new system must be borne by the body manufacturer or its client.
• All deviations from the Mercedes-Benz Body/ The submitted information shall be treated confidentially
Equipment Mounting Directives by Daimler Truck AG and shall not be handed over to
third parties without the prior approval of the creator/
• Influence on the base model vehicle sender.
• Data on dimensions, weights and centers of When applying for load capacity increases, the following
gravity (weight certificates) documents must be submitted:
• Body mounting to vehicle • A dimensioned drawing of the body layout which
• Usage profile/markets clearly indicates the permanent installations
• List of removed/modified Daimler Truck AG parts (generally a plan view).
(module/item number/major assembly model • A record of the weights of the vehicle in the ready-to-
designation/code) drive state, including axle loads
• Design/wiring diagram: Roll-off dump truck - General information
• Parts lists (item, material, weight etc.) • Stability analysis for work mode/loading roll-off
• Installation instructions container (both calculations based on technically
• Design data (3D data incl. installation location, permissible axle loads/gross vehicle mass)
etc.) • Distance from start of roll-off container to center of
• Interface with the base model vehicle: front axle
• Mechanical interface with the base model vehicle • Distance from end of roll-off container to center of
(dimensions, tolerances, welded and adhesively front axle
bonded connections, fasteners etc.) • Distance from start of roll-off dump truck frame to
• Electrical interface with the base model vehicle center of front axle
and wiring diagram (electrical connection/pin • Distance from start of roll-off dump truck frame to
assignment/actuation of electrical components center of front axle
etc.)
General
• Distance from end of roll-off dump truck frame to • Distances from end of sectional transitions to center
center of front axle of front axle
• Frame dimensions of roll-off dump truck, material • Illustration and dimensioning of respective sectional
thickness and material class transitions
• Information about/illustration of subframe mounting If a hydraulic axle support is installed on the rear
on vehicle frame axle for work mode of the roll-off dump truck
• Distance (start) of rigid connection of subframe and • Installation sketch/photographic documentation of
vehicle frame to center of front axle design/mounting of hydraulic axle support on vehicle
• Information about design of torsion-stiffening with specification of effective lever arms and intended
measures in subframe threaded connections to vehicle frame.
Additional specifications of sectional changes in • Specification of actual maximum effective vertical

subframe force on support cylinder (further boundary
conditions), (see document "Roll-off dump truck").
• Distances from start of sectional transitions to center
of front axle

Specification of the following

values
GC Overall container load
(based on technically
permissible axle loads/gross
mass/vehicle)
L Overall length of roll-off
container
XR X-value for center of
discharge roller (from center
of front axle)
HR Height of roller (top) above
roadway
hC Height of load center above
roller plane
α Roll-off container angle when
lifting off W00.00-A024-05
XG X-value of gripper arm pivot
point
XS X-value for payload (if
known)
HG Height of gripper over axle
roller
Additional information required for combination of • Distance from center of trailer coupling pin to center
roll-off dump truck and crossmember/overhang/ of front axle
trailer coupling combinations for rigid drawbar • On trailer couplings: Distance from center of trailer
trailer (SDAH) or center axle trailer (ZAA) operation coupling pin to upper edge of vehicle frame and
that are not approved ex factory information/illustration/mounting of trailer coupling to
• V-value vehicle frame
• Dc value • Axle load calculation empty/loaded with specification
of individual weights and positions and tongue weight
• Tongue weight
at trailer coupling (based on technically permissible
• Permissible gross mass of SDAH or ZAA (without axle loads/gross vehicle mass)
tongue weight)
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Skip loader - General information • Drawing of body/overall body situation
• Stability analysis for work mode/loading skip • Distance from start of skip container to center of front
container (both calculations based on technically axle
permissible axle loads/gross vehicle mass)
General
• Distance from end of skip container to center of front Additional information required for combination of
axle skip loader and end crossmember/overhang/trailer
• Distance from start of skip loader subframe to center coupling combinations for rigid drawbar trailer
of front axle (SDAH) or center axle trailer (ZAA) operation that are
not approved ex factory
• Distance from end of skip loader subframe to center
of front axle • V-value
• Skip loader subframe dimensions, material thickness • Dc value

and material class • Tongue weight
• Information about/illustration of subframe mounting • Permissible gross mass of SDAH or ZAA (without
on vehicle frame tongue weight)
• Distance (start) of rigid connection of subframe and • Distance from center of trailer coupling pin to center
vehicle frame to center of front axle of front axle
• Information about design of torsion-stiffening • On trailer couplings: Distance from center of trailer
measures in subframe/superstructure coupling pin to upper edge of vehicle frame and
information/illustration/mounting of trailer coupling to
Additional specifications of sectional changes in vehicle frame
subframe
Axle load calculation empty/loaded with specification of
• Distances from start of sectional transitions to center individual weights and positions and tongue weight at
of front axle trailer coupling (based on technically permissible axle
• Distances from end of sectional transitions to center loads/gross vehicle mass)
of front axle
• Illustration and dimensioning of respective sectional
transitions
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Cement mixer vehicle • Information about design of torsion-stiffening
measures in subframe
General information
• Information about/illustration of design of torsion-
• Drawing of body/overall body situation stiffening measures in subframe
• Distance from start of subframe to center of front axle • Information about/illustration of subframe mounting
• Distance from end of subframe to center of front axle on vehicle frame
• Distance from center of front axle to start of front • Information about possible frame modifications/
drum bearing bracket overhang modifications
• Distance from center of front axle to end of front drum Additional specifications of sectional changes in
bearing bracket subframe
• Distance from center of front axle to start of rear • Distances from start of sectional transitions to center
drum bearing bracket of front axle
• Distance from center of front axle to end of rear drum • Distances from end of sectional transitions to center
bearing bracket of front axle
• Planned service countries • Illustration and dimensioning of respective sectional
• Subframe dimensions and material class transitions
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Dump truck possibly with rigid drawbar trailer or • Subframe dimensions, material thickness and
center axle trailer material class
General information • Distances from contact points of dump body on

subframe to center of front axle (generally front dump
• Drawing of body/overall body situation truck crossmember, rear tilt shaft and possibly with
• Distance from start of dump truck to center of front additional "center contact point" in area of dump truck
axle lift ram)
• Distance from end of dump truck to center of front • Information about/illustration of design of torsion-
axle stiffening measures in subframe
• Distance from start of subframe to center of front axle • Information about/illustration of subframe mounting
on vehicle frame
• Distance from end of subframe to center of front axle
General
Additional specifications of sectional changes in • Distances from end of sectional transitions to center
subframe of front axle
• Distances from start of sectional transitions to center • Illustration and dimensioning of respective sectional
of front axle transitions

Specification of following values

(see illustration "Required
information for dump trucks")
GKges Payload (based on
technically permissible
axle loads/gross
vehicle mass)
XKges Distance from center of
front axle to dump
truck payload center of
gravity (dump truck in
drive position)
XZyl Distance from center of
front axle to center of
tilt cylinder bearing in
subframe
XDA Distance from center of W00.00-A025-05
front axle to center of Necessary dump truck information
dump truck pivot/tilt
shaft
Xi Tangential coordinate
hc Height of payload
center of gravity
relative to center of
pivot/tilt shaft (dump
truck in drive position)
α Maximum tilt angle
1 Subframe
2 Tilt cylinder
3 Tilt load (total mass)
Position untilted/at start
of tilting
4 Dump truck pivot
Additional information required for combination of • Distance from center of trailer coupling pin to center
dump truck and end crossmember/overhang/trailer of front axle
coupling combinations for rigid drawbar trailer • On trailer couplings: Distance from center of trailer
(SDAH) or center axle trailer (ZAA) operation that are coupling pin to upper edge of vehicle frame and
not approved ex factory information/illustration/mounting of trailer coupling to
• V-value vehicle frame
• Dc value • Axle load calculation empty/loaded with specification
• Tongue weight
• Permissible gross mass of SDAH or ZAA (without axle loads/gross vehicle mass)
tongue weight)
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Curtainsider/platform truck, possibly with rigid • Distance from start of body to center of front axle
drawbar trailer or center axle trailer • Distance from end of body to center of front axle
General information • Distance from start of subframe to center of front axle
• Drawing of body/overall body situation • Distance from end of subframe to center of front axle
General
• Subframe dimensions, material thickness and • Dc value

material class
• Tongue weight
• Information about/illustration of subframe mounting
• Permissible gross mass of SDAH or ZAA (without
on vehicle frame
tongue weight)
Additional specifications of sectional changes in • Distance from center of trailer coupling pin to center
subframe of front axle
• Distances from start of sectional transitions to center • On trailer couplings: Distance from center of trailer
of front axle coupling pin to upper edge of vehicle frame and
• Distances from end of sectional transitions to center information/illustration/mounting of trailer coupling to
of front axle vehicle frame
• Illustration and dimensioning of respective sectional • Axle load calculation empty/loaded with specification
transitions of individual weights and positions and tongue weight
Additional information required for combination of axle loads/gross vehicle mass)
platform and end crossmember/overhang/trailer
coupling combinations for rigid drawbar trailer
(SDAH) or center axle trailer (ZAA) operation that are
not approved ex factory
• V-value
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Tank/silo bodies • Subframe dimensions, material thickness and
material class
General information
• Position of tank/silo body bearing on subframe
• All refueling conditions/chamber fillings (based on relative to center of front axle
technically permissible axle loads/gross vehicle
mass) • Specification of tank/silo body version (rigid/flexible)
• Drawing of body/overall body situation • Information about/illustration of design of torsion-

stiffening measures in subframe
• Distance from start of tank/silo body to center of front
axle • Information about/illustration of subframe mounting
on vehicle frame
• Distance from end of tank/silo body to center of front
axle Additional specifications of sectional changes in
With continuous subframe: subframe
• Distance from start of front subframe to center of • Distances from start of sectional transitions to center
front axle of front axle
• Distance from end of subframe to center of front axle • Distances from end of sectional transitions to center
of front axle
With split subframe:
• Illustration and dimensioning of respective sectional
• Distance from start of front subframe to center of transitions
front axle
• Distance from end of front subframe to center of front
axle i
• Distance from start of rear subframe to center of front Where necessary, the body manufacturer must
axle supply proof of compliance with UN‑R 111 "Tilt
stability of tank vehicles", indicating the following
• Distance from end of rear subframe to center of front
values. (see the table)
axle

General

GKges Payload (based on technically permissible axle loads/gross vehicle mass)
XKges Distance from center of front axle to fuel tank payload center of gravity
hc Height of payload center of gravity
For trailer operation • Distance from center of trailer coupling pin to center
of front axle
Additional information required for combination of
towing vehicle and end crossmember/overhang/ • On trailer couplings: Distance from center of trailer
trailer coupling combinations for rigid drawbar coupling pin to upper edge of vehicle frame and
trailer (SDAH) or center axle trailer (ZAA) operation information/illustration/mounting of trailer coupling to
that are not approved ex factory vehicle frame
• V-value • Axle load calculation empty/loaded with specification

• Dc value at trailer coupling (based on technically permissible
• Tongue weight axle loads/gross vehicle mass)
• Permissible gross mass of SDAH or ZAA (without

tongue weight)
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Roll-off dump truck with loading crane • Specification of static weight moment of crane
General information • Specification of maximum static lifting moment of

crane towards front in the direction of travel
• Stability analysis of loading crane work mode
• Specification of maximum static lifting moment of
• Stability analysis for roll-off dump truck work mode, crane towards rear in the direction of travel
empty/loaded (based on technically permissible axle
loads/gross vehicle mass). Additional specifications of sectional changes in
• Drawing of body/overall body situation subframe
• Distance from center of crane pivot pin to vehicle • Information regarding connection of subframe in
center crane area to roll-off dump truck subframe
• Distance from center of right supporting leg to center • Information about design of torsion-stiffening
of front axle measures in subframe
• Distance from center of left supporting leg to center • Crane plate/loading crane side plate dimensions,
of front axle material thickness and material class
• Distance from front crane U-bolt mounting to center • Start and end of crane side plate/loading crane side
of front axle plate relative to center of front axle
• Distance from rear crane U-bolt mounting to center of • Mounting of subframe/roll-off dump truck frame to
front axle vehicle frame behind crane plate up to frame end
• Distance from start of subframe to center of front axle If a hydraulic axle support is installed on the rear
• Distance from end of subframe to center of front axle axle for work mode of the roll-off dump truck
• Distance from start of roll-off dump truck hydraulic oil • Installation sketch/photographic documentation with
reservoir to center of front axle specification of effective lever arms and intended
threaded connections to vehicle frame
• Distance from end of roll-off dump truck hydraulic oil
reservoir to center of front axle • Specification of actual maximum effective vertical
force on support cylinder
• Subframe dimensions, material thickness and
material class in crane area • The support for the cylinder at the end of the leaf
springs may only take the form of a plastic support on
• Subframe dimensions, material thickness and the piston rod of the cylinder (not steel on steel).
material class of roll-off dump truck

General
Specification of the following

values (see the figure "Required
information for roll-off dump
trucks with loading crane")
Gc Overall roll-off container load
(based on technically
permissible axle loads/gross
vehicle mass)
L Overall length of roll-off
container
XR X-value for center of
discharge roller (from center
of front axle)
HR Height of roller (top) above
roadway
hc Height of load center above
roller plane W00.00-A024-05
α Roll-off container angle when Required information for roll-off dump trucks with loading crane
lifting off
XG X-value of gripper arm pivot
point
XS X-value for payload (if
known)
HG Height of gripper over axle
roller
A Distance from vehicle center to center of pivot pin

1 Crane pillar center
2 Vehicle center
3 Pivot pin center
W00.00-A030-01
---------------------------------------------------------------------------
Loading crane possibly with rigid drawbar trailer or • Distance from center of right crane supporting leg to
center axle trailer center of front axle
General information • Distance from center of left crane supporting leg to

center of front axle
• Stability analysis of loading crane work mode (based
on technically permissible axle loads/gross vehicle • Distance from center of left additional support
mass) supporting leg to center of front axle
• Drawing of body/overall body situation • Distance from center of right additional support
supporting leg to center of front axle
• Distance from start of body to center of front axle
• Distance from front crane U-bolt mounting to center
• Distance from end of body to center of front axle of front axle
• Distance from start of subframe to center of front axle • Distance from rear crane U-bolt mounting to center of
• Distance from end of subframe to center of front axle front axle
General
• Subframe dimensions, material thickness and • Distances from end of sectional transitions to center
material class of front axle
• Information about/illustration of design of torsion- • Illustration and dimensioning of respective sectional
stiffening measures in subframe transitions
• Information about/illustration of subframe mounting Additional information required for combination of
on vehicle frame rear crane and operation with SDAH or ZAA
• Crane plate/loading crane side plate dimensions, • V-value
material thickness and material class
• Dc value
• Start of crane side plate/loading crane side plate to
center of front axle End of crane side plate/loading • Tongue weight
crane side plate to center of front axle • Permissible gross mass of SDAH or ZAA (without
• Distance from start of rigid connection of subframe tongue weight)
and vehicle frame to center of front axle • Distance from center of trailer coupling pin to center
• Specification of maximum static lifting moment of of front axle
crane towards front in the direction of travel • On trailer couplings: Distance from center of trailer
• Specification of maximum static lifting moment of coupling pin to upper edge of vehicle frame and
crane towards rear in the direction of travel information/illustration/mounting of trailer coupling to
vehicle frame
• Specification of static weight moment of crane
• Axle load calculation empty/loaded with specification
• Specification of distance "A" from center of crane
pivot pin to vehicle center (see the following figure)
Additional specifications of sectional changes in axle loads/gross vehicle mass)
subframe
• Distances from start of sectional transitions to center
of front axle

A Distance from vehicle center to center of pivot pin

1 Crane pillar center
2 Vehicle center
3 Pivot pin center
W00.00-A030-01
---------------------------------------------------------------------------
Cargo liftgate possibly with rigid drawbar trailer or • Distance from start of rigid connection of subframe
center axle trailer and vehicle frame to center of front axle
General information Additional specifications of sectional changes in

• Distance from start of body to center of front axle subframe
• Distance from end of body to center of front axle • Distances from start of sectional transitions to center
of front axle
• Distance from start of subframe to center of front axle
• Distances from end of sectional transitions to center
• Distance from end of subframe to center of front axle of front axle
• Subframe dimensions, material thickness and • Illustration and dimensioning of respective sectional
material class transitions
• Information about/illustration of subframe mounting
on vehicle frame
General
Specification of the following values (see the figure • Permissible cargo liftgate payload
"Cargo liftgate in driving mode" and "Cargo liftgate • Details of screw connection of cargo liftgate to
in work mode") subframe/vehicle frame
• Specification of number of cargo liftgate lift cylinders
on right in direction of travel Additional information required for combination of
cargo liftgate and SDAH or ZAA
• Specification of number of cargo liftgate lift cylinders
on left in direction of travel • V-value
Driving mode: • Dc value
• EG - Dead weight of cargo liftgate • Tongue weight
• A1 - Distance from dead weight center of gravity (EG) • Permissible gross mass of SDAH or ZAA (without
of cargo liftgate to center of front axle tongue weight)
Cargo liftgate work mode (lifting arm and platform • Distance from center of trailer coupling pin to center
position horizontal/maximum deflection): of front axle
• EG - Dead weight of cargo liftgate • On trailer couplings: Distance from center of trailer
coupling pin to upper edge of vehicle frame and
• A2 - Distance from dead weight center of gravity of
information/illustration/mounting of trailer coupling to
cargo liftgate to center of front axle
vehicle frame
• N - Maximum lift capacity/cargo liftgate payload
• Axle load calculation empty/loaded with specification
• A3 - Distance from payload center of gravity to center of individual weights and positions and tongue weight
of front axle at trailer coupling (based on technically permissible
• Position of additional cargo liftgate supports relative axle loads/gross vehicle mass)
to center of front axle
• Theoretical proof of stability (based on technically
permissible axle loads/gross vehicle mass/
technical)

W00.00-A026-01 W00.00-A027-01
Cargo liftgate during driving operation Cargo liftgate in work mode
Product and vehicle information for body manufacturers
General
Along with the possibility of making direct contact with manufacturers" document), you – in your role as body
the body manufacturer support contact persons at manufacturer – can also obtain detailed information
Mercedes-Benz (see "Advice for body about our products and systems.
---------------------------------------------------------------------------
Bodybuilder Portal • Body/Equipment Mounting Directives archive for all
The Mercedes‑Benz Bodybuilder Portal is the central truck model series
communication platform of Daimler Truck AG and the • Power take-off drawings in installation position in
body manufacturer industry. PDF and DXF format
Next we will introduce individual modules of the portal in • Vehicle equipment of Mercedes-Benz commercial
more detail. Make the most of the benefits of the vehicles: Sales codes, brief descriptions and
Mercedes-Benz Bodybuilder Portal! technical details of all packages (including "Custom
http://bb-portal.mercedes-benz-trucks.com Tailored Trucks" (CTT) packages)
• Bodybuilder Information Bulletins: Archive for
Company profile (body manufacturer profile) and the newsletters about changes at Mercedes-Benz Trucks
Qualified Partner List (QPL) that are relevant to body manufacturers
You will have to register as a body manufacturer on your • Body manufacturer information with body-
first visit; this will make all the information on the portal manufacturer-relevant changes for Mercedes-Benz
available to you. For this, you must enter your company UNIMOG and ECONIC
name, contact details, user profile and your company's
contact person. • Technical Manual for UNIMOG with detailed technical
data (engine power diagrams, tractive force
Additional advantages and attractive sales opportunities diagrams, weights etc.)
are available to Qualified Partners of Mercedes-Benz
Trucks. For these, in a second step, you have to start • Body/Equipment Mounting Directives for the
the extended self-disclosure procedure for the QPL UNIMOG (also accessible without registration)
process, which you can also initiate at a later stage
independently of the registration process. Based on your
self-disclosure, you will be assessed by a team of i
Mercedes-Benz experts according to standardized 3D chassis data in STEP format are available on
criteria regarding quality, sales and service. request for UNIMOG and Econic. Registration as a
body manufacturer on the portal is also required for
Vehicle-related data this purpose.
The area supports you in selecting the appropriate If necessary, request it from the contact person
vehicle for your customer from a range far in excess of responsible for the vehicle model series, (see
100,000 truck chassis and vehicle variants. Clearly "Advice for body manufacturers" document).
structured filters assist you in selecting your desired
vehicle. All the relevant technical data and information
about this vehicle is then available to you: Unimog Partner / Unimog Expert Partner
• Scaled and dimensioned CAD drawings in DXF or The more intensive our level of cooperation, the more
PDF format as well as 3D surface models for the options will be available to you. As a registered user of
entire vehicle the Bodybuilder Portal, you already have access to
• Configurator for individual 2D chassis drawings technical data that are relevant for body and modification
(tender drawings) with the most important special solutions. You also benefit as part of the various
equipment combinations partnership models from offers for your sales pitch and
sales activities.
• Simplified, reduced-line 2D chassis drawings (tender
drawings) (vignettes) from four views (side, top, rear The partnership models offered by Mercedes-Benz
and front view) with the most important main Special Trucks provide support for body manufacturers
dimensions in DXF format in marketing their products using the Mercedes-Benz
word mark. The partnership models also form the basis
• 3D data
for further cooperation (incl. for general contractors).
• Technical data sheets and engine diagrams
Partner status is awarded to qualified body
• Body/Equipment Mounting Directives for Trucks in manufacturers that meet the minimum requirements of
various languages Daimler Truck AG in terms of quality, service, sales and
technology.
General
The "Qualified Partner by Mercedes-Benz" partnership Our Bodybuilder Portal has an integrated mail response
model is the central partnership model at Mercedes- system, which has a contact form you can use at any
Benz Special Trucks for the Econic and Zetros model time to send queries to us. The system ensures that your
series. questions are forwarded to the correct contact at
In comparison to the "Qualified Partner by Mercedes- Mercedes-Benz and are answered quickly and expertly.
Benz" partner status, the "Unimog Partner by Mercedes- Our contact persons database provides a convenient
Benz" status and the "Mercedes-Benz Unimog Expert way of finding a contact from different areas of expertise,
Partner" status are reserved exclusively for the and of contacting that person by telephone, email or
Mercedes-Benz Special Trucks Unimog model series. post.
Further information about Unimog Partner and Expert Our hotline is also available in the case of questions
Partner is available on the following internet sites: about the portal:
www.unimogpartner.com
Partnership and contact options

Short and direct paths are critical to the success of our
collaboration. This is why we offer different ways to get
in touch with us through the portal:

Telephone: +49 711 17 33322
Email: abh‑portal@daimlertruck.com
www: http://bb-portal.mercedes-benz-trucks.com
Information for body manufacturers outside the • Parameterizable special module (PSM)
sales network • Diagnosis
Body manufacturers outside the sales network that are • Special tools
not based in Germany can request the following
information from their respective national contact person • TIPS
(see "Advice for body manufacturers" document). Manufacturers in Germany can retrieve data directly
• Service/parts information from the XENTRY Portal:
• Wiring diagrams http://xentryportal.mercedes-benz.com
• SAM with additional functions (XMC)
---------------------------------------------------------------------------
Workshop Information System (WIS) • Repair instructions
The Workshop Information System (WIS) is available in • Maintenance sheets
"Service & Parts net." under the heading "Service/parts Body manufacturers outside the sales network can
information". In the WIS, you will find, e.g. : purchase access to WIS from the following address:
• Basic data (dimensions, tightening torques) https://service-info.mercedes-benz-
• Function descriptions trucks.com/eu/en/
• Wiring diagrams
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XENTRY Kit Fault entries which occurred during the mounting of the
The XENTRY Kit is available to you as a tool for the body can also be erased.
XENTRY system as a component of In addition, XENTRY Kit can also be used to update
"Service & Parts net." under the heading "Diagnosis". control units using SCN coding. Online SCN coding must
The XENTRY Kit diagnostic tool was developed by be used on Actros BR 963x, Arocs BR 964x,
Mercedes-Benz to facilitate vehicle diagnosis. The Atego BR 967x, Econic BR 956x, e.g. to update the data
XENTRY Kit can be used to read out fault entries from (coding) for the instrument cluster.
the vehicle and diagnose them. It can also be used to The XENTRY Kit can also be connected to the central
change parameters in control units, e.g., in the SAM with server of Daimler Truck AG online during SCN coding
additional functions (XMC). using a LAN or WLAN connection. The relevant SCN
General
coding is requested online and is used to uniquely XENTRY Kit can be purchased or leased by body
identify the control unit variants installed in the vehicle. manufacturers. If you have questions about XENTRY
Furthermore, it is possible to update the control units or Kit, contact your Mercedes-Benz Service Partner or use
to commission them during replacement. The the contact form under Service & Parts net.
appropriate software is determined online and installed
using the suitable data storage medium.

Contact data
Telephone: +49 1805 010 7979
Fax: +49 1805 010 7978
Email: customer.support@daimlertruck.com
CERON Use of the CERON system is subject to a fee.

The CERON (Certification Online) system is a platform It is possible to register for the CERON system using a
for exchanging and providing documents on the system form which is available in the "Additional information"
approvals and overall operating permits of the EC catalog in the Bodybuilder Portal.
(European Community) and UNECE (Economic
Commission for Europe). It also provides,
e.g., documents relating to ETA (European type
approval).
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European type approval (ETA) and EC Certificate of The manufacturer, who is in possession of an EC type
Conformity (CoC) approval certificate or EC small series type approval
Directive 2007/46 EC or Regulation 2018/858/EC of the certificate, is obliged to provide every vehicle which
European Parliament forms the basis for the approval of corresponds to an approved model with a certificate of
motor vehicles and motor vehicle trailers, as well as of conformity.
systems, component parts and independent technical The vehicle-specific data on the EC certificate of
devices for these vehicles. In this directive, regulations conformity (CoC) for the basic vehicle are available in
have been enacted concerning the approval of vehicles the Bodybuilder Portal for convenient and quick
that are manufactured in several stages, i.e. the multi- processing of the body scope.
stage type approval procedure. Accordingly, every If you plan an ETA in a subsequent stage (multi-stage
manufacturer involved in the construction of a vehicle is type-approval certificate), a contract is required as per
itself responsible for the approval of modified or added 2007/46 EC Appendix XVII Para. 1.1. or Regulation
scopes in its own manufacturing stage. The 2018/858 Appendix XI Para. 1.1. This contract also
manufacturer can choose from one of the following four governs the use of CERON. The manufacturer
procedures: agreement concerning the multi-stage procedure can be
• EC type approval (ETA) obtained at:
• EC small series type approval multistage-cv@daimlertruck.com
• National small series type approval
• Individual approval
i
CoC stands for Certificate of Conformity. A document You can find the data for the basic vehicle in the
that attests that certain goods - i.e. including vehicles Bodybuilder Portal under "My portal" > "My order
and bodies - conform to recognized (international) data" > "Order data system" > "Order list/order
standards. The meaning and purpose of this EC number" > "Approval data". You can choose
Certificate of Conformity is to simplify the approval between an overview and an Excel file, but not the
process for introducing international brands to the original document of the EC certificate of conformity.
markets. This document is therefore required, in
particular, in import and export for customs clearance.
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General
Product Information Tool (PIT) PIT is accessed via:

The PIT system contains information on vehicle http://pit.mercedes-benz-trucks.net/
equipment options (codes, suspension variants,
overview of products, towing capacities etc.).
Custom Tailored Trucks Code (CTT)
General
Dimensions and weight specifications
Dimensions and weight specifications Page 47
Customer special requests that are not available as CTT modifications are conducted with the factory as a
special equipment/options can be realized through the single-invoice transaction and are always invoiced using
Mercedes-Benz Custom Tailored Trucks (CTT) business the factory invoice of the vehicle.
unit. Customer special requests can be recognized in the
vehicle's order data by the four-digit equipment code
beginning with Jxxx.
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In the case of CTT, dimensions for relocating • Specification of the position to which certain
components are relative to the area from the center of component parts are to be relocated: Dimension from
the front axle up to the front edge of the component part the center of the front axle to the front edge of the
to be relocated (see document "Dimensions and component part to be relocated?
weight specifications"). Your Mercedes-Benz Service Partner will gladly advise
Under certain circumstances and following a feasibility you and, where necessary, will also consult the factory.
check, the components listed below can be repositioned Chassis that have been modified considerably at
via CTT before the vehicle leaves the factory: customer special request, such as
• Fuel tank • wheelbase modification beyond the longest standard
• AdBlue® tank wheelbase,
• Battery carrier • any type of axle attachment,
• Exhaust aftertreatment unit • modification of the suspension type,
• Electronic air-processing unit (EAPU) are not described in these Body/Equipment Mounting
Directives.
Prior to a consultation, the customer should address the
following questions, as there are two options with regard If equipment, attachments and bodies are implemented
to the specification submitted to CTT: on a vehicle, a certificate of non-objection is required
from the relevant contact person (see document
• Specification of the required clearances on the frame:
"Advice for body manufacturers").
Which vehicle side is to be used?
How much clearance is required, from where to
where (measured from the center of the front axle)?
Product safety and product liability
General
Threaded connections and weld joints
Threaded connections and weld joints Page 58
Product safety The body manufacturer must ensure compliance in

Both vehicle manufacturers and body manufacturers particular with Directive 2001/95/EC concerning general
must always ensure that the products they manufacture product safety.
are safe when they are brought into circulation and do Furthermore, the body manufacturer must guarantee
not present any danger to persons or property. compliance with standards relating to functional safety
Otherwise there may be consequences under civil, (preferably ISO 26262).
criminal or administrative law. Every manufacturer is
always liable for the product that it has manufactured.
This also applies to general contractors on behalf of
Daimler Truck AG.
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Product liability • consequential damage resulting from retrofitted
The body manufacturer bears responsibility for the electrical and electronic systems.
operational and road safety of the body mounting work • Maintaining the functional reliability and unobstructed
performed by him, and in particular for: movement of all moving parts of the chassis
• testing and maintaining the operating and driving (e.g. axles, springs, propeller shafts, steering,
safety of the overall vehicle after the body is mounted gearshift linkage, etc.) after body mounting work has
(the body must not have a negative effect on the been performed, even in the case of diagonal torsion
driving, braking or steering characteristics of the of the vehicle
vehicle) Work carried out or modifications on the chassis or body
• the effects of body mounting work on the chassis must be entered in the maintenance booklet, section
"Confirmations of the body manufacturer".
• consequential damage arising from body mounting
work
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Safety-relevant features • Avoiding sudden failure of drive force
Components and systems are safety-relevant when their • Avoiding leakage of operating fluids/risk of fire
fault or failure could result in an immediate danger to the • Avoiding loosening of cargo/trailers/parts/bodies/
life and limb of road users. semitrailers
Daimler Truck AG requires that an assessment of the • Avoiding injury while driving and during alternative
safety relevance of the components or functions be operation of the vehicle
carried out for the following work:
The following customer-related influences in particular
• Chassis modifications must be considered when evaluating safety relevance:
• Vehicle installations • Extreme operating conditions
• The interface between vehicle and body (mechanical • Wear
components, electrics/electronics, power take-offs,
hydraulic components, pneumatics) • Ambient conditions
A component or function must be classified as safety- Documentation
relevant if one of the following ten safety functions in
If safety relevance is identified according to the ten
particular is affected:
safety aspects in particular, these aspects are to be
• Occupant protection system in accidents appropriately marked as safety-relevant in paper and
• Avoiding momentary loss of road view data records and the associated functions and features
documented as well as the measures taken to avoid the
• Avoiding steering failure dangers. Safety-relevant threaded connections must be
• Avoiding loss or partial failure of braking function documented according to the procedure in (see
• Avoiding failure of driving function document "Threaded connections and weld joints").
• Avoiding any uncontrolled drive
Accident prevention
General
The body and attached or installed equipment must In Germany, information for commercial carriers is
comply with all applicable laws and regulations, and with available from the Berufsgenossenschaft für
health and safety and accident prevention regulations, Fahrzeughaltungen (German Trade Association of
safety regulations and information sheets issued by Vehicle Owners):
accident insurers.
All technical means shall be used to avoid operating
conditions that may be unsafe or liable to cause an
accident.

Telephone: +49 4039‑800
Fax: +49 4039‑801999
Email: info@bgf.de
Home page: http://www.bgf.de
Postal address: Berufsgenossenschaft für Fahrzeughaltungen

Fachausschuss "Verkehr"
Sachgebiet "Fahrzeuge"
Ottenser Hauptstrasse 54
D-22765 Hamburg
All national laws, directives and registration

requirements must be observed! i
The installation and body manufacturer shall be Risk of accident
responsible for compliance with these laws and Observe all accident prevention regulations listed in
regulations. This also applies for interfaces between the operator's manual at all times.
the vehicle and the implement as well as in terms of The vehicle speed is to be adapted to match the
safety when assembling and disassembling given road and traffic conditions, whereby the
demountable implements. influence of the implement/body during braking
• Drive shafts must be equipped with a contact procedures, cornering, driving on slippery roadways
protection to ensure shearing and crushing points are or unsurfaced roads, in slopes, on uphill or downhill
avoided. gradients etc. should be taken into consideration
during preventive driving.
• Engageable systems must be secured against any
incorrect use and unintentional operation. The body manufacturer shall ensure that the vehicle
owner/customer has received training and/or
• Fans for oil coolers or similar must be enclosed in theoretical and practical instructions about the
such a manner that they cannot be reached into implement operation or vehicle operation in
when the fan is turning. combination with the implement.
• All sharp edges and corners must be avoided.
• The implement and body manufacturer shall ensure
that the care and maintenance operations can be
conducted safely.
• Drive shafts must not rotate when switched off, if this
is unavoidable then they must be capable of being
stopped easily by hand.
Trademarks
General
The Mercedes-Benz brand in interaction with Actros BR 963x, eActros BR 983x, Arocs BR 964x,
external body manufacturers Atego BR 967x, Econic BR 956x and Unimog BR 405x
In terms of the relationship between Mercedes-Benz and to body manufacturers.
body manufacturers, it is not just product safety and The individual provisions of the guidelines do not release
product liability which are of particularly high importance. body manufacturers from their liability for aftermarket
The usage of the brand is also very important. modifications to Mercedes-Benz vehicles.
The aim of these guidelines is to explain the brand-
related interests of Mercedes-Benz for the
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The function of a brand The brand indicates the origin of a product and allows
Every company which wishes to operate a successful the product to be recognized and remembered. The
brand must ensure that the characteristics of the brand brand acts as a guarantee for the quality of a product,
are consistently protected. This also applies to the embodying its characteristic values and identity.
brands of Daimler Truck AG.
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Trademark rights trademarks) of the Mercedes-Benz Group AG. Use takes
The "Mercedes star", "Mercedes badge" and "Mercedes- place as part of license rights agreements.
Benz" word mark/lettering are brands (registered

S72.20-A004-01 S88.40-A002-01 S72.20-A005-01
Advice on the affixing of Mercedes-Benz trademarks not hesitate to contact your respective contact person
If you have any questions regarding applying Mercedes- (see document "Advice for body manufacturers").
Benz trademarks to Mercedes-Benz trucks, please do
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Use of Mercedes-Benz trademarks Mercedes-Benz trademarks on vehicles with
technical modifications
Principle
Vehicle modifications that comply with the Mercedes-
Only Mercedes-Benz trademarks may be applied to Benz Body/Equipment Mounting Directives may still bear
completely unchanged Mercedes-Benz vehicles. the Mercedes-Benz trademark on the vehicle.
Modification of the Mercedes-Benz trademarks on Extensive vehicle modifications significantly change the
vehicles of the Mercedes-Benz brand is not permissible. original condition of the vehicles, e.g. through
Applying Mercedes-Benz trademarks to vehicles and modifications to the suspension, body structure, engine,
parts other than those of the Mercedes-Benz brand is brake system and on-board electronics.
not permissible.
Trademarks
General
These modifications are generally not covered by the product liability and product safety legislation. The body
Body/Equipment Mounting Directives. This can result in manufacturer must obtain a written certificate of non-
deterioration of the overall vehicle with associated risks objection from Daimler Truck AG covering technical
which Daimler Truck AG is not liable for according to feasibility and product safety.
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Brand separation/identity • The use of the Mercedes badge is not permissible on
vehicles with a cab separately designed by the body
Principle manufacturer.
Mercedes-Benz model series have specific
characteristics and values as well as a brand-specific Model series and vehicle model designation at front
design. The modifications should be in the style of the of vehicle
Mercedes-Benz design characteristics. The vehicles have model series designations on the
Separating the Mercedes-Benz trademarks from the front end of the vehicle. Different model series
body manufacturer trademarks ensures that a distinction designations may not therefore be applied to vehicles
can be made between the brands. This applies, in modified by body manufacturers.
particular, to product origin and the resulting Trademarks at the rear area of the vehicle
responsibilities.
Use of the Mercedes star
Trademarks on the front of the vehicle Coordinate appropriately when attaching the Mercedes
Use of the Mercedes star star to the rear area of vehicles where the appearance
• On vehicles with genuine Mercedes-Benz cabs, the has been fundamentally altered by the body or
Mercedes star must be retained in the as-delivered modification.
state. Body manufacturer trademarks in combination with
• On vehicles with a cab designed separately by the Mercedes-Benz trademarks
body manufacturer, the Mercedes star may be Body manufacturers that attach their trademarks to their
applied to the front-end assembly in the center in body must ensure that they are located at a suitable
order to identify the chassis. If the body manufacturer distance away from Mercedes-Benz trademarks or
brand is also applied, it must be applied at an badges.
appropriate distance from the Mercedes star.
Use of the Mercedes badge

• The Mercedes badge signifies an original
Mercedes‑Benz design. It may only be retained on
vehicles with a genuine Mercedes-Benz cab.
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Trademark communication When displaying modified vehicles that comply with the
Use of Mercedes-Benz trademarks in Mercedes-Benz guidelines and that bear our
communication trademarks, care should be taken to ensure that any
modification to the vehicle or the vehicle body made by
The use of Mercedes-Benz trademarks in the body manufacturer is visible in the display. Only the
communication instruments such as, e.g. brochures, obvious accentuation of Mercedes-Benz trademarks
flyers, advertisements or pennants will be governed in without any visible attachment, extension or conversion
future by the style guide for the body manufacturers of is not permissible.
Mercedes-Benz trucks.
The use of Mercedes-Benz trademarks in corporate
The body manufacturer must be clearly identifiable in all design, i.e. on letterhead paper, business cards, on work
its communication media and channels as the originator clothes, etc. and in the showrooms, offices and
of the communication. workshops is not permitted.
Reuse of component parts - Recycling
General
• It must be ensured that components can be

i dismantled easily for recycling, e.g. by snap-on
Documentation obligation according to the European fasteners, predetermined fracture points, easy
Chemical Directive REACH. Otherwise vehicles may accessibility, use of standard tools.
not be put on the market. In single invoice • It must be ensured that service fluids can be removed
transactions with Daimler Truck AG, information simply and in an environmentally responsible manner
sharing must be processed via the Bodybuilder by means of drain screws etc.
Portal.
• Wherever possible, painting and coating components
should be avoided and dyed plastic parts should be
used instead.
Already during the planning of the bodies, the following
principles for environmentally friendly construction and • Components in areas at risk from accidents must be
material selection must be observed, taking into account designed in such a way that they are damage-
the legal requirements. tolerant, repairable and easy to replace.
Body manufacturers shall ensure that attachments and • All plastic parts are to be marked in accordance with
bodies (or conversions) comply with current VDA material data sheet 260 ("Components of motor
environmental legislation and applicable regulations, in vehicles; marking of material"), e.g. "PP ‑ GF30R".
particular EU Directive 2000/53/EC concerning end-of-
European Chemicals Directive REACH
life vehicles and EU Directive 2003/11/EC concerning
restrictions on the bringing into circulation and use of As per Article 33 of the European Chemicals Regulation
certain dangerous substances and dangerous REACH (Registration, Evaluation and Authorization of
preparations ("low flammability" and certain flame Chemicals, Regulation (EC) No. 1907/2006), there is an
retardants) to specify the Directive 76/769/EEC. obligation to provide information on substances
contained in structures and products and which fulfill the
The installation documentation for the conversions shall
criteria of Article 57 and Article 59, para. 1 and which
be kept by the vehicle owner and, if the vehicle is to be
have a concentration of over 0.1 percent by weight.
scrapped, handed over to the dismantling company
concerned at the time of vehicle handover. This is The substances affected are listed in the current version
intended to ensure that even converted vehicles are of the REACH Candidate List. A process via the
processed in an environmentally responsible manner. Bodybuilder Portal has been installed which enables
Daimler Truck AG to comply with the obligation to
Materials with a potential risk to health and the
provide information as per the REACH Regulation within
environment are prohibited. Additional contractual
the framework of single invoice transactions and
obligations under a general contractor agreement with
business with Daimler Truck AG as general contractor.
Daimler Truck AG must be observed.
According to body manufacturer information bulletin
In general, country-specific substance bans and disposal 02/2018, your internal processes as body manufacturers
regulations must be observed. must be adapted accordingly, and compliance with the
• It is preferable to use materials which permit REACH directive must be verified. To do this, you must
recycling and closed material cycles. immediately file information/confirmation of conformity of
the modifications/bodies in the form of data sheets
• Materials and production processes that generate and/or appropriate templates for certifying conformity of
only low quantities of easily recyclable waste during the modifications/bodies via your portal access.
production must be selected.
The obligation to comply with the European Chemicals
• Plastics are to be used only where they provide Directive REACH lies solely with the respective body
advantages in terms of cost, function or weight. manufacturer within the framework of a dual-invoice
• In the case of plastics, and composite materials in transaction for the body solution.
particular, only compatible substances within one
material family are to be used.
• For components which are relevant to recycling, the i
number of different types of plastics used must be Further information is available at:
kept to a minimum. http://www.reach-info.de/
• It must be assessed whether a component can be https://echa.europa.eu/de/regulations/reach/
made from recycled material or with recycled understanding-reach
elements.
System for quality assurance
General
Worldwide competition, increased quality standards • Identification and instruction obligation
demanded by the customer from the truck product as a In the case of bodies with machine functions,
whole, national and international product liability laws, compliance with the European Machinery Directive
new organizational forms and rising cost pressures must be confirmed or demonstrated by means of the
make efficient quality assurance systems a necessity in CE marking. Other country-specific requirements
all sectors of the automotive industry. must also be taken into account. The customer must
The requirements for such a quality management be instructed in the functions of the body before
system are described in DIN EN ISO 9001. taking over the vehicle. Operating and maintenance
For the reasons quoted above, Daimler Truck AG instructions must be handed over to the customer in
urgently advises all body manufacturers to set up and the respective national language.
maintain a quality management system with the • Measuring and test equipment monitoring
following minimum requirements: The body manufacturer must label all measuring and
• Responsibilities, processes and procedures test equipment and monitor and calibrate it at regular
The responsibilities and authorizations must be intervals. The calibration results must be documented
regulated. The body manufacturer must determine and archived. In the case of calibration results that
the processes and procedures required for the quality are not OK, a procedure for risk assessment must be
management system and define their application defined.
within the organization. • Production
• Procurement / purchasing The body manufacturer must inspect delivered
Incoming goods inspections must be carried out and vehicles for completeness and freedom from damage
detected defects must be documented. A process for and document the result of this inspection. During
supplier evaluation (criteria, benchmarks and production, intermediate and final tests must be
possible measures) must be implemented. When carried out on vehicles and documented in a
awarding contracts to a subcontractor, a process or checklist accompanying the vehicle. Serial numbers
procedure must be defined. of components (e.g. loading crane, cargo liftgate)
must be recorded. Parts lists and drawings must be
• Subcontracting or outsourcing of orders archived together with the vehicle-related documents.
The body manufacturer must ensure that applicable The archiving period must comply with the
laws, standards and guidelines as well as quality requirements from the contractor partnership
specifications are complied with when subcontracting (vehicle-related documents 15 years after delivery, or
or outsourcing, i.e. by the body manufacturer carrying after the end of series production). Employees must
out the work. be deployed in accordance with their qualifications.
Appropriate proof of qualification must be provided.
• Development of products, technology, work
Training and instruction plans for the employees must
preparation
be available. Safety and registration-relevant features
The current Mercedes-Benz body/equipment must be subjected to special tests during the
mounting directives must be known and taken into manufacturing process. The result of these tests
account for vehicle conversions, attachments or must be documented in vehicle-specific documents
bodies. The procedure for applying for certificates of (e.g. order folder, checklist).
non-objection must be familiar and observed.
• Handling of faults and faulty parts
Certificates of non-objection must be applied for in
accordance with the requirements of the current The handling of faults and faulty parts / material must
body/equipment mounting directives (chapter be regulated. Defective parts and material must be
Additional information). A check of the technical marked and the responsibilities for quarantine
feasibility and economic efficiency (e.g. axle load storage and release must be regulated. Defects and
calculations, compliance with the body/equipment defective parts / material as well as corrective actions
mounting directives, stability checks) must be carried must be documented. A procedure for avoiding
out. The result of these tests must be documented repeat defects must be defined.
and archived with the vehicle-related documents. In • Identification and traceability
the case of in-house developments, a procedure for
identifying product-specific risks (e.g. FMEA, risk The body manufacturer must ensure that installed
analysis in accordance with the Machinery Directive) parts, components and assemblies are identifiable at
must be specified. Safety and registration-relevant all times. The traceability of installed parts,
features must be identified during development and components and assemblies to the order as well as
marked accordingly in the production specifications. to the chassis number must be ensured.
Safety and registration-relevant features must be Disassembled parts of a vehicle must be marked and
subjected to special tests during the manufacturing stored in such a way that they can be clearly
process. The result of these tests must be assigned to the vehicle.
documented with the vehicle-related documents (e.g. • When Daimler Truck AG is the general contractor,
order folder). the relevant requirements are contractually defined.
Safeguards and traceability
General
If potential risks in your body become known after which registered owners are affected, we urgently advise
delivery, measures in the market may be necessary you to file the serial number/identification number of your
(customer notification, warning, recall). In order to make implement/attachment linked to the vehicle identification
these measures as efficient as possible, your product number in your databases. On this note, the storage of
must be traceable after delivery. customer addresses is also recommended as is giving
For this purpose and to enable the Federal Office for subsequent acquirers the possibility to register their
Motor Vehicles' Central Vehicle Register (ZFZR) or details.
comparable registers abroad to be used for determining
Selection of chassis
Overall vehicle
i i
In this chapter, representations, code scopes and Do not exceed gross vehicle mass and axle loads.
pre-installations of other model designations and The braking distance may increase considerably if
model series are listed for reasons of the vehicle is overloaded. Otherwise, the vehicle
standardization. The information that is applicable to support structure may be damaged. Observe the
your model designation/model series must weight variant of the vehicle (sales code Wxx). The
exclusively be used. axle designation or the axle load capacity has only
limited relevance to the gross mass of the vehicle.
Adjust the vehicle design accordingly.
i
When planning attachments, bodies, equipment or
modification work, the selected vehicle must be i
checked to verify whether it fulfills the necessary Ensure reliable operation of Stability Control Assist,
requirements. In order to ensure safe operation of ESP®. Semitrailer trucks for trailer operation must
the vehicle, it is essential to choose the chassis and always be equipped with code S1E (Stability Control
equipment carefully in accordance with the intended Assist, ESP® for trailer operation on semitrailer
use. The non-availability of a vehicle version may be trucks).
an indication that the vehicle is not suitable for the
intended application.
i
Semitrailer truck vehicle model designations
(963.4xx, 964.4xx) are only suitable for fixed or swap
bodies under certain conditions. Modifications to the
basic vehicle may be necessary in order to
guarantee that the vehicle will be safe. Coordination
with the relevant contact person is required (see
document "Advice for body manufacturers").
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Selecting the chassis • Position of the center of gravity
Mercedes-Benz has specific vehicle versions and • Statutory licensing requirements, e.g. underride
wheelbases available for different areas of operation. guard
As well as selecting the correct vehicle version, the • Permissible and technical gross mass
following standard and special equipment should be 8x4 vehicles with vehicle model designation 964.031 and
taken into consideration when planning and should be enlarged wheelbase at the front axles of 2000 mm (sales
adequate for the intended use: code AZZ) were developed specifically for use in
• Wheelbase combination with 4-outrigger bodies (concrete pumps).
• Engine/transmission The installation of different body types must be
coordinated in advance with the relevant department
• Power take-offs (see "Advice for body manufacturers" document).
• Axle ratio
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The following model designations can be ordered for the C983.003 Platform 4x2 18 t / air
eActros: C983.020 Platform 6x2 25 t / air, ENA

Selection of chassis
Overall vehicle
Actros/Arocs model code system

1+2 Model series
96 = New model series
98 = eActros
3 Intended purpose
3 = On-road
4 = Off-road
4 Configuration
0 = Platform
2 = Dump truck
W00.00-A080-01
3 = Concrete
4 = Semitrailer
5+6 Axle configuration/tonnage/version
00 = 4x2 18 t/–
01 = 4x2 20 t/–
02 = 4x2 20 t/air
03 = 4x2 18 t/air
04 = 4x2 18 t/air, low frame
05 = 4x2 18 t/air, car transporter
06 = 4x2 18 t/air, lowliner
07 = 4x4 18 t/all-wheel drive
11 = 6x2 25 t/DNA
14 = 6x4 26 t/–
16 = 6x4 33 t/–
20 = 6x2 25 t/air, ENA
21 = 6x2 25 t/air, low frame
22 = 6x2/4 25 t/air
23 = 6x2/2 25 t/air
24 = 6x4 26 t/air
25 = 6x2 25 t/air, DNA
26 = 6x4 33 t/air
27 = 6x2/2 24 t/air
30 = 8x4/4 32 t/–
31 = 8x4/4 41 t/–
32 = 8x6/4 41 t/all-wheel drive
33 = 8x8/4 41 t/all-wheel drive
38 = 8x4/4 32 t/air
41 = 8x4 32 t/air, ENA
42 = 8x2/4 air, VLA/DNA
43 = 8x2/4 VLA/DNA
45 = 8x2/6 air, ENA
7 Steering
1 = Left-hand drive vehicle
2 = Right-hand drive vehicle
8 Body
2 = Chassis
Overall vehicle
i i
Do not exceed gross vehicle mass and axle loads. Possible loss of registration eligibility. Due to the
The braking distance may increase considerably if combination of equipment features (cab, spoilers,
the vehicle is overloaded. Otherwise the vehicle body floor height, tires, etc.), the chassis may be
support structure may be damaged. Observe the higher than 4000 mm. Observe notes on equipment
weight variant of the vehicle (sales code Wxx). The list/order data and check registration eligibility in
axle designation or the axle load capacity has only country of deployment.
limited relevance to the gross mass of the vehicle.
Adapt vehicle design accordingly.
i
Information about changes in weight is available
i from the relevant contact person (see document
The vehicle's tire load capacity (load index) must not "Advice for body manufacturers").
be exceeded by overloading the vehicle beyond its
specified axle load. The tires could otherwise
overheat and suffer damage. This could cause the
driver to lose control of the vehicle. Adapt vehicle
design accordingly.
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General They are based on a vehicle that is fitted with standard
Information on the permissible technical axle loads and equipment. Weight tolerances of +5% in production must
the gross mass can be found on the vehicle identification be taken into consideration (permissible in the Federal
plate. Republic of Germany according to DIN 70020).
All legal requirements governing the permissible vehicle The permissible axle loads and the maximum
height must be taken into account when planning bodies. permissible gross mass specified in the technical data
In the Federal Republic of Germany, the permissible may not be exceeded.
vehicle height is limited to max. 4000 mm. In other The technical data can be found in the vehicle
countries (and if the vehicle is operated in international documents, on the vehicle identification plate or in the
transport), comply with all the relevant national code definitions in the order data.
regulations. Please refer to the operator's manual!
Dimensions and weight details can be found in the 2D
chassis drawings (offer drawings) and technical data.
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Compliance with the permissible overall vehicle drive position to improve suspension comfort. This is
height (large volume transporters) displayed in the instrument cluster.
On vehicles with a low frame height and air suspension Observe the permissible total vehicle height and
(large volume transporters), it is possible to set a raised maximum headroom information.
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Chassis coordinate system

Overall vehicle
Origin (BR 963)

X=0 BR 963: Center of front axle
Y=0 Vehicle frame symmetry axis
Z=0 Center of upper row of holes in
longitudinal frame member, distance to
underside of upper flange: 57.5 mm
W00.10-A017-10
BR 963 - Origin and vertical axis
Chassis (BR 963)

x-Achse: Parallel to roadway in longitudinal
direction of vehicle, with positive
direction opposite to direction of
travel
y-Achse: Parallel to roadway, lateral to
direction of travel, with positive
direction towards right side of vehicle
z-Achse: Vertical axis perpendicular to
roadway, with positive direction
upwards W00.10-A018-10
BR 963 - Coordinates parallel to roadway
Origin (BR 964)

X=0 BR 964: 100 mm in front of front axle
W00.10-A019-10
Chassis (BR 964)

travel
Overall vehicle
Origin (BR 983)
X=0 BR 983: Center of front axle
W00.10-A069-80
Chassis (BR 983)

travel
W00.10-A016-10
BR 963, 964, 983 longitudinal frame member
Chassis center of gravity height Please note that the maximum permissible height of the
The height of the chassis center of gravity is specified for center of gravity specified there is relevant only for
most chassis taking into account characteristic standard vehicles which are operated within the scope of UN-
and special equipment in the UN‑R 111 tilt threshold R 111, e.g. tank vehicles for hazardous goods.
calculation tool in the Mercedes‑Benz Bodybuilder Portal Vehicles used for other purposes may exceed the values
(http://bb-portal.mercedes-benz-trucks.com) specified therein, taking into account all specifications
stated here.
under the heading "Vehicle overview".
Vehicle modifications
Overall vehicle
Custom Tailored Trucks Code (CTT) Page 37
Checks after work on the brake system Page 479
Product and vehicle information for body manufacturers Page 33
i
Risk of injury
Do not modify any safety-relevant threaded
connections, e.g., that are required for wheel
alignment, steering or braking functions.
When unfastening threaded connections make sure
that, when work is complete, the threaded
connection again corresponds to the original
condition.
Welding on the chassis/body may only be carried out
by specialist personnel.
Major assemblies installed during work to
implements/bodies must comply with the applicable
laws and directives, as well as work safety or
accident prevention regulations, safety rules and
accident insurer leaflets.
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i i
Any modifications to the steering and the brake Customer special requests can be realized through
system may result in these systems malfunctioning the Mercedes-Benz Custom Tailored Trucks (CTT)
and ultimately failing. This could cause the driver to business unit. Customer special requests can be
lose control of the vehicle. There is a risk of recognized in the vehicle's order data by the four-
accident! Do not carry out any modifications to the digit sales code (Jxxx). Modifications on vehicles
steering or brake system! with customer special requests may only be carried
out after confirmed non-objection by the relevant
contact person (see "Custom Tailored Trucks
Code (CTT)" document)
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The following applies for model series 963, 964, 967, Standard production vehicles comply ex factory with EC
983: and UN-R directives and national regulations (vehicles
Alterations to the basic vehicle are generally possible produced for countries outside of Europe may be
within the framework of the procedures described in exceptions).
these Body/Equipment Mounting Directives. The vehicles must still comply with EC and/or UN-R
• For all other work, consent in the form of a certificate regulations or national regulations after modifications
of non-objection can be obtained from the relevant have been carried out. If all legal acts are not fulfilled, an
contact person (see "Advice for body EU data confirmation instead of a CoC document is
manufacturers" document) before modifications enclosed with the vehicle.
are made. No changes to the vehicle scope of delivery may be
made without the consent of Daimler Truck AG.
Vehicle modifications
Overall vehicle
Consultation with Daimler Truck AG must be held at all • Conduct a complete check (function, efficiency and
times. visibility) on the entire brake system after any work
• The body manufacturer must inform the officially on the brake system, i.e. even after simply removing
recognized approval authority or inspector of any parts (see "Checks after work conducted on the
modifications to the chassis when the vehicle is brake system" document).
inspected. If necessary, present a certificate of non- • If a change to the physical location of the brake
objection from Daimler Truck AG, e.g. drawing with assemblies in the chassis is absolutely necessary,
approval note, or the applicable Body/Equipment use lines and connecting parts of the same type,
Mounting Directives. quality and dimensions.
• Modifications may need to be made to the chassis to The complexity of the chassis means that when making
enable bodies to be implemented. Even minor a practical check of the body, it is not possible for
changes (e.g., to the exhaust or brake system, the Daimler Truck AG employees to determine and identify
shifting of component parts, removal of components all externally conducted chassis modifications (after
etc.) can lead to expiry of the General Operating leaving the production plant).
Permit (GP).
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The following applies for model series 956: • Modifications to the hydraulic system
No changes to the vehicle scope of delivery may be • Modifications to the lighting system
made without the consent of Daimler Truck AG. • Modifications to the noise capsule
Consultation must be held with Daimler Truck AG, Body
Manufacturer Management TE/ORB-B before the • Modifications to the engine
following modifications can be made: • Modifications to the electrics, e.g., including the
• Shortening or extending the chassis overhang shifting of electrical control units
• Drilling and welding on the vehicle frame or on the • Military equipment, modification kit integration
axles • Attachment of mil. protective measures (e.g., in or on
• Modifications to the frame, including mounting the cab)
supports and end crossmembers
• Modifications to the brake and steering systems
(e.g., modifications to the brake line lengths) i
Further information about threaded connections and
• Modifications to the intake and exhaust system weld joints, see "Threaded connections and weld
• Modifications to wheels, tires, suspension joints" document and the "Product and vehicle
(e.g., blocking of the suspension) information for body manufacturers" document.
• Modifications that impair the safety of the cab
(e.g., drilling into the A-pillar or B-pillar)
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The following procedures, in particular, apply for
chassis modifications to model series 405, 437: i
• Creation and transfer of a list of all the chassis Mercedes-Benz would like to emphasize here that
modifications made by the body manufacturer only the scopes cited in this list are deemed to be
coordinated and safe, that have been explicitly
• Clarification of legality and documentation of consent
confirmed by Daimler Truck AG.
from responsible development teams at Mercedes-
Benz Special Trucks for all the points cited in this list A vehicle inspection conducted by employees of
Daimler Truck AG is generally not sufficient to
The UNIMOG chassis is designed so that implement approve any scopes not cited in this list.
attachments and bodies can generally be conducted at
the specified implement attachment points without the
need for any modifications to the chassis.
Tires
Overall vehicle
• the distance between the tire and the fender or wheel

i well is sufficient (adherence to valid regulations) even
Changes to the braking and handling characteristics when snow or anti-skid chains are fitted, with the
possible. There is a risk of accident! On vehicles suspension fully compressed (including any torsion).
with electronic brake system, sales code B1B, adapt • Observe information about this in the 2D chassis
the parameterization of the brake system when the drawings (offer drawings).
tire size is changed.
• appropriately adjusted load and speed indexes are to
be used when the tire size is changed.
The body manufacturer must ensure that: If the possibility of fitting snow and anti-skid chains
cannot be guaranteed, the operator should be informed
• the largest permissible tires can be fitted. by the body manufacturer (operator's manual).
Soundproofing
Overall vehicle
i
Possibility of engine damage and loss of vehicle's
registration eligibility. Do not perform any
modifications on the intake air system. This can
change not only the external noise but also the flow
and pressure conditions in the intake air system.
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Comply with all national regulations and directives! In the • tires, etc.
Federal Republic of Germany the guideline UN- sound level measurements must be taken.
R 51/UN-R 02 or § 49.3 StVZO (low-noise) must be
observed. To prevent modifications from changing the vehicle's
sound levels, it must be ensured that interior sound
If modifications are carried out on any parts whose levels are reduced when planning bodies.
operation produces noise, e.g.:
• Noise-insulating parts fitted as standard must not be
• engine removed or modified.
• exhaust system • The level of interior noise must not be adversely
• soundproofing affected.
Service and maintenance
Overall vehicle
aDanger
Risk of fire/risk of explosion due to short circuit and No fires, sparks, open flames or smoking. Wear acid-
escaping oxyhydrogen gas. Risk of (burn) injury caused resistant gloves, clothing, and glasses. Pour battery acid
by caustic burns to eyes, skin and mucous membranes only into suitable and appropriately marked containers.
from battery electrolyte/mist, short circuit and arcing. Risk
of poisoning caused by swallowing battery electrolyte or
absorption of lead through the skin or body orifices. Risk
of death due to voltage U >= 30 V AC and U >= 60 V DC.
Transport mode Page 74
Maintenance and repair
i
Avoid surface damage. After vehicle transfers in
winter (salted roads), the vehicle must be cleaned
without delay, especially the transmission housing
and light-alloy wheels.
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Maintenance and repair of the vehicle should not be • Check the condition and capacity of batteries and
made unnecessarily difficult by the body. service them in accordance with the manufacturer’s
Maintenance points and major assemblies must be specifications.
easily accessible. Any extra costs arising from the body in connection
• The operator's manual must be complied with and with warranty, maintenance, or repair work will not be
supplemented as necessary. borne by Daimler Truck AG.
• Stowage boxes must be fitted with maintenance flaps

or removable rear panels.
• The battery box must be sufficiently ventilated, with
provision for air to enter and exit.
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Daimler Truck AG shall not bear the costs for
i disassembly and reassembly of the body/implement
Important information for body manufacturers in the event of maintenance if the fixed body
prevents access to the listed items.
The following chassis parts must be accessible on
fixed body equipment/implements:
‑ Brake fluid reservoir
‑ Test connections of brake system
‑ Starter batteries
‑ Upper shock absorber screw
‑ Air drier
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Maintenance instructions • The automatic load-dependent brake (ALB) must be
The following must be observed by the body adjusted (if present).
manufacturer before delivery of the vehicle: • The brake fluid of the hydraulic brake system (up to
• Any service measures that are due must be carried Euro V) must be replaced if the non-operational time
out by a Mercedes-Benz service station. of the chassis is unknown. The brake fluid must be
replaced at least once per year.
Overall vehicle
• Check the condition and capacity of batteries and • Mercedes-Benz recommends that body maintenance
service them in accordance with the manufacturer's be coordinated with the valid Mercedes-Benz
specifications. maintenance systems for the respective vehicle. This
• Check the headlamp adjustment or have this applies to both the scope and type of service work,
checked by a qualified Mercedes-Benz Service and for determining the service due dates for
Partner. servicing intervals based on time elapsed and
distance covered.
• Retighten the wheel nuts to the specified tightening
torque. • If major assemblies have been removed/installed by
the implement/body manufacturer, the attachment
• Operator's manuals and maintenance procedures for must be checked for firm seating. On major
major assemblies installed during attachment, assemblies that contain liquids (coolant, lubricant
construction, installation or modifications must be etc.), the filling quantities must be checked and,
provided with the vehicle by the body manufacturer in where necessary, the prescribed operating fluids
the language of the country of use. must be refilled.
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Preparation for storing the vehicle Storing the vehicle in the open (> 1 month)
Storage in enclosed premises • Carry out the same procedure as for storing in an
enclosed space.
• Fold the windshield wipers away from the windshield.
i • Close all air inlets and set the heating system to
On vehicles with steering, Servotwin, sales "Off".
code C6H, additional buffer batteries may be • Remove the battery and store it in accordance with
installed in the vehicle depending on the vehicle the manufacturer's specifications.
equipment. These must also be disconnected and
the cable lugs and terminals must be lubricated. Maintenance work on stored vehicles (in storage for
> 1 month)
• Check the oil level once a month (except model 983)
• Clean the overall vehicle
• Check the coolant once a month (except model 983)
• Check the oil and coolant levels (except model 983)
• Check the tire pressures once a month
• Inflate the tires to 0.5 bar above the specified tire
pressure • Remove the 12-volt battery
• Release the parking brake and chock the wheels Removing the vehicle from storage
• Disconnect the battery and grease cable lugs and • Check the fluid levels in the vehicle
terminals.
• Adjust the tire pressures to the manufacturer's
Storing the vehicle in the open (< 1 month) specifications
• Carry out the same procedure as for storing in an • Check the state of charge and install the 12-volt
enclosed space. battery
• Close all air inlets and set the heating system to • Clean the overall vehicle
"Off".
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Perform maintenance on the high-voltage battery damage, the high-voltage batteries should be maintained
In order to guarantee a maximum service life for high- in accordance with the specification.
voltage batteries and to avoid any consequential

Overall vehicle
Use case/charge Maximum non- Maximum non- Non-operational Vehicles in

specification operational time operational time time > 12 weeks showrooms
6 weeks 12 weeks (inventory vehicles)
High-voltage battery Before the non- Before the non- Before non- Before non-
(on electric vehicle) operational time: If the operational time: If the operational time and operational time and
state of charge (SOC) state of charge (SOC) then every 6 months: then every 2 months:
of the high-voltage of the high-voltage If the state of charge If the state of charge
battery is < 30% , the battery is < 30% , the (SOC) of the high- (SOC) of the high-
high-voltage battery high-voltage battery voltage battery is voltage battery is
must be charged to an must be charged to an < 30% %, then the < 30% , then the high-
SOC value of approx. SOC value of approx. high-voltage battery voltage battery must
50% . 50% . must be charged to an be charged to an SOC
SOC value of approx. value of approx. 50% .
50 %.
Note: The non-operational time must be deducted from

ASSYST manually because the service computer only
operates under power.
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In the case of new vehicles, make sure that transport Transport mode can be reactivated (after service in the
mode is activated, i.e. until the delivery inspection showroom) up to 350 km. Before activation, the vehicle
immediately prior to handover to the customer. with connected 12 volt battery must be charged.
Special equipment
Overall vehicle
i i
Intended function impaired or operational safety of Avoid potential dangers to people or property
vehicle jeopardized. There is a heightened risk of damage due to lack of knowledge. Before installing
accident and injury! Modifications or changes to the any attachments, bodies, equipment or carrying out
vehicle with non-approved parts are prohibited. any modifications to the basic vehicle and/or its
Ensure that only approved parts are used. major assemblies, you must read the chapters of the
vehicle operator's manual relevant to assembly, as
well as the operating and installation instructions
issued by the manufacturer of the accessories and
items of special equipment.
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Special equipment, e.g. reinforced springs, frame
i reinforcements, additional fuel tanks, stabilizer bars etc.,
Contact person for vehicle configurations and or retrofitted equipment increases the curb weight of the
special equipment for model 963, 964, 967, 983: vehicle.
Technical advice for body manufacturers Mercedes- When chassis are equipped with different springs or tire
Benz Trucks sizes, the frame height can change considerably, in both
Tel.: +49 7271 71 2506 loaded and unloaded states.
Email: sosbb@daimlertruck.com The actual vehicle mass and axle loads must be
determined by weighing before mounting.
Contact person for vehicle configurations and
special equipment for model 405, 437, 956, 959: Not all special equipment can be installed in every
Technical advice for body manufacturers for vehicle without problems. This applies, in particular, in
Mercedes‑Benz Special Trucks (MBS) the case of aftermarket installations because the
necessary installation space may be occupied by other
Tel.: +49 7271 71 2503
components, or the special equipment may require
Email:sosmbs@daimlertruck.com additional parts.
Overall vehicle
aDanger
The high voltage used for electric welding presents a Use insulating mats. Wear protective clothing, safety
lethal hazard. Risk of explosion from welding in areas glasses and a protective mask. Remove highly
close to highly inflammable materials. Risk of injury from inflammable materials from the danger zone. Use air
weld splatter and UV-light when welding. Risk of extraction system.
poisoning from inhaling welding gases
Welding Page 130
Position and relocation of ESP(R) module Page 452
i i
Possible loss of intended function. Loss of control by Perform assembly of additional Mercedes‑Benz
the driver possible. Do not modify any screw genuine parts e.g., fuel tanks, on the vehicle frame
connections that are relevant to safety, e.g., that are as per the specifications "Tightening procedure for
required for wheel control, steering or braking existing threaded connections".
functions. For reasons of quality and process safety, it is
recommended that all threaded connections are
made according to "Tightening procedure for existing
threaded connections".
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Threaded connections on the vehicle frame commercial vehicles are maintenance free,
If it is necessary to replace standard screws with longer i.e.retightening of the bolts in the context of service
screws, only screws: intervals is not necessary. All threaded connections used
for work on Mercedes-Benz vehicles must satisfy the
• of the same diameter same requirements.
• of the same strength grade
Causes for the loosening of threaded connections
• of the same type
Threaded connections work loose when a permanent
• with the same thread pitch change in length occurs in the axial direction of the bolt.
may be used. This leads to a reduction in the preload force and thus a
reduced clamping force under operating loads. A
The following must also be observed:
permanent change in length can be caused by:
• VDI guideline2862 must be applied to all installation
• Settling
work.
• The surfaces of parts that make contact with other
• Any shortening of the free grip lengths, conversion to
parts, e.g.,nuts, washers, are coated with anti-
a stretch shank or the use of screws with a shorter
corrosion protection and settle under the pressure
free thread cannot be approved.
of the preload force. This means that as the
• The settling properties of threaded connections must number of interfaces connected with a bolt
be taken into account. increases, the greater the length change due to
• Additionally clamped component parts must exhibit settling.
an identical or higher strength than the previous • Creeping
clamped assembly.
• The pressure per unit area of the bolt and nut on
Use Mercedes‑Benz standard parts. the contact surfaces exceeds the specific
pressure strength of the material of the clamped
Flange head bolts parts.
Thanks to the use of flange head bolts, the threaded
connections on the chassis of Mercedes-Benz

Overall vehicle
Description of flange head bolts
The main feature of this type of bolt is a press-fitted
flange that increases the bolt head contact surface.
Properties
Flange head bolts and nuts that comply with Mercedes-
Benz standards MBN10105 and MBN13023 reduce the
danger of loss of preload caused by settling on the
contact surfaces. The unit pressure that is created under
the bolt head during the process of tightening is low in
contrast to other designs, because it is spread over the
increased contact surface.
W00.00-A029-11
Flange head bolt
Advantages of flange head bolts and nuts that • The elasticity of the threaded connection can be
comply with MBN10105 and MBN13023 increased further by selecting a high grip length ratio
• Reduced risk of creep due to an enlarged contact l/d (l=shank length, d=shank diameter).
surface and thus a lower pressure per unit area than • The use of flange head bolts and nuts guarantees a
other types of bolt heads. secure and maintenance-free threaded connection.
• Reduced settling effect due to a lower number of • Conformity in terms of grip lengths and screw-in
parts to be connected compared with threaded depths in blind holes must be ensured.
connections with washers. • Since the nuts are equipped with a self-locking
• The pressed-on concave contact disk increases the feature as per MBN13023, they must not be used
elasticity of the connection so that any settling or more that once.
creep behavior that still occurs can be compensated, • When flange head bolts and nuts are used with a
largely preventing any decrease in the clamping torque-controlled tightening process, the tightening
force. torques in the tables below must be complied with.

Permissible flange head bolts and nuts

The following flange head bolts and nuts are used at the factory:
• Flange head bolt M16 × 1.5 class 10.9 similar to MBN 10105 "head
height 10 mm", with adapted flange and T50 internal toothing on the
face side.
N42.60-A026-01
Flange head bolt (example)
Overall vehicle

Part number Shank length l [mm]
A 020 990 52 01 30
A 020 990 53 01 35
A 019 990 68 01 40
A 019 990 69 01 50
A 019 990 72 01 60
A 019 990 73 01 70
A 019 990 74 01 80
A 019 990 88 01 90
A 020 990 54 01 100
A 020 990 55 01 110
A 020 990 56 01 120
A 020 990 57 01 130
A 020 990 58 01 140
A 020 990 59 01 150
A 020 990 60 01 160
A 020 990 61 01 170
A 020 990 62 01 180
A 020 990 63 01 200
A 020 990 64 01 220
• Lightweight flange head nut M16 × 1.5 class 10,

integrated grip length extension (4 mm) without
clamping part, part number A 005 990 78 50

W00.00-A042-01
Flange head nut (example)
Alternative: • Flange head bolt M16 × 1.5 class 10.9 similar to

MBN 10105 "head height 10 mm" and adapted flange
(without T50 internal toothing on the face side)
Overall vehicle
• Flange head bolt M16 × 1.5 class 10.9 as per MBN space and the minimum grip length of the threaded
10105 "head height 14.4 mm" connections is guaranteed. From a technical
• Hexagon flange head nut M16 × 1.5 class 10, perspective, it is permissible to use all the listed variants
integrated grip length extension (4 mm) without at the same time, but this is not recommended.
clamping part, part number A 002 990 76 50 For flange head bolt M16 × 1.5 class 10.9 similar to
• Hexagon flange head nut M16 × 1.5 class 10 as per MBN 10105 "head height 10 mm", with adapted flange
MBN 13023 without grip length extension with and T50 internal toothing on the face side:
clamping part, part number N 000 000 00 57 38 In combination with specially equipped assembly
The flange head bolt and nuts listed here are screwdrivers ("Hold and Drive"), the required counter-
manufactured with a total friction coefficient µtotal torque (holding torque) is applied via the flange head nut
to the flange head bolt during the tightening process at
= 0.08 … 0.14 and with suitable anti-corrosion
the factory via the T50 internal toothing (instead of via
protection.
the bolt head as previously).
All the available flange head bolts (lengths, variants) can
For threaded connections not made at the factory, the
also be found in the interface parts catalog of the
required counter-torque can of course still be applied via
Mercedes-Benz Bodybuilder Portal .
the bolt head.
(http://bb-portal.mercedes-benz-trucks.com).
It is not permitted to tighten the threaded connection via
The flange head bolts and nuts listed as alternatives can the T50 internal toothing on the face side.
also be used, provided that the required installation
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Tightening method of existing threaded connections • The threaded connection must not be retightened
(torque and tightening angle tightening method) • New bolts and nuts must be used after disassembly.
• Preload force Fv min. = 108 kN
i Tightening method of additional threaded

Effective as of July 01, 2007, the surface protection connections (torque tightening method)
(9440.40) must not contain chromium 6.
The following requirements for the connection and for
the tightening procedure are to be optionally complied
with and implemented for all additionally provided (in
vacant bores) threaded connections of the vehicle frame
i with components/detachable parts installed by the
For attached components, e.g.,fifth-wheel couplings, body manufacturer:
the maintenance guidelines of the component
manufacturer should be followed! • Use permissible M16 flange head bolts and nuts
• Minimum grip length: 1.0 × bolt diameter
• Tightening torque: 260 Nm
The following requirements for the connection and for (MBN 10130 Part 3 Class II, torque wrench, nut
the tightening procedure are to be complied with and runner with shut-off clutch) preload force Fv min.
implemented for all existing threaded connections on the = 74 kN
vehicle frame and/or on chassis-mounted components/
detachable parts that are loosened or removed in the or
course of installing bodies and accessories: • 225 Nm (MBN 10130 Part 3 Class III, impact driver,
• Use of flange head bolts M16x1.5class10.9 as per "good impact wrench") preload force Fv Min 58 kN
MBN10105 • Total friction coefficient µtotal = 0.08 … 0.14 (do not
• Either lightweight flange head nuts M16x1.5class10, use any additional lubricants)
part number A0059907850 or flange head nuts with • The threaded connections may be retightened
clamping part M16x1.5class10 as per MBN13023,
part number N000000005738 or
• Minimum grip length: 1.0 x bolt diameter Screws conforming to standards ISO 4162 and
ISO 1665 (both of the normal shank design) and nuts
• Tightening torque: 225Nm (MBN10130 Part 3 Class conforming to ISO 7044 of property class 10.9, in
III) combination with surface protection to VDA 235 102.40
• Torque angle of 90° subsequently applied (do not or a final top coat of paint.
use any lubricants) Tightening instructions, permissible total friction
• Total friction coefficient µ tot=0.08 to 0.14 (do not use coefficients and achievable preload forces etc. are to be
any additional lubricants) defined by the user on a case-by-case basis.
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Overall vehicle
Using retainers (upper hole pattern row) and 17.5 mm (other hole
The longitudinal frame members have a continuous pattern rows).
50x50 mm hole pattern and hole diameters of 16.5 mm

For this reason, screw connections with M16 screws and nuts are mainly
used on the longitudinal frame member.
With secondary bolted joints, e.g., for cable brackets or wheel chock
holders, screw connections with a diameter of 10 mm can also be used in
combination with retainers (reducing shims).
N31.00-A002-01
Retainer M16 on M10 (part no.
A 000 990 74 83)
1 Retainer
2 Holder
3 Longitudinal frame member
N31.00-A000-02 N31.00-A001-02
Screw connection with two retainers Screw connection with one retainer
Screw projection
To ensure the load capacity of a threaded connection,
the nut thread must be fully used. This is the case when
the nut thread is completely filled. This rule deviates
from DIN 78.
This rule applies to all dimensions/nut variants.
A Protrusion ≥ 0 mm
N00.00-A009-10
Nut thread completely filled
Overall vehicle
Handling of safety-relevant threaded connections • Sudden loss of sight of the road
• Loss of ability to steer
• Loss or partial failure of braking function
i
Obligatory documentation requirement! • Failure of driving functions
Reference to the respective employee and the • Uncontrolled driving
assembly equipment must be provided. • Sudden failure of drive force
More detailed information can be found in the table
• Leakage of operating fluids/risk of fire
below.
• Loosening of cargo/trailer/parts
• Injuries during operation and other forms of control
It should be clarified at the outset using a screw joint
• Occupant protection system in accidents
classification, which threaded connections always
require torque-controlled tightening or angle-controlled RB: Function-relevant threaded connections
tightening and why this must occur. > Immobility cases
The following table clarifies the procedure for a safety- A screw joint is classified in risk class B if failure of this
relevant threaded connection (RA), whereby particular screw joint leads to vehicle malfunction.
attention should be placed on the issue of safety.
Examples include: fan wheel
Screw joint classification:
There is no obligatory documentation requirement.
RA: Safety-relevant threaded connections
RC: Subordinate threaded connection
> Danger to life and limb
> Customer irritation
A screw joint is classified in risk class A if failure of this
screw joint is highly likely to lead to safety-relevant Threaded connections from risk class C are connections
failure or to destruction of the overall vehicle and thus that lead only to customer irritation if they fail.
presents a direct or indirect danger to life and limb. There is no obligatory documentation requirement.
Examples include: wheels, doors, cab bearing, steering
A component or function is to be classified as safety-
relevant when at least one of the following safety
aspects could reasonably be expected to occur:

Overall vehicle

Handling of RA threaded connections
Pneumatic screwdriver/nut runner Calibrating screwdriver
Initial tightening Initial torque: Final torque:

(1st worker) Position and hold screwdriver, until the screw Position the screwdriver and hold it until the
head is in contact. torque of the screw to be tightened has been
(Up to approx. 75% of the final tightening reached.
torque can be applied in doing so.) (Calibration intervals must be defined in
accordance with DIN 6789.)
Torque tightening: Visual check:

Position torque wrench and apply torque until Visually check whether the screwing process
the torque wrench clicks once. and threaded connection are OK.
(When carried out correctly, clear continued (Criteria for assessment must be defined in
turning must be discernible.) the work instructions.)
Tightening angle: Tightening angle:

Execution of the additional tightening angle Execution of the additional tightening angle
with a non-releasing tool. with a non-releasing tool.
Documentation of the torque wrench and the Documentation of the screwdriver and the
worker carrying out the work in the checklist. worker carrying out the work in the checklist.
Validation Four-eyes principle

(2nd worker) (Critical tasks must not be carried out by one individual person.)
A second worker re-checks the screw connection (to ensure it has not been forgotten).

Apply and crack off torque wrench set at 110% of the nominal value. The screw connection
must not continue turning when doing so!
This process must only be used with tightening angle threaded connections.
Documentation with the 2nd torque wrench and the 2nd worker carrying out the work in the
checklist
Torque wrench use • Do not move the torque wrench jerkily; this leads to
• When adjusting the desired torque, always initially set incorrect results.
a value that is 5 to 10% above the desired value and Before storing the torque wrench, always set it to the
then turn back to the desired value. Only in this lowest torque value.
manner can a high degree of torque precision be Protect the torque wrench against impacts, shocks,
achieved. moisture and soiling from dust, sand and other particles
• Always place the torque wrench on the screw or nut and store it in the corresponding storage container as far
at a right angle in order to prevent slipping. as possible.
• Tighten the threaded connection with even pressure Only store the torque wrench at room temperature (15 to
until you hear and feel a click. The wrench indicates 25 °C) in a dry, sheltered location.
when the preset torque value has been reached with If you suspect the torque wrench is damaged, hand it
this click. Always trigger the torque wrench with a over to the person responsible for test equipment at
tightening process! once for inspection.
• Do not continue to strain the torque wrench after Torque wrenches must be calibrated once a year or after
releasing it in order to prevent damage to the 5000 load cycles.
mechanical components and threaded connection.
---------------------------------------------------------------------------
Overall vehicle
Welded connections Welding on the chassis/body may only be carried out by
specialist personnel.
Work instructions are available in the "Welding"
i document and in the Mercedes-Benz Workshop
Constant durability is not guaranteed. Do not weld Information System (WIS).
on major assemblies such as engine, transmission,
axles, etc. or on the vehicle frame (except
wheelbase and frame changes).
On model 983 vehicles, only make changes at the
frame overhang.
Riveted joints at the longitudinal frame member
i
Avoid damage to the vehicle longitudinal frame
member or to component parts.
If necessary, remove component parts beforehand,
especially electronic component parts, e.g., ESP®
module, (see "Position and relocation of ESP(R)
module" document).
Depending on the chosen vehicle model designation or

equipment combination, the following connections,
e.g., to the longitudinal frame member are made with
standard riveted joints:
W00.00-A113-81
• Crossmembers – from transmission to end of frame
Riveted joints on model 956
(except for the end crossmember - this is always
bolted.)
• Semitrailer bracket
• Connection between front end of frame and
longitudinal frame member.
Depending on the vehicle, these riveted joints can also
be made with threaded connections ex factory upon
request.
Sales code C5P, Bolted frame, is available for this
purpose.
If necessary, the described riveted joints can
subsequently be replaced with threaded connections as
per the specifications (see "Threaded connections on
the vehicle frame" section).
Display without fault message
General operations/modifications
The instrument cluster notifies the driver of all dynamic

and static driving conditions as well as about the current
condition of the systems installed in the vehicle.
In the event of faulty vehicle functions or functions
relevant to safety, corresponding warnings are issued
via the display in the instrument cluster.
As a result of work on the basic vehicle, the associated
networking can cause events to occur, e.g. fault
messages, even if the affected system has not been
modified.
W54.30-A058-80
Existing events must be checked and rectified at a Example: Event "Active Brake ASSIST not available" present
qualified Mercedes-Benz Service Partner.
Mercedes-Benz recommends that this be done by a
Mercedes-Benz Service Partner.
Observe the operator's manual.
View of event memory

The Event memory main menu (stack) is called up using the arrow buttons
< left and > right using the left steering wheel buttons.
The arrow buttons " up" and "down" are used to scroll through the submenu
(card), e.g. to call up events of the individual control units.
N82.90-A000-01
Steering wheel buttons
Line installation of Bowden cable
When the lines for the Bowden cables are installed, it during modification work. It must also be ensured that
must be ensured that the Bowden cables move easily the line is not crushed or kinked or installed with a radius
and smoothly when operated. This is of particular that is too small.
importance if the lines need to be changed or detached
Warning boards
Warning boards (also called hazard boards) mark • Standardized dimensions can be seen in the figure
hazardous materials transport trucks or tank containers. (see below).
These transport units must be provided with two • Reflective
rectangular, vertically attached, orange-colored plates • Numbers are legible even after the effects of a
(warning boards) (see figure). The following 15 min fire
specifications must be observed (Art. 22a German
vehicle licensing regulations (StVZO)): • Number for identifying the hazard in the upper part of
the plate
• Attach one to the front and one to the rear (vertical to
the longitudinal axis). • UN number in the bottom part of the plate
• Must always be clearly visible • Stroke width 15 mm
• Rattle-free mounting
Specifications regarding the warning sign (DIRECTIVE
2008/68/EC and Art. 22 StVZO):

1 Number for identifying the danger

2 UN number
W88.00-A022-71
Operations prior to vehicle delivery
Overview of documents/catalogs/instructions/circuit Page 730
diagrams
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Tire pressure table
Certain requirements must be met before a vehicle is

handed over to the customer.

Tire pressure monitoring system
i
See "Overview of documents/catalogs/instructions/circuit
diagrams" document.
i
The tire pressure changes depending on the outside temperature. A
10 ℃ change in air temperature corresponds to a difference of 0.1 bar.
If the outside temperature increases, the tire pressure also increases.
Check and adjust tire pressures with the tires cold. Pressure increases
due to heating of the tires while driving are normal and should not be
taken into consideration.
An operational and safe vehicle must be handed over to the customer. It

must therefore be ensured before vehicle handover that the installed tires
have the correct air pressure (see tire pressure illustration).
To ensure that the installed tires are inflated correctly, the tire pressure
N40.10-A000-03
tables are also provided in the Mercedes-Benz Workshop Information
Tire pressure
System (WIS).
A Tire pressure correct
B Tire pressure too low
C Tire pressure too high

Tire pressure table with associated document numbers
Designation Document number
Tire pressure table 17.5" AP40.15-W-4060-01C
Tire pressure table 20.0" AP40.15-W-4060-01E / AP40.15-W-4060-01S
Tire pressure table 22.5" AP40.15-W-4060-01F
Tire pressure table 24.0" AP40.15-W-4060-01G

Tire pressure table with associated document numbers, model 405/437
Validity Document number
Model 437.420/421/425/426/429/430/431/435/436 AP40.15-G-4060-01C
Model 437.46 AP40.15-G-4060-01F
Models 437.427/437 AP40.15-G-4060-01UH
Model 405.05/10/12/20/22 AP40.15-G-4060-01B
Model 405.210/230 only for USA/Canada AP40.15-G-4060-01NA
Model 405.090/104/105/110/125/202/222 AP40.15-G-4060-01UG
Steering wheel straight-ahead position ± 18 mm. If the steering wheel is outside this tolerance,
The straight-ahead position of the steering wheel must the straight-ahead position of the steering wheel must be
be checked and, if necessary, adjusted. The tolerance adjusted by a Mercedes-Benz Service Partner.
for the center steering position is TDC (top dead center)

W00.00-A082-76
Steering wheel straight-ahead position correct ≤ 18 mm.
W00.00-A083-76
Steering wheel straight-ahead position incorrect ≥ 18 mm.
Checking of the tachograph and recording was performed at the factory, this check must be carried
equipment out by the body manufacturer. Here, the body
According to Art. 57b StVZO (German vehicle licensing manufacturer is obliged to perform the check prior to
regulations), the tachograph on vehicles equipped with delivery to the customer in accordance with the
recording equipment (see Art. 57a StVZO) must be requirements of Art. 57b StVZO either themselves or to
checked in accordance with Art. 57b before the vehicle have it performed by an officially recognized company.
is delivered. In the case of vehicles on which no check
---------------------------------------------------------------------------
Removal of dirt residue on vehicle following
modification/body mounting
After the body manufacturer has completed the
modification work/body mounting, it must ensure that dirt
residues such as chips are removed.

W00.00-A076-76
Incorrect: Chips that, in this case, are already beginning to corrode are on the inside of
the frame.
W00.00-A077-76
Correct: The vehicle has been cleaned and there are no chips in the frame.
---------------------------------------------------------------------------
Reset of the time-based servicing scheme after a short after the actual commissioning of the vehicle, and
long period of non-operational time the customer reports this as implausible. The time-based
As a result of long non-operational times after activation servicing scheme is already shown as due in the display
of the maintenance system at the plant, the remaining shortly after the approval of the vehicle.
time of the time-based servicing scheme may be too
With the XENTRY data status 06/2021, the total lifetime MS maintenance system (A2 a3)→
of the maintenance system can be reset for up to 18 Commissioning→
months after activation at the plant or up to a mileage of
2000 km. This means that the maintenance calculation Special functions→
can be adapted to match the vehicle's actual delivery 4.1 Reset of values ''Total running times in maintenance
date. system''
The total lifetimes can be reset once using XENTRY
Diagnosis in the following menu:
Transport mode
aDanger
i
Possible discharge damage to the main batteries by
consumers that are not switched off. Either
disconnect the battery or activate the transport mode
for conversion and storage times of more than 24 h.
From production month 04/2019, all vehicles have an active transport mode
in the delivery condition ex works.
The transport mode includes the deactivation of various electrical
consumers when the engine is not running and serves to protect the
batteries from discharging when the vehicle has been parked for an
extended period of time.
After the ignition is switched on, the activated transport mode is displayed
for five seconds as pop-up information in the vehicle display or is
permanently stored in the event menu.
If the converted/modified vehicle is handed over directly to the end
customer, the transport mode must be deactivated immediately N54.00-A000-01
beforehand. The transport mode must be activated when the vehicle is Example of Classic line
handed over to a body manufacturer or vehicle handover representative.
Consumer • Heating for outside mirrors

The following functions are not available in transport • Subwoofer
mode: • Lamp for bunk
• EPAC deactivation • Rear luggage compartment lighting
• Shortening of lighting duration of interior lighting (5 h • Radio
to 30 min)
• Refrigerator
• Shortening of lighting duration of Follow Me Home
function • WMI charging function
• Night illumination • Reading light
• Cigarette lighter • Cargo lift gate
• Seat heater • Alternator charge management
• Upper stowage compartment lighting • Multimedia functions (incl. USB interface)
• Cargo area lighting • Low beams (with ignition OFF)
• 24 V/12 V sockets (12 V socket only if there is no • Ignition (to stage 1 after 15 min, if engine off and
connection point for body manufacturers) diagnostic device not connected)
• Ambient/camper lighting • Compressed air drier heater
• Work lamps (sales code L3x)
• Opening the sliding or tilting roof
Transport mode
Manual changeover To avoid discharge damage to the main batteries by
Simultaneous operation of the following control elements consumers that are not switched off, either disconnect
for at least 3 s within 3 s after switching on the ignition: the battery or activate or reactivate the transport mode
for conversion and storage times of more than 24 h. In
• Hazard warning light switch the event of damage, internal vehicle documentation
• Headlamp flasher (pull steering column lever towards makes it possible to trace when the transport mode was
driver) activated. If the converted/modified vehicle is handed
over directly to the end customer, the transport mode
• Turn signal sensor (press steering column lever down
must be deactivated immediately beforehand. The
= activate or up = deactivate)
transport mode must be activated when the vehicle is
The changes are documented by the vehicle with time handed over to a body manufacturer or vehicle handover
and mileage stamps. representative.
In the event of damage, internal vehicle documentation
makes it possible to trace when the transport mode was
activated.
Painting
Color deviations cannot be ruled out if paints with RAL

Environmental note number are used.
Paints and lacquers are harmful to health and to the The surface quality of components, parts and bodies that
environment if they are not handled correctly. are mounted on the vehicle by the body manufacturer
Dispose of paints and lacquers in an environmentally must be meet the same criteria as for genuine parts.
responsible manner.
Mask the following areas before painting:
• Sealing surfaces
Paintwork compatibility should be checked when • Window(s)
repainting. In order to avoid color deviations on painted
• Contact surfaces between the disk wheels and the
bodies, Mercedes-Benz recommends that paints be
wheel hubs
used only if they have been tested and approved for the
vehicle model in question. Information on the primers • Contact surfaces of wheel nuts
used at the factory and on Mercedes-Benz color • Breathers on transmissions, axles, etc.
numbers can be obtained from the relevant contact
person (see "Advice for body manufacturers" • Disk brakes
document). • Door locks
To avoid color deviations, only paints with Mercedes- • High-voltage lines (eVehicles)
Benz color numbers should be used when carrying out
• High-voltage components (eVehicles)
painting work on Mercedes-Benz commercial vehicles.
---------------------------------------------------------------------------
Paint drying object temperature of the high-voltage components of
The temperature of the drying chamber must not exceed 60 °C (eVehicles) must not be exceeded during a paint
80 °C, and the duration of the drying process must not drying process.
exceed 1 hour at this temperature. In principle, the

Viewing distance
Parts must be assessed without using optical aids (e.g.,
mirrors, lamps, magnifying glass). When doing so, the
assessor must be located at a distance of approx.
800 mm from the test object (length of outstretched
arm). At the entrance area (door opening, door inside
and entrance), the distance must be reduced to
300 mm.
a Approx. 800 mm
N98.00-A000-12
Viewing distance
Painting
Viewing position
The components must be assessed according to the
installation angle and position on the vehicle or
corresponding to its functional position.
The component is assessed by a person standing
upright at the assessment position.
N98.00-A001-12
Viewing angle
Painting assessment (view zones) View zone C: Concealed/secondary view zone

The following quality zones have been defined for (primary chassis view zone)
assessment of the paintwork: This includes the roof from above, rear of roof, cab rear
View zone A: Direct view zone panel, front-end assembly below maintenance flap, outer
chassis including crossmember (outer side), underride
This includes the surface area on the cab between the guard (outer and inner sides). In the drivetrain, this view
lower door edge up to the roof drip rail (lower edge of zone includes areas visible from the outside and with
roof), and the complete area of the interior door and the tilted cab: Engine (not hot parts), bell hub. On the body,
stowage compartment flap opening. Detachable parts in the visible surfaces at the left, right and on the rear
this view zone: Front-end assembly maintenance flap, panel.
front air deflector and cab side wall, outer stowage
compartment flap. Also the entrances on the Atego. View zone D: Interior view zone (secondary chassis
view zone)
View zone B: Indirect view zone
This includes the chassis inside of the longitudinal
This includes less prominent surface areas that could member and the engine's hot parts. On the body, the
become direct view zones: Roof front and roof side on underside (e.g., dump truck).
cab.

Painting
Actros as example
W98.00-A001-76
Actros as example
W98.00-A002-76
Painting
Example on the Atego
W98.00-A003-82
W98.00-A004-73
Painting
W98.00-A005-76
Painting

Fault description in quality zones
Error type View zones
A B C D
Direct view zone Indirect view zone Concealed/secondary Interior view zone
view zone
Dust/dirt inclusions Particle size ≤ 2.5 mm permissible ≤ 3 mm permissible > 3 mm > 3 mm

permissible permissible
Cracked top coat Not permissible Not permissible Not Not

Particles with color Not permissible Not permissible Not Not

shade deviation permissible permissible
(irrespective of size)
Particles in Not permissible Not permissible

decorative coating
area if they can be
seen through the
decorative coating
film.
Paint spots ≤ 3 mm ≤ 2.5 mm permissible ≤ 3 mm permissible > 3 mm > 3 mm

(rework) permissible permissible
Craters/popping/blisters Defect size ≤ 2.5 mm permissible ≤ 3 mm permissible > 3 mm > 3 mm

Cracked top coat Not permissible Not permissible Not Not

Faults with color Not permissible Not permissible Not Not

shade deviation permissible permissible
(irrespective of size)
Faults in decorated Not permissible Not permissible

area if these faults
are visible through
decorative foil.
Lean paint job, paint Not permissible Not permissible Not Not
flaws (filler/cathodic permissible permissible
electrodeposition
coating visible)
Runs (cathodic Number and size of 0 x < 5 mm permissible 1 x < 5 mm 1x≥5- ≥ 30 mm

electrodeposition runs per component permissible 30 mm permissible
coating, filler, topcoat) part surface area permissible
Porous runs Not permissible Not permissible Not Not

Droplet formation Not permissible Not permissible Permissible Permissible
Undulating Not permissible Not permissible Permissible Permissible

discharge
Painting
A B C D
Cathodic Not permissible Not permissible Not Permissible

electrodeposition permissible
coating runs
(irrespective of
number and size)
Distribution/structure Matt areas Not permissible Not permissible Not Permissible

permissible
Partial differences Not permissible Not permissible Permissible Permissible

on visible
component surfaces
Differences to Not permissible Permissible Permissible Permissible

adjacent
components
Damage with cracked Not permissible Not permissible Not Not

top coat (scratches, permissible permissible
dents, ….) or porous
areas
Surface damage Not permissible Not permissible Not Permissible

(scratches, dents, ….) permissible
Color deviations Not permissible Not permissible Not Permissible

permissible
Luster deviations Widespread, Not permissible Not permissible Permissible Permissible

homogeneous
deviations in luster
Clouding Not permissible Not permissible Permissible Permissible
Grinding/score marks Not permissible Not permissible Permissible Permissible
Peeling/poor adhesion Not permissible Not permissible Not Not

Paintwork rectification/ Not permissible Not permissible Not Permissible

paint fog permissible
Polishing marks Polishing marks Not permissible Not permissible Permissible Permissible
Polishing marks with Not permissible Not permissible Not Not

cracked top coat permissible permissible
Misting with different Not permissible Not permissible Not Not

color permissible permissible
Painting
A B C D
PVC sealing and Flaws, residue Not permissible Not permissible Not Max. 3
seams*** permissible flaws
permissible,
at certain
points only
& smaller
than 3 mm
& not on a
flange for a
length of
30 cm in
total.
Blisters, damage Not permissible Not permissible Permissible Permissible

if the if the
functionality functionality
of the seal of the seal
is not is not
impaired. impaired.
Chatter marks, Not permissible Not permissible Permissible Permissible

unevenness if the if the
functionality functionality
of the seal of the seal
is not is not
impaired. impaired.
i
Further information on painting can be found in the
Mercedes-Benz Workshop Information System
(WIS).
Routing of electric lines, compressed air lines and fuel lin...

diagrams
i i
Lines must always be routed in such a way that they The part numbers are available in the interface parts
are not damaged due to stone chippings, abrasion, catalog (see "Overview of documents/catalogs/
crushing or contact with sharp edges or heat instructions/circuit diagrams" document).
sources!
i
Parts which are approved by Mercedes-Benz and
which, in some cases, can be reused are available
for securing lines to the longitudinal frame member.
---------------------------------------------------------------------------
The information on routing applies to electrical, • Lines which rest against bolt heads, rivet heads or
compressed-air and fuel lines. gusset plates must be provided with a spacer at the
• In the lower area, route the lines along the inside of attachment point, in front and behind.
the longitudinal frame member. • Lines between components that move relative to
• Lines are secured to fixing points or holders using each other, e.g., frame relative to engine/
cable ties or clamps. transmission, must be fixed in place without tension
and with adequate clearance. The line lengths must
• The holders must not damage the lines or the anti- be able to compensate the maximum possible
corrosion protection of the longitudinal frame relative movements.
member.
• Lines must not be attached to or lie against
• To ensure that routing in the longitudinal frame pneumatic, diaphragm or spring-loaded brake
member is not impeded by bolt protrusions, gusset cylinders.
plates or other protrusions, it is necessary to use
spacers (of different types). • Lines must not be routed over sharp edges or moving
parts.
The distance between the individual fixing points must
not exceed max. 500 mm. • Appropriate feed-through grommets must be used at
openings in frame longitudinal members and
When lines are attached in other areas, specially shaped crossmembers. Chafe protection, e.g., in the form of
holders with notches for positioning the cable ties are a corrugated plastic tube, can also be used.
normally used.
• If lines are routed around the lower frame flange,
The following criteria also apply: suitable peripheral holders must be used.
• Owing to the effect of heat, lines must not lie against The following minimum distances must be observed at
or be attached to the compressor line or compressed- heat sources:
air lines.
• For exhaust pipes without shielding: 200 mm
• Lines that cross over are to be fixed in place at the
intersection point using a cable tie. • In the area close to the exhaust gas aftertreatment
unit, without shielding: 150 mm
• Mount the cable tie lock toward the line. To minimize
the risk of injury, cut off the excess end of the cable • For heat sources with sheet metal shielding: 100 mm
tie flush at the head. • For heat sources with sheet metal shielding with
• Lines which run parallel to elbow fittings should be additional insulation: 80 mm
fixed to the elbow fitting.
---------------------------------------------------------------------------
Cable tie

Incorrect:
Cable ties are not cut off flush. Risk of injury.
W60.00-A006-10
Correct:
Cable ties are cut off flush.
W60.00-A007-10
Incorrect:
Cable strap missing; the position of the line bundle is not
assured.
W60.00-A008-11
Correct:
Cable strap is mounted at the intended position.
W60.00-A009-11
Incorrect:
Cable tie is loose because tightening force is not
optimal.
W60.00-A010-10
Correct:
Cable tie is correctly tightened (note cable tie pliers
tightening instructions).
W60.00-A011-10
Assembly fault

Incorrect:
Cable strap must not be attached in the transition area
of the barbed end. PA line (polyamide line) may be
damaged by attaching the cable strap.
W60.00-A012-11
Correct:
Attachment on the barbed profile up to 10 mm before
the barbed profile end (picture A) or where the distance
of the cable tie from the stop shoulder is at least 40 mm
is permissible (1, picture B).
W60.00-A013-11
Incorrect:
Incorrect installation, cable strap must not be attached in
the transition area of the barbed end. PA line can be
damaged when cable strap is attached.
W60.00-A014-11
Correct:
Attachment on the barbed profile up to 10 mm before
the barbed profile end (picture A) or where the distance
of the cable tie from the stop shoulder is at least 40 mm
is permissible (1, picture B).
W60.00-A015-11
Incorrect:
Compressed-air line is pinched between the wiring
harness and a component.
W60.00-A016-11
Correct:
Compressed-air line is unattached.
W60.00-A017-11
Holder
Incorrect:
Correct attachment of the spacer is not assured and
tightening force of cable strap not sufficient. The holder
is partially loose.
W60.00-A018-11
Correct:
Spacer is lying flat against surface, cable/holder is fixed.
W60.00-A019-11
Incorrect:
Some lines are too long, suitable line bracket is missing,
lines chafe against crossmember.
W60.00-A020-11
Correct:
Wiring harness is mounted on a suitable bracket with
spacer disk.
W60.00-A021-11
Incorrect:
Wiring harness is secured on holder, bolt damages the
topcoat.
W60.00-A022-11
Correct:
Wiring harness is mounted on a suitable holder.
W60.00-A023-11
Incorrect:
Holder has different design. It collides with other
components.
W60.00-A024-11
Correct:
Correct holder design. There are no collisions in the
installation space.
W60.00-A025-11
Approved line brackets

Example
Line bracket with spacer disks for attaching lines in
longitudinal frame member (cannot be used in top hole
pattern row)
1 Expansion rivet: A 000 991 81 40
2 Spacer disk: A 008 990 74 82 (max. 2 pcs./rivet
3 Line bracket: A 002 995 24 77
W60.00-A026-10
Line bracket (Hellermann clips)
Example
Cable clamp for attaching lines in longitudinal frame
member (cannot be used in top hole pattern row)
A 960 543 41 40 (can be used several times with a new
cable tie.)
W60.00-A027-10
Line bracket
Sharp edge

Incorrect:
Line is routed over sharp edge, risk of chafing.
W60.00-A028-11
Correct:
Correct holders mean no chafing.
W60.00-A029-11
Incorrect:
Battery cable poorly installed, line is lying on sharp edge
on the BGT (battery carrier).
W60.00-A030-11
Correct:
Battery cable routed with clearance (cable is allowed to
lie on top of battery).
W60.00-A031-11
Line chafes

Incorrect:
PA line chafes against cable tie lock.
W60.00-A032-11
Correct:
PA line is routed with clearance.
W60.00-A033-11
Incorrect:
Line chafes/is lying against thread of a bolt.
W60.00-A034-11
Correct:
Line is routed with clearance.
W60.00-A035-11
Incorrect:
Chafe protection missing at frame opening. Line can
chafe.
W60.00-A036-11
Correct:
Chafe protection present in the form of a feed-through
grommet at frame opening.
W60.00-A037-11
Incorrect:
Brake lines poorly installed, cable ties missing.
W60.00-A038-11
Correct:
Brake lines are secured using cable ties to prevent
chafing.
W60.00-A039-11
Incorrect:
Brake line chafes/rubs against pressure regulator.
W60.00-A040-11
Correct:
Brake lines are fixed in place using cable ties so that
lines do not lie against spring housing of the pressure
regulator and so that clearance relative to other
components is provided.
W60.00-A041-11
Incorrect:
Intersecting point is not fixed in place, line can chafe.
W60.00-A042-11
Correct:
Intersecting point is fixed in place using a cable tie.
W60.00-A043-11
Bending radii
Incorrect:
PA line is kinked. Bending radius is not observed.
W60.00-A044-11
Correct:
Bending radius and length of the line are observed; line
is not kinked.
W60.00-A045-11
Incorrect:
Electric lines are poorly installed. Strain-relief clamps
missing.
W60.00-A046-11
Correct:
Cable and plug are routed free of tension.
W60.00-A047-11
Incorrect:
Minimum bending radius for compressed-air lines is not
observed.
W60.00-A048-10
Correct:
Minimum bending radius is observed.
W60.00-A049-10

Minimum bending radii for compressed-air lines
Bending radius min. Nominal size
30 mm Nominal size 6x1 mm (NG6)
60 mm Nominal size 12.5x1.5 mm (NG12)

Minimum bending radii for fuel lines
Pipe dimension rmin. on the inner edge of the pipe [mm]
13x1.5 65
16x2 95
This table refers only to pipes made of the materials PA12-HIPHL, PA11-PHLY and PA12-PHLY.
Damage

Incorrect:
Connecting part damaged! Installation will lead to a
leaky compressed-air system and can impair the system
performance.
W60.00-A050-11
Correct:
Connecting part is without any form of damage.
W60.00-A051-11
Routing of hydraulic lines
If hydraulic lines or hoses need to be routed on The selected hoses must be such that they can
Mercedes-Benz chassis, proper mounting and execution withstand the operating pressure of the respective
must be ensured. equipment as well as the mechanical, chemical and
Here, it is important to observe the specifications from thermal loads that may occur.
the hydraulic hose manufacturer and the component
manufacturer (crane, cable winch, etc.).

Example
The hose in the example is a pressure hose for
supplying a tilt cylinder. The working pressure of the
device is approx. 230 bar. A hose with a maximum
permissible working pressure of 250 bar is used. This
means that the used hose is suitable for the intended
application.
W55.30-A011-11
1 Hose manufacturer and type

2 2 = Double-layer high-pressure hose
16 = Nominal diameter
3 Standard designation
4 Maximum permissible working pressure
5 Month and year of manufacture
W55.30-A012-10
Storage period and usage duration of hydraulic lines

Storage period and usage duration as per DIN 20066

1 Manufacturing date of hose yard ware
2 Manufacturing date of hose line
3 Usage duration of hose yard ware: max. 4 years
4 Usage duration of hose line: max. 6 years
5 Storage period of hose line max. 2 years
W55.30-A013-10
The hose can therefore be used for up to ten years This means that the yard ware used to manufacture a
(4 + 6 years). hose line must not have been stored for longer
than 4 years. A newly manufactured hose line can be
used for up to six years, provided that it is put into
service immediately (i.e. the hose line is not stored

beforehand). Note
A manufactured hose line can only be stored for Hydraulic lines that are routed close to the areas for
max. 2 years; the usage duration decreases by the the vehicle driver, the front passenger and other
actual storage period. passengers and the areas which are intended to be
occupied to allow controls to be operated, must be
routed or secured in such a way
that persons are not endangered if the hydraulic
lines fail.
---------------------------------------------------------------------------
Line routing
Hydraulic lines must not be secured to lines of the
chassis (e.g. compressed-air lines, electrical cables,
etc.).

Incorrect:
Hydraulic hose is secured to the wiring harness of the
chassis.
W55.30-A014-11
Correct:
Hydraulic hoses are secured
separately using a holder and hose
clamp.
W55.30-A033-75
The relative movements occurring during vehicle stretching and compression of the line must be taken
operation (e.g. between the engine and chassis or into consideration.
between the body and chassis) and the associated

Incorrect:
Relative movement of engine causes chafing and
results in damage.
W55.30-A016-11
Correct:
Torsional movements are compensated for by means of
appropriate hydraulic hoses.
W55.30-A017-11
When installing lines, holders must be used that are connections, e.g. the longitudinal members,
designed for that type of hose/pipe installation. Secure crossmembers, engine bearings, stabilizer bar bushings,
the holders only at existing holes in the chassis. Never spring bearings, tensioning straps, etc.
secure the holders at existing, heavily loaded threaded

Incorrect:
Clamp is bolted to tensioning strap of air reservoir.
W55.30-A018-11
Correct:
Holder is secured on existing hole pattern.
W55.30-A019-11
If possible, intersections of hydraulic hoses must be If intersections of hydraulic hoses are present, it is
avoided by implementing appropriate design measures. important to ensure that the hoses are attached in such
If this is not possible, double clamps must be used. a way that they cannot chafe against each other.

Incorrect:
Intersection of hydraulic hoses without secure
attachment.
W55.30-A020-11
Correct:
Double clamp is used to secure intersection of hydraulic
hoses.
W55.30-A021-11
Acceptable:
Intersection is fixed in place using PVC protection and
cable tie.
W55.30-A022-11
If it is not possible to avoid chafing points, chafe

protection must be used.

Incorrect:
Chafe protection missing, hydraulic hose chafes against
crane support foot.
W55.30-A023-11
Correct:
Chafe protection attached as chafe-free installation is
not possible.
W55.30-A024-11
In the case of parallel hose routing, cable ties can be suitable for the intended purpose and have the correct
used to secure the hoses. When using holders for heavy diameter.
air intake and pressure hoses, use clamps which are

Incorrect:
Clamp is too big for hose; protective rubber becomes
detached due to pulsing of line.
W55.30-A025-11
Correct:
Suitable hose clamp is used.
W55.30-A026-11
Incorrect:
Attachment of pressure hose is inadequate.
W55.30-A027-11
Acceptable:
Holder with PVC protection and cable tie; the dead
weight of the hoses is carried by the holder.
W55.30-A028-11
Always route hose lines in such a way that the minimum undershot. For this reason, it is important to ensure that
bending radius is not undershot. The weight of a hose the hose is secured appropriately.
line can also cause the minimum bending radius to be

Incorrect:
Minimum bending radius is undershot.
W55.30-A029-11
Correct:
Minimum bending radius is observed by means of angle
adapter.
W55.30-A030-11
The following must also be noted in the case of • An optical oil level gauge must be present on the
hydraulic systems: hydraulic oil reservoir.
• With large distances, e.g. in the case of lines that • Always install the stopcock on the hydraulic oil
have to be routed from the front to the rear end of the reservoir in such a way that it cannot be operated by
vehicle, use pipes with threaded connections suitable external influences during vehicle operation. A cable
for the pressure in place of hoses. tie must additionally be attached to lock the valve.
• Avoid painting over hydraulic hoses. • The oil quality must be checked via a visual check,
• Hydraulic hoses, hydraulic connections and hydraulic e.g. visual check for water in the hydraulic system
oil reservoirs must be checked for leak tightness. (milky oil).
Basic vehicle, general
Welding Page 130
Welding on the chassis/body may only be carried out by

i specialist personnel.
Possible loss of intended function. Loss of control by Major assemblies installed during work to implements,
the driver possible. Do not modify any threaded bodies, equipment or modifications must comply with the
connections that are relevant to safety, e.g., that are applicable laws and directives, as well as work safety or
required for wheel control, steering or braking accident prevention regulations, safety rules and
functions. Parts must be refitted in accordance with accident insurer leaflets.
Mercedes-Benz service instructions. Use genuine
MB parts only.
---------------------------------------------------------------------------
Model series 983
Subsequent mounting of components on frame in area
of rear axle for vehicles with battery-electric drive.

W31.00-A083-78
A Min. 30 mm B 635 mm C Min. 25 mm
Mount detachable parts at side on frame only in structures (highlighted in blue) must note be restricted by
implement mounting space shown (picture W31.00- attachments, to ensure that a collision detection system
A083-78) in Y-direction up to outer edge of high-voltage with, where applicable, connected high-voltage
battery at maximum (distance B = 635 mm). Always deactivation can be provided that complies with the
observe minimum distances to batteries (A) and carrier design specification.
for battery guard cover (C).
The freedom of movement and deformation of the side
battery guard cover, crash sensors and their holder
Vehicle overhang and technical wheelbases
Technical threshold values for planning

Load distribution Page 113
Calculations Page 732
Steerability Page 115
i i
All national laws, directives and registration Calculation of technical wheelbases (see document
requirements must be observed! "Calculations"). Note the different calculation
methods for 4-axle chassis with or without axle load
compensation at the two front axles.
---------------------------------------------------------------------------
General • Observe the minimum front axle load (see document
• The specifications are based on a uniform load "Steerability").
distribution (see document "Load distribution"). • Take the weight of special equipment into
Deviations are only permissible in compliance with consideration when making calculations.
the minimum loads (steerability, brakes) and the • With trailer operation, also pay attention to possible
maximum axle loads. tongue weights.
The maximum permissible shear-out dimension must
be observed.
• When calculating the length of the vehicle overhang,
always take into account the permissible axle loads
and the minimum front axle load.
---------------------------------------------------------------------------
Maximum vehicle overhangs

Maximum vehicle overhangs (Ü)
2-axle vehicles 65% of wheelbase
3-axle vehicles 70% of technical wheelbase
4-axle vehicles 70% of technical wheelbase
A large number of overhang lengths and end

crossmember positions are available ex factory.

Vehicle overhang and technical wheelbases
R Wheelbase
Ri Technical wheelbase
Ü Overhang
W00.10-A021-03
Wheelbases and overhang
Load distribution

when evenly loaded up to the technically permissible
i gross mass.
Impairment of driving characteristics, particularly When the vehicle is unloaded or partially loaded, there
with regard to the transmission of steering and brake may be an inclination angle along the longitudinal axis
forces as a result of excessive load weight at the depending on the vehicle model designation, axle load
rear. When designing bodies, avoid excessive load configuration and suspension type.
weight at the rear.
Front or rear loads, e.g. a loading crane, may produce a
greater inclination angle in the longitudinal direction.
The vehicles are designed so that they are This effect is to be taken into account when designing
approximately horizontal in the longitudinal direction the overall concept.
---------------------------------------------------------------------------
Wheel load Example 1:
• Permissible technical axle load 10000 kg
• Permissible wheel load distribution 5000 kg to
i 4600 kg
Wheel load differences (left/right) can cause
unexpected driving, steering and braking behavior, Example 2:
and lead to one-sided wear characteristics on all the
• Actual existing axle load 7693 kg
affected components.
• Permissible wheel load distribution 4000 kg to
3693 kg
The objective is to achieve a uniform distribution of
wheel load on the completed vehicle.
i
If a wheel load difference (left/right) should
nevertheless occur while observing the technically
permissible wheel and axle loads, this must not
exceed 4% of the actual axle load. The maximum
permissible wheel load on each side is 50 percent of
the technically permissible axle load.
---------------------------------------------------------------------------
Rear axle load vehicles with two front axles. If necessary, additional
For regulation-compliant operation of the vehicle, the ballasting in the body should be provided. If this
load must be distributed such that the percentage of the specification is not observed, the approval requirements
actual vehicle mass on the rear axle is at least 33 % on for the brake system may no longer be ensured for every
vehicles with one front axle, and at least 32 % on point.
---------------------------------------------------------------------------
Axle load configurations 8x4/4 and 8x2/4 with air- guard etc.) at the rear axles relative to the center of the
sprung rear axles technical rear axle compared to the curb weight of the
To allow the rear axle to be lowered completely to the vehicle in operational condition (as per data sheet or
hard stop on vehicles with axle load configurations 8x4/4 weight as weighed). The amount of weight required is
and 8x2/4, the body manufacturer must provide an plotted against the wheelbase in the diagram below. If
additional minimum weight (e.g. by means of body this requirement is ignored, there is a risk of damage to
structures, longer rear frame overhangs or additional the air suspension bellows.
attachments such as a spare wheel, rear underride

Load distribution
A Wheelbase [mm]
B Minimum weight [kg]
W00.10-A025-11
Required minimum weight at center of rear axles
Steerability

Due to national regulations, e.g. UN-R 13 on brakes or

i UN-R 79 on steering, it is necessary to maintain a
In this chapter, representations, code scopes and minimum front axle load in all load conditions. This
pre-installations of other model designations and ensures sufficient steerability and/or sufficient braking
model series are listed for reasons of power (auxiliary braking effect in the event of a circuit
standardization. The information that is applicable to failure). The following table contains guideline values
your model designation/model series must that are minimum front axle loads for safe handling
exclusively be used. characteristics and compliance with national regulations
based on empirical values. Observe the design criteria
with regard to body load and payload (see "Load
distribution" document).
i If deviations are nevertheless required, the relevant

Do not exceed the front axle load. The braking contact person (see "Advice for body manufacturers"
distance may increase considerably if the vehicle is document) must be consulted.
overloaded. Otherwise, the vehicle support structure
may be damaged.

Actros, Arocs, Atego
Vehicle Conditions Minimum front axle load
2-axle, 3-axle and 4-axle - 25% of the actual gross vehicle mass
vehicles
2-axle vehicles With cargo liftgate 30% of the actual gross vehicle mass
With loading crane at rear area
Other rear loads
Operation with rigid drawbar trailer (SDAH) or
center-axle trailer (ZAA), tractor/trailer
combination ratio ≤ 1:1
Operation with rigid drawbar trailer (SDAH) or 35% of the actual gross vehicle mass
center-axle trailer (ZAA), tractor/trailer
combination ratio > 1:1
Single tires (only on model series 967) Minimum axle load ratio of 1:1.451)
2-axle, 3-axle and 4-axle Solo operation and no major assemblies at 22% of the actual gross vehicle mass2)
vehicles rear area
1) For reasons of driving dynamics, the specified ratio FA:RA must be maintained in every load condition.
2) For model designation 963.042 and wheelbase 3850 mm (sales code C1Y), 23% of the actual gross vehicle mass must be
maintained.
Steerability

Econic
Axles and tires Application Minimum front axle load
2-axle vehicles in solo operation Waste collection vehicle, rear loader 25% of gross vehicle weight
3-axle vehicles in solo operation Waste collection vehicle, rear loader 20% of gross vehicle weight
19% of gross vehicle weight with
steered ENA/leading axle
4-axle chassis with triple rear axle in Waste collection vehicle, rear loader 20% of gross vehicle weight
solo operation
2-axle vehicles - With cargo liftgate 30% of gross vehicle weight

- With loading crane in rear area
- Operation with 1-axle trailer (center-
axle trailer)
Operation with center-axle trailer, 35% of gross vehicle weight

truck/trailer combination ratio > 1:1
2-axle and 3-axle vehicles in solo - Without major assemblies in rear 22% of gross vehicle weight
operation area
- No operation with center-axle trailer
- Not high load at center of gravity
Other configurations Other applications 25% of gross vehicle weight
If multiple conditions apply to the vehicle, the higher

minimum front axle load must be observed.
Clearance for major assemblies and cab

Hydraulic auxiliary drive (HAD) Page 244
External gearshift
i • Sufficient clearance from the body, even when the
Information on the tilt radius of the cab variants can cab is tilted.
be found in the 2D-chassis drawings (offer drawings)
• Observe the vertical slewing range of the semitrailer.
in the Mercedes‑Benz Bodybuilder Portal.
(http://bb-portal.mercedes-benz-trucks.com). Spring-loaded brake cylinder
On vehicles with drum brakes, observe clearance and
easy access for the spring-loaded brake emergency
Certain gaps must be maintained in order to ensure the release screw.
function and operational safety of major assemblies.
The dimensional data in the 2D-chassis drawings must Engine, transmission, retarder
be observed. The minimum distance from the body is 30 mm. On
vehicles with hydrostatic auxiliary drive (HAD), sales
Permanent chassis-mounted component parts code A1H, note the additional installation space required
Minimum distance from body 20 mm for the hydraulic pump on the engine (see document
"Hydrostatic auxiliary drive (HAD)").
Exception
High-voltage batteries (model series 983 only)
In the area of the cab suspension system, the distance
from the body may be reduced to 10 mm. However, this The distance of any body parts to the high-voltage
reduced distance is permissible only for vehicles used batteries must be at least 30 mm.
exclusively on roads. This is necessary to ensure that
the body begins at 2350 mm.

Attachment above cab

Observe the permissible center of gravity location and the front axle load.
Make sure that there is sufficient space for tilting.
W00.10-A013-01
Cab tilting range clearance
Cab
The distance (a) between the tilt cab (including detachable parts) and the
body or any components permanently attached to the frame must be at
least 50 mm. This dimension refers to a straight body contour. The
clearance must be greater at the top.
W00.10-A014-01
Front of body and clearance behind cab
Frame lowering on air-sprung vehicles
Condition after ignition off/ignition on:

i If the ignition is switched off while the functions of codes
Depictions, code scopes and pre-installations for Q3Y, Q3Z and Q3U are active, the functions of these
other vehicle model designations and model series codes are completely deactivated.
are listed in this chapter for reasons of
If the ignition is then switched on again, the functions of
standardization. Only use the information valid for
the codes remain deactivated.
your vehicle model designation/model series.
The functions of codes Q3Y, Q3Z and Q3U must
therefore be requested/activated again after an ignition
change by means of a separate request (e.g. switch,
PSM 2).
i
Possible limitations with respect to stability and This functional behavior of the vehicle must be taken into
possible damage to air suspension components. account by the body manufacturer when designing the
There is a risk of accident and damage. Observe the application.
afore-mentioned specifications and design the body In combination with models 963, 964 and sales codes
accordingly. Q3Y, Q3Z and Q3U, the frame is lowered automatically
when the factory-fitted transmission power take-offs
and/or the live power take-off versions are activated.
On air-sprung vehicles, frame lowering may be
In combination with models 963, 964 and non-
necessary/prescribed for the work mode, depending on
engageable engine power take-offs or on model 983xxx,
the vehicle variant/body combination and use of the
automated frame lowering cannot be implemented ex
vehicle.
factory due to the absence of the feedback signal "PTO
The following options for frame lowering are available ex engaged".
factory for this: Code Q3Y (for models 963, 964), Q3Z
The relevant "Frame lowering" requirement must
and Q3U (for models 963, 983).
therefore be transmitted separately by the body
The appropriate assignments are listed in the table application (body manufacturer) via the appropriate
below and also in the information in the tab "Design of interfaces to the PSM 2 (model 963, 964 - non-
bodies". engageable engine power take-offs - equation 030,
Ensure that the function of sales code Q3Y or Q3Z or model 983 - equation 010). The parameterization in the
Q3U is activated before the work mode is commenced ASAM must also be adjusted accordingly.
and that the vehicle is completely lowered.
A return to driving level may only be initiated when work
mode has been completely ended.


Overview of required sales codes
Vehicle type Semitrailer truck Platform vehicle Dump truck Cement
mixer
vehicle
Air suspension Partial Full Partial Full Partial Partial
Roll-off dump truck Q3Y³⁾ Q3U³⁾ Q3Y Q3U Q3Y Q3Y³⁾
Skip loader¹⁾ Q3Y³⁾ Q3U³⁾ Q3Y Q3U Q3Y Q3Y³⁾
Dump truck Q3Y³⁾ Q3U³⁾ Q3Y³⁾ Q3U³⁾ Q3Y Q3Y³⁾
Dumper semitrailer in
combination with:
4x2 vehicle Q3Z Q3Z Q3Z³⁾ Q3Z³⁾ Q3Z³⁾ Q3Z³⁾
6x4/8x4 vehicle Q3Z/Q3Y Q3Z/Q3U Q3Z/Q3Y³⁾ Q3Z/Q3U³⁾ Q3Z/Q3Y³⁾ Q3Z/Q3Y³⁾
Vehicle loading crane¹⁾ Q3Y³⁾ Q3U³⁾ Q3Y Q3U Q3Y Q3Y³⁾
Elevating platform/concrete Q3Z³⁾ Q3Z³⁾ Q3Z Q3Z Q3Z Q3Z

pump²⁾
1) Operations in which the vehicle is supported but the axles do not hang freely (e.g. skip loader, vehicle loading crane)
2) Operations in which the vehicle is supported and the axles hang freely (e.g. elevating platforms, concrete pumps, turntable ladders)
3) Unusual body combination, certificate of non-objection required

Sales code explanations
Q3Y Compulsory lowering without residual bellows pressure regulation at the rear axle(s). Control of the air
suspension is not active.
Q3Z Compulsory lowering with residual bellows pressure regulation at all air-sprung axles. Control of the air
suspension is active as part of the residual bellows pressure regulation.
Q3U Compulsory lowering with residual bellows pressure regulation at the front axle and compulsory lowering
without residual bellows pressure regulation at the rear axle(s).
A residual pressure of 2 bar is applied at the front axle, which is not readjusted. Control of the air
suspension at the front and rear axles is not active.
If different body types are to be used alternately on the must be coordinated with the relevant contact person
same chassis ("swap body systems"), the correct (see document "Advice for body manufacturers")
selection of the necessary frame lowering system (code) and, if necessary, submitted for approval.
Permissible roof loads
Fastening points for retrofitting the wind deflectors on the Page 257
cab roof
i i
In this chapter, representations, code scopes and Design-related measures to prevent the vehicle from
pre-installations of other model designations and tipping over: Due to the higher center of gravity, it
model series are listed for reasons of may be necessary to install a check cable or similar
standardization. The information that is applicable to device to prevent the cab from tilting too far forward
your model designation/model series must when it is tilted. Include an additional note in the
exclusively be used. vehicle operator's manual to indicate that when the
cab is tilted with additional roof loads, the cab may
tilt too far or loose roof loads may fall off. Additionally
inform the operator that, during the tilting process,
no loose payload must be situated on a roof rack or
similar device, no one must be situated in front of the
cab and a sufficient safe distance from the cab must
be ensured.
---------------------------------------------------------------------------
Roof loads can be mounted at the factory-fitted These must be used for the roof loads listed below.
attachment points (see "Fastening points for Additional bores in the roof are not permissible.
retrofitting wind deflectors on cab roof" document)
for wind deflectors.
---------------------------------------------------------------------------
Permissible roof loads, model 967 mass of the cab. The following max. tilting weights must
The attachment points for wind deflectors are identifiable be observed:
by punch marks on the roof. • S cab: 775 kg
The operator's manual must be observed. The cab tilt • L cab: 1075 kg
system may have to be adapted to the higher gross

High roof 50 kg
Long low roof 75 kg
Short low roof 100 kg
The accident prevention regulations must be observed.

---------------------------------------------------------------------------
Permissible roof loads model 963, 964, 983
The operator's manual must be observed. The accident
prevention regulations must be observed.

Permissible roof loads

L cab 50 kg
S cab 75 kg
M cab 75 kg
Roof attachments with higher roof load • Type of roof load (distributed load, point load, etc.)
For higher roof loads, a non-objection check must be • Rigidity of roof attachment (torsionally stiff, self-
submitted to the relevant contact person (see "Advice supporting)
for body manufacturers" document). • Type and position of mounting (screws, adhesive
The following information is required for this: bonding, etc.)
• Cab and roof variant (sales code) Under certain circumstances, a complex (chargeable)
• Type of cab suspension (sales code) strength test may be required here.
• Weight of roof load
Usage-dependent limit values for total vehicle mass and axle...
As of a static axle load > 16.0 t, tubeless tires,

i 385/65 R 22.5, VA/VLA/NLA, sales code I2P, and steep-
Do not exceed gross vehicle mass and axle loads. shoulder rims 11.75x22.5, NLA, sales code R1Z, must
The braking distance may increase considerably if be selected. According to ETRTO (the European Tire
the vehicle is overloaded. Otherwise the vehicle and Rim Technical Organization), no additional increase
support structure may be damaged. Observe the in the tire pressure is required for short-term overloading
weight code of the vehicle (sales code Wxx/Txx). of the tire (e.g. when tipping or unloading skips).
The axle designation or the axle load capacity has If other tires are used, their suitability must be confirmed
only limited relevance to the gross mass of the by the manufacturer of the tire or rim.
vehicle.
Suspension and steering geometry setup
New vehicles are generally supplied with a suspension
The permissible vehicle and axle loads are defined by and steering geometry setup which is based on a
the weight code (three-digit sales code: Txx/Wxx). This balanced collective of unloaded and loaded operations.
information is also available in the valid vehicle
When bodies and items of equipment are installed which
documents/registration papers or in the vehicle data
result in a permanent loading of > 80% of the maximum
card. These must be complied with. The only exception
permissible gross mass, it is recommended to have an
to this is the static loading and unloading process. The
authorized Mercedes-Benz service partner check and, if
technically permissible value may be exceeded here by
necessary, adjust the suspension and steering geometry
max. 1.8 fold.
in the course of the body mounting or conversion work.
For trailing axles (NLA), the maximum permissible axle
If the vehicle is to be used by the customer frequently
load must not exceed the following nominal axle load
close to the maximum permissible static weight limits,
value when loading and unloading:
then robust axle versions should be selected.
• Model 964 (sales code A4Q/A4T/A4Y/A4M, axle
throw 120/5) max. 2.2 times the technically
permissible axle load of the trailing axle.
• Model 963 (sales code A4Y, axle throw 150/5) max.
2.0 times the technically permissible axle load of the
trailing axle.
Electrical system
Damage prevention
Notice
Information on preventing damage to electronic

components due to electrostatic discharge
Vehicle safety Page 15
Work on electrical system Page 582
i i
Work carried out incorrectly on the electrical system Model 963, 964
may impair its function. This may lead to the failure On vehicles with steering, Servotwin, sales code
of components or safety-relevant component parts. C6H, additional buffer batteries may be installed in
There is a risk of accident! the vehicle depending on the vehicle equipment.
Also disconnect these from the on-board electrical
Any work carried out on the vehicle must comply
system.
with accident prevention regulations.
Comply with all national regulations and laws!
i
Observe the information on vehicle and operational
i safety in the documents "Vehicle safety" and
Work on live electrical lines carries a risk of short "Working on the electrical system".
circuit.
Disconnect the on-board electrical system from the
batteries before working on the electrical system.
Battery - Notes on handling batteries
Damage prevention
Notes on charging lead batteries at all times. Ensuring that the batteries are always
adequately charged will increase their service life.
State of charge check
Where non-operational periods longer than >1 week are
Before the vehicle is handed over or put into operation, involved, disconnect the vehicle battery (disconnect
the state of charge of the batteries must be tested and ground line from battery) to avoid damage to the battery.
the batteries recharged if necessary. The open circuit This prevents any battery discharging caused by no-load
voltage of a battery must not drop below the limit of current consumers.
12.55 V. The battery must be charged if the open circuit
voltage drops below this limit. If the vehicle is non-operational for periods >1 month,
remove the battery and store it in a dry place at
If the vehicle is parked up for a long period of time, temperatures of between 0 °C and 30 °C. Store the
check the state of charge of the battery more frequently. battery in an upright position. The battery voltage level
It is essential to avoid deep discharging of the battery. must be kept above 12.55 V at all times. If the battery
Deep discharging can reduce the service life of the voltage drops below 12.1 V, the battery is damaged and
battery considerably. it will have to be replaced.
The battery capacity is dependent on the ambient
temperature and age of the batteries. The actual battery
capacity may therefore be lower than the rated capacity i
specified on the battery. On all vehicles, the batteries should not be
disconnected until at least five minutes after the
Long non-operational times
engine has been switched off because the
Recharge the battery if the battery voltage drops below regeneration function may still be active.
12.55 V. This will ensure that the vehicle is ready to start
---------------------------------------------------------------------------
Charging every year. Top up with distilled or deionized water only
The ambient temperature for charging the battery must and according to the manufacturer specifications.
be above 0 °C and preferably between 10 °C and 25 °C. Storage must be performed in compliance with the
The electrolyte must not be frozen. Dangerous Substances Directive.
The batteries on a vehicle may only be charged if they Replacement of batteries
are of the same age and type. A new battery must not be
combined with a used battery. If batteries with a different capacity are installed, the
corresponding parameters must be changed in the
Use a commercially available charger to charge the ASAM.
batteries. Make sure that the charging voltage is correct.
Do not charge new batteries using the rapid-charge
function as this can damage the battery. With used
i
batteries, the charging current with rapid charging must When batteries are charged, an extremely explosive
not exceed 75 % of the battery capacity. gas mixture is produced. It is therefore important to
ensure that the charging location is always
adequately ventilated. The relevant regulations of
i the trade association must be observed.
The charging current of new batteries must not
exceed 10 % of the battery capacity. A higher
charging current can damage the battery. Consumers must not be connected directly to the battery
To charge the batteries, they must first be terminals. This will lead to uncontrolled discharge and
disconnected and then be charged separately. The prevent the battery sensor from determining the charge
assembly notes must be observed when connecting correctly.
the battery clamps. Drawing power at just one battery will cause damage to
both batteries. Body manufacturers provide for additional
power withdrawal at the power distributor panel only.
Maintenance and storage
Check the battery fluid level regularly according to the
operating conditions of the vehicle, but at least once
---------------------------------------------------------------------------
Damage prevention
Extension of "consumer shutoff" function and Description of normal battery behavior
discontinuation of battery status indicator The battery as an energy storage unit is continuously
The following electrical consumers are switched off charged and discharged during normal operation of the
automatically if the engine is switched off and the battery vehicle, and is therefore subject to a natural aging
capacity drops below a defined limit: process. The battery status indicator fluctuates
• Audio equipment dynamically depending on usage of the vehicle,
e.g. long-distance haulage with overnight stop or
• 24 V sockets (sales codes E3L, E3M, E3Q, E3S) distribution haulage without overnight stop. Other factors
• Power socket 24 V/25 A, front passenger footwell are the outside temperature and the engine speed. It is
(sales code E3R) important to remember that, owing to the technology
used, a battery can only absorb a limited charge per
• 12 V socket (sales codes E3B, E3E)
hour, irrespective of the output of the alternator. This
• Cigarette lighter (standard) limited charge decreases considerably at low
• Seat heating (depending on seat variant) temperatures so that battery charging can take
significantly longer in winter.
• Cargo liftgate (sales code E9H)
• Switch no. 1 for other make body electrics, sales
code E5A (e.g. load compartment lamp) i
• Stowage compartment flaps, above windshield, one It is essential to avoid exhaustive discharge as this
lockable, sales code D7F can cause permanent damage to the battery.
Energy-saving usage can significantly prolong the
• Ambient lighting (sales code D5B)
service life of the battery.
If the engine is started, the electrical consumers become
available again.
Sales code E5A cannot be shut off (e.g. load Description of extended consumer shutoff
compartment lamp) with simultaneous installation of the Automatic shutoff of defined consumers as well as step-
sales code E3R. by-step information regarding measures for ensuring
From this time onward, consumer shutoff only takes engine startability, shown on the display of the
place with the engine "Off". instrument cluster and indicated by means of additional
acoustic signals, can lead to customer complaints.
---------------------------------------------------------------------------
Description of standard function consumers (e.g. 24 V sockets, radio, etc.) by means of
the "consumer shutoff" when the engine is OFF. The
Stage 1: Consumer shutoff active radio can be switched on again manually.
When a defined battery capacity is reached, the energy
management automatically switches off certain

Display message:
Consumer shutoff active
Stage 2: Warning message and warning tone Acoustic warning: 1 brief warning tone
Remaining battery capacity reaches second lower limit.

Display message:
Battery state of charge low – Switch off electrical consumers.
To avoid a further drop in state of charge, additional

consumers must be switched off manually.
---------------------------------------------------------------------------
Damage prevention
Stage 3: Warning message and several warning Acoustic warning: 3 brief warning tones
tones
Remaining battery capacity reaches third lower limit.

Display message:
Battery state of charge too low – Start engine. Please start engine and/or charge battery.
Depending on the display, the engine should be started

or the battery charged in order to ensure startability of
the engine.
---------------------------------------------------------------------------
• Consultation with the TE/ORB-B department is • Never attach electric lines to battery lines, brake
required for the aftermarket installation of a battery lines, a compressor line, hydraulic lines and
main switch. compressed-air lines.
Brake hoses or cables and lines
Damage prevention
i
Risk of accident
Work carried out incorrectly on brake hoses, cables
and lines may impair their function. This may lead to
the failure of components or safety-relevant
component parts.
There is a risk of accident!
• Welding, drilling or grinding work or work with cutting disks must not be
carried out at the vehicle frame in the area between the axles of
electrified vehicles.
• Compressed-air, fuel and hydraulic lines as well as brake hoses must
be covered or removed if necessary before carrying out any welding,
drilling and grinding work and before working with cutting disks.
• After installing compressed-air, fuel, gas and hydraulic lines and brake
hoses, the system must be tested for pressure loss and leaks.
• Retrofitted lines (e.g. hydraulic lines of body implements) must not be
attached to lines of the chassis (e.g. brake hoses, hydraulic lines,
battery lines etc.). When routing lines, the relative movements that
occur in the event of chassis diagonal torsion between the body and
chassis and the elongation or compression of the lines associated with
this must be taken into account. Mercedes-Benz recommends that body
manufacturers manufacture and install holders for routing lines that are
coordinated with the line or pipe routing in the chassis. Secure the
holders only at existing holes in the chassis. Never attach these to W42.10-A017-02
existing, heavily loaded threaded connections, e.g. longitudinal member Prohibited work
frame connections, engine bearings, stabilizer bar bushings, spring
bearings etc.
• No other lines may be attached to brake hoses.
• Lines must be protected from heat by means of appropriate insulation.
• Line routing must be designed to prevent any increase in pressure loss.
• Existing holders at the chassis can be used provided that the holder can
bear the additional load. Changes to the brake system (e.g. in the
event of wheelbase or frame extensions) may only be implemented
using pipe connection parts and plastic lines that have been approved
by us.
• Cable ties are required for the attachment. The distance between the
cable ties may not exceed 500 mm. If no plastic lines are available, it is
permissible to install steel pipes with the same dimensions that have
been galvanized with zinc on the inside and outside.
• If vehicles with 15 bar supply pressure in the air suspension circuit are
dried completely in a drying chamber following painting work, the supply
pressure in the air suspension circuit must be reduced to under 10 bar
prior to heating up the drying chamber. If the supply pressure is not
reduced, the heat development and the high pressure may cause the
compressed-air lines to slip off the drive-in fittings.
Comply with all national regulations and laws!
Mobile communications systems
Damage prevention
Concept of these body/equipment mounting directives Page 13
The German regulation concerning the transport of reciprocal influences. Ensure that the
dangerous goods by road, rail and inland waterways electromagnetic compatibility is certified by the radio
(GGVSEB/ADR) and the manufacturer's information and equipment manufacturer.
installation specifications must be observed.
Connection and wiring
If mobile communication systems (e. g. telephone, CB
radio) are retrofitted, the following requirements must be • The connection should be made directly to
fulfilled in order to avoid malfunctions developing on the terminal 30 via an additional fuse
vehicle at a later stage. • Power to 12 V equipment may only be supplied via a
voltage converter on vehicles with a 24 V system
Device
• Disconnect the equipment from the electrical system
• The equipment must have official approval and before starting assistance is supplied.
correspond to DIN VDE 0879, Part 2.
• Lines should be wired via the shortest possible route
• The equipment must be permanently installed. (not looped) and twisted.
• Operation of portable or mobile equipment inside the • Ensure that the system has good ground connections
cab is only permitted if this equipment is connected to (antenna and equipment).
a permanently installed antenna outside the vehicle.
• Route the antenna line and connecting lines between
• Install the transmitter physically separated from all the transmitter, receiver and control element
other on-board electronics. separately from the vehicle wiring harness.
• Protect equipment from moisture. • Make sure that the antenna line is not kinked or
• Observe the permissible operating temperature. crushed.
• Protect the equipment against severe mechanical
vibrations.
i
Antenna (for two-way radio sets) Information on operational and vehicle safety must
• The antenna must be officially licensed. be observed (see document "Concept of this
body/equipment mounting directive").
• The combination of two-way radios and equipment
control panels installed in the cab may result in
Electromagnetic compatibility (EMC)
Damage prevention
Concept of these body/equipment mounting directives Page 13
Electromagnetic compatibility describes the ability of an • CISPR 25

electrical system to act neutrally in the vicinity of other • DIN EN 55012
systems when operating at full function.
• DIN EN 55025
The system in question does not interfere with any of the
active systems in the vicinity, nor does it suffer any • ISO 7637
interference. • ISO 10605
Electrical interference occurs in vehicle on-board • ISO 11451
electrical systems because of the various consumers.
• ISO 11452
Mercedes-Benz tests all factory-installed electrical and
• MBN 10284
electronic components for their electromagnetic
compatibility in the vehicle. • UN-R 10
If subsequent modifications are made, this may cause a When radio equipment is retrofitted, the instructions for
reduction in comfort in some cases (e.g. radio noise). installation as per ISO /TS 21609 must be observed.
When retrofitting electrical or electronic systems, they Certified EMC test points are listed in the German
must be tested for electromagnetic compatibility and this Federal Ministry of Transport and Digital Infrastructure
must be documented. gazette (Verkehrsblatt) "Recognition and accreditation of
technical services as testing laboratories" (regulation no.
All electrical equipment fitted must be tested in
24, published on 29.02.2008). Information about certified
accordance with UN R 10 and must bear the CE mark.
EMC test points can be obtained from the Verkehrsblatt
The following standards provide information on this: publisher via the following address:
• CISPR 12

Telephone: +49 (0) 1 80 / 5 34 01 40
Fax: + 49 (0) 1 80 / 5 34 01 20
Internet: http://www.verkehrsblatt.de
Postal address: Verkehrsblatt-Verlag

Borgmann GmbH & Co. KG
Hohe Straße 39
D-44139 Dortmund
i
Information on operational and vehicle safety must
be observed (see document "Concept of this
body/equipment mounting directive").
Welding
Damage prevention
aDanger
aDanger
Remove voltage from high-voltage on-board electrical

system/put high-voltage on-board electrical system into
operation
Welding on vehicle frame Page 152
i i
Welding in the vicinity of the restraint systems Work on live electric lines carries a risk of short
(airbag or seat belts) can cause these systems to no circuit. Disconnect the on-board electrical system
longer function correctly. from the batteries before working on the electrical
If restraint systems no longer function correctly, the system.
vehicle occupants may be unprotected in the event On vehicles with steering, Servotwin, sales code
of an accident. There is a risk of injury! C6H, additional buffer batteries may be installed in
Welding is therefore not permitted in the vicinity of the vehicle depending on the vehicle equipment.
the restraint systems. Disconnect these from the on-board electrical
system too.
The airbag could be triggered or it may no longer
function correctly. Disconnect battery-electric vehicles when welding or
at the body before beginning work.
i
Loss of certification, impairment of crash safety and
of high-voltage on-board electrical system:
On model 983 vehicles, do not perform any welding
at the vehicle frame in the area between the axles
(e.g. wheelbase modifications).
Welding
Damage prevention
i
Do not connect the welder ground clamp to major
assemblies such as the engine, transmission, axles
or component parts of the high- and low-voltage
system. The welding current can cause arcing at
bearing points inside the major assembly. The
structural changes that occur as a result of this at
the contact points of the bearings can be clearly
determined as new hardness zones and this
preliminary damage leads to premature failure of the
major assembly.
Parts which must not be welded:
Major assemblies such as the engine, transmission,
axles and component parts of the high-voltage on-
board electrical system.
Vehicle frame (exceptions: also see document
"Welding at the vehicle frame")
Hydraulic units such as valves, cylinders.
Cavities in which electric lines and/or other heat-
sensitive lines are routed.
---------------------------------------------------------------------------
All laws governing explosive substances must be • Avoid welding on inaccessible cavities in the cab.
complied with. • Plug welding is only permissible in the vertical webs
The following safety measures must be observed to of the longitudinal frame member (also see
prevent damage to electronic component parts caused document "Welding on the vehicle frame").
by overvoltage during electric welding work: • The plug must be removed from the control unit
• Disconnect the positive and negative terminals from before carrying out welding.
the batteries and cover them up. • Weld seams must be ground down and reinforced
• Connect the welder ground clamp directly to the part with angular profiles to prevent notching from welding
to be welded. penetration.
• Disconnect model 983 vehicles before beginning • Avoid weld seams in bends.
(see document "Manually deenergize/activate • The distance from a weld seam to the outer edge
high-voltage on-board electrical system") should always be at least 15 mm.
• Do not touch electronic component part housings,
e.g. control units, and electric lines with the welding
electrode or the ground clamp of the welder.
i
• Before welding, cover up springs and air suspension Further information is available (see document
bellows to protect them from welding spatter. Do not "Threaded and welded connections").
touch springs with welding electrodes or welding
tongs.
• Cover up the fuel tank, gas and fuel systems (lines
etc.) as well as high-voltage components before
carrying out welding.
Anti-corrosion protection
Damage prevention
aDanger
Risk of explosion caused by paint vapors igniting. Risk No smoking! No open fire! Use respiratory protection,
of poisoning caused by inhaling paint vapors. protective clothing, gloves, safety glasses and protective
skin cream. Ensure that the area is well ventilated.
General work, the anti-corrosion protection must be repaired

In order to preserve the service life and quality standard using a reactive adhesive primer.
of the vehicle, measures must be taken to protect it If the topcoat on the vehicle has been damaged or the
against corrosion when the vehicle is modified and when cataphoretic dip priming system coating is visible on
installing bodies and detachable parts. chassis parts, e.g. due to the repositioning of
Information on the design, execution of work and the components, the topcoat must be repaired at the
requirements of the materials and components to be affected areas.
used with regard to anti-corrosion protection is listed The components mounted by the body manufacturer
below. must also be given anti-corrosion protection that
To achieve good anti-corrosion protection, the areas of corresponds to the state of the art. A corrosion-resistant
design, production and materials must be perfectly design is always presupposed.
matched. Following work on the cab or when attachments and
The ex-factory anti-corrosion protection consists of a bodies are mounted, cavities must be protected against
cataphoretic dip priming system coating plus top coat. corrosion by taking appropriate measures.
If the ex-factory cataphoretic dip priming system coating

was damaged, e.g. due to welding, grinding or drilling

Optimal anti-corrosion protection

1 Anti-corrosion protection
2 Materials
3 Production
4 Design
W97.30-A000-01
Optimal anti-corrosion protection
Disassembly of components Damage to component parts

Before the chassis is assembled, the component parts If component parts are damaged during disassembly
are primed by means of cathodic electrodeposition (scratches, scuff marks), they must be professionally
(KTL). When assembly is complete, the chassis receives repaired. This applies especially for bores and openings.
its top coat. These production steps form the basis for 2K epoxy primers are particularly suitable for repair
optimum anti-corrosion protection of the chassis. work. Suitable painting materials are listed on the
If the body manufacturer makes structural modifications internet sites of the approved Mercedes‑Benz refinishing
to the chassis, anti-corrosion protection in the affected paint suppliers.
areas must be restored to match the production Cutting of component parts
standards of Mercedes‑Benz. The areas must also be
finished with appropriate paintwork. Information on When cutting and grinding work is carried out, the
approved Mercedes-Benz refinishing paint suppliers is adjacent painted component parts must be protected
available on request from your respective contact person against flying sparks and shavings. Grinding dust and
(see document "Advice for body manufacturers"). shavings must be carefully removed because these
contaminants can spread corrosion. Edges and bores
Damage prevention
must be cleanly deburred in order to guarantee optimum addition to galvanizing, cataphoretic dip priming system
anti-corrosion protection. and zinc dust paints in sufficient coating thicknesses
have proved especially satisfactory for this purpose
Anti-corrosion protection on reinforcements and
detachable parts
Reinforcements and detachable parts must receive
adequate anti-corrosion priming prior to assembly. In

Structure of chassis paintwork

1 Application of top coat
2 Cathodic electrodeposition (KTL)
3 Steel
W97.30-A001-01
Structure of chassis paintwork
Additional anti-corrosion protection for chassis If the protective coating applied at the factory is
At the factory an additional anti-corrosion protection can damaged by the body manufacturer, it must be repaired
be ordered for models 956, 963, 964, 967 properly and appropriately by the body manufacturer.
(Mercedes‑Benz Chassis Protective Sealing, sales Properties of Carlofon 81:
code Y3M), for models 405, 437 (Tectyl protective
underseal, sales code Y64). Here, for value retention • The single-coat anti-corrosion agent leaves behind a
purposes, the chassis is coated with anti-corrosion agent transparent, waxy protective film.
for models 956, 963, 964, 967 with Carlofon 81, and for • The transparent protective film allows metal surfaces
models 405, 437 with Tectyl. This additional anti- to be visually inspected and identification plates to be
corrosion protection is particularly recommended for read.
vehicles that are exposed to corrosive materials during
• Partial rectification is possible.
operation, e.g. in the case of winter service vehicles.
• If inspected annually, it provides durable protection.
It is also recommended to coat all relevant components
of the body with the anti-corrosion agent.

Examples of inadequate anti-

corrosion protection
N98.10-A000-71 N98.10-A001-71
Topcoat missing, parts are primed only, Topcoat missing, ex-factory thin-layer
anti-corrosion protection is not assured. cataphoretic dip priming system coating
does not provide adequate anti-corrosion
protection.
Damage prevention
N98.10-A002-71 N98.10-A003-71
Design is not conducive to corrosion Parts are coated with topcoat only, primer
protection and sealing is absent; surface missing. Anti-corrosion protection is
coating cannot be applied in the gaps. inadequate.
Anti-corrosion protection of bodies and attachments painted. Top coating of untreated zinc surfaces directly
Anti-corrosion protection on bodies and attachments can lead to premature, widespread peeling of the finish.
should be applied in the same way as on the chassis in Cataphoretic dip priming system (KTL) finishes
order to guarantee the quality and corrosion resistance
of the overall vehicle in the long term. A suitable coating Cataphoretic dip priming system finishes have good anti-
structure is to be applied according to the weathering corrosion protection properties, but are not sufficiently
and stone chipping to which the part item is exposed. resistant to weathering and stone chipping without a top
The coating structure consists of: coat.
• Pretreatment (e.g. degreasing, phosphating or Galvanic coatings
sandblasting)
Zinc or zinc/nickel electroplated coatings should have a
• Priming, e.g. cataphoretic dip priming system, corrosion resistance of min. 480 h in the salt spray test
2K‑epoxy primer (ISO 9227 NSS) and be passivated with a
• Application of top coat chromium (VI)‑free conversion layer.
Top coating of zinc-plated surfaces

Zinc-coated components must be cleaned appropriately
and pretreated with a suitable primer before they are
Corrosion protection-compliant welding
Damage prevention
aDanger
i
Risk of corrosion! Plug and slot welds, particularly on
horizontal surfaces, should be avoided. If
unavoidable, these weld seams must receive
additional preservation. Avoid structures in which
moisture can accumulate. These must include
additional drain bores or gaps in the weld seam, if
necessary.
---------------------------------------------------------------------------
In order to avoid crevice corrosion at weld seams, the • Deburr edges.
weld seams should be made in accordance with the • Remove any burned paint and thoroughly prepare
examples shown. surfaces for painting.
Preparation • Remove silicate residues (melts) from weld seams.
The welding area must be free from corrosion, grease, • Prime and paint all unprotected parts.
dirt or similar contamination. When painted surfaces are • Preserve cavities with wax.
to be welded, the paint coat must first be removed by
grinding or stripping. If this is not done, the paint will • Carry out anti-corrosion protection measures on the
burn and the residues can impair corrosion resistance. underbody and frame parts.
After welding work

• Remove drilling chips.

a Positive
b Negative
W97.00-A000-02
Example: Weld seams
Threaded connections
Damage prevention
i
Danger of electrochemical corrosion. A galvanic
connection occurs if two different metals are brought
into contact with each other through an electrolyte,
e.g. air humidity, and the less noble of the two
metals is damaged. The further apart the two metals
are in the electrochemical potential series, the more
intense electrochemical corrosion becomes. For this
reason, electrochemical corrosion must be
prevented by insulation or by treating the component
parts accordingly, or it can be minimized by selecting
suitable materials.
---------------------------------------------------------------------------
Top-coated components the threaded stud during assembly. We recommend
If top-coated component parts are to be bolted together, restoring the anti-corrosion protection by means of a
the coats of paint must not cause settling effects in the topcoat.
threaded connections. In such cases, hard high-density Information on identifying suitable coatings can be
paints, e.g. cathodic electrodeposition coatings or obtained from your local bolt supplier.
powder paints, should be used. The coat thicknesses Details on threaded connections (see document
should be kept as small as possible (cathodic dip paint "Threaded and welded connections").
approx. 20 µm, powder paints approx. 100 µm).
• If using bolts with serrations under the head, an Preventing contact corrosion
additional top coat must be applied to touch up any Direct contact between materials with different electrode
paint damage. potentials can lead to corrosion of the less noble
• The use of hexagon socket or internal Torx bolts in a material when exposed to moisture and salt ions.
horizontal position is to be avoided, as moisture When selecting materials, avoid the following
accumulates in the bolt head, leading to corrosion. combinations:
Fasteners • Chrome/nickel-steel with aluminum
In areas susceptible to corrosion, always use bolts, nuts, • Chrome/nickel-steel with zinc-dipped steel
etc. with corrosion resistance (> 720 h salt spray test
Insulation by coating
according to ISO 9227) regardless of the required
property class. This standard is satisfied, e.g. by screws Contact corrosion can be prevented by using insulation
with electroplating as well as additional thick-coat such as washers, sleeves or bushings. Even in this
sealing and zinc flake coatings with sealer, case, however, the connecting points must not be
e.g. Dacromet or Deltaseal; refer to VDA persistently exposed to moisture.
recommendation VDA 235‑104.
When geometrically clamping nuts are used, it should be
noted that these damage the anti-corrosion protection on

Threaded connections
Damage prevention
1 Insulating washer
2 Insulating sleeve
W98.00-A000-02
Design of connection to prevent
electrochemical corrosion
Vehicle cleaning and care aggressive chemicals and environmental influences. If

When the vehicle is handed over to the body the vehicle comes into contact with chemicals or salts,
manufacturer, it must immediately be cleaned of salt and e.g. winter service operations, it must be cleaned
dirt. If it is to be stored for some time, the vehicle must thoroughly at regular intervals.
be preserved.
During modification it must be ensured that load-bearing
component parts are additionally protected against
Engine/transmission
Damage prevention
i
The operational safety of the vehicle is at risk. If the
warning buzzer sounds, switch off the engine
immediately and determine the cause. If bodies are
operated from outside the cab, e.g. loading cranes,
an additional visual warning system must be
installed in the vicinity of the controls.
---------------------------------------------------------------------------
Warning buzzer On some vehicle equipment versions of model series
A warning buzzer is installed in the cab within the 963 and 964, there is, as a result of the design, no cover
hearing range of the driver. supplied for the transmission ex factory in order to keep
installation space free for the body (e.g. short cab, sales
The buzzer serves as a warning tone when, e.g. : code F1P in combination with exhaust system, upright
• the maximum permissible engine speed is exceeded, behind cab, for fastening parts, for loading crane, at the
front, sales code C5G, pre-installation, road dumper
• the maximum permissible coolant temperature is
truck, without subframe, sales code C5X, space for
exceeded,
crane supporting feet, sales code C7Q., power take-off
• the coolant level is too low or linked to the engine, sales code N4W/N4X/N4Y/N4Z,
• the oil level or oil pressure in the engine is too low. and engine power take-off at rear, sales code
N7I/N7K/N7L/N7M/N7N/N7O/N7P/N7Q). This must be
Protective covers retrofitted by the body manufacturer. The cover must be
attached to the frame or body. The precise position of
If parts of the engine, transmission, or exhaust system
the drivetrain and any protective covers can be found in
incl. exhaust gas aftertreatment unit, can be damaged
the chassis drawings in the Mercedes-Benz Bodybuilder
through operation of the body or due to the load
Portal:
(e.g. bulk goods, road salt), an appropriate protective
cover must be installed. If necessary, a protective cover http://bb-portal.mercedes-benz-trucks.com
(sales code P0W) can be ordered ex factory,
for example.
Leaf springs
Damage prevention
Parabolic springs • Do not damage the surface or the anti-corrosion
• Damaged parabolic springs have to be replaced protection of the spring leaves when carrying out
completely. installation work.
• It is not permissible to replace individual spring • Before carrying out welding work, cover the spring
leaves. leaves to protect them against welding beads. Do not
touch with welding electrodes or welding tongs.
• Only use spring leaves that have been tested and
approved for the vehicle model in question.
Reinforcement by installing additional spring leaves is
not permitted.
Tilt cab
Damage prevention
i
Hazards might not be detected and persons could
be injured. The vehicle could be damaged. Before
tilting the cab, read the chapter "Tilting the cab" in
the operator's manual.
Towing
Damage prevention
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Hazards might not be detected and persons could Battery-electric driven vehicles can be towed over
be injured. The vehicle could be damaged. Before short distances while in a deactivated state. For this,
towing or tow-starting, please make sure that you ensure that the neutral gear of the electrically driven
read the chapter "Towing" in the operator's manual axle is engaged and that the ignition (and therefore
and the brochure "Towing and recovery". the axle oil pump) is switched on. Tow the vehicle for
a maximum distance of 100 m at a maximum of
5 km/h.
Fire hazard
Damage prevention
Electrics/electronics - General, wiring diagrams, Page 579

interfaces, body CAN
i i
With all bodies, make sure that neither flammable Stationary heater in GGVSEB/ADR (hazardous
objects nor flammable liquids come into contact with goods) vehicles: When the power take-off is
hot assemblies (e.g. through leakages in the activated, the vehicle changes from driving mode to
hydraulic system) such as the engine, transmission, the work mode. In this state, the stationary heater
exhaust system, exhaust gas turbocharger, etc. must be deactivated on GGVSEB/ADR (hazardous
Install appropriate covers, seals and trims on the goods) vehicles.
body in order to avoid the risk of fire.
i
Work on live electrical lines carries a risk of short
circuit. To avoid the risk of fire, before starting work
on the electrical system, disconnect the on-board
electrical system from the power source,
e.g. battery.
---------------------------------------------------------------------------
Bodies and add-on equipment • If necessary, use line ducts, protective hoses,
• To avoid the possibility of fires, all body-mounted corrugated pipes or similar.
components that are susceptible to leakage, The following minimum distances must be maintained in
e.g. hydraulic valves, threaded connections, etc., are the vicinity of heat sources:
to be positioned so that, in the event of failure, any • Exhaust pipe without shielding: 200 mm
escaping fluids, e.g. droplets, spray, liquids blown by
the air stream or fans, cannot land on hot vehicle • Exhaust gas aftertreatment unit without shielding:
parts. 150 mm
• If this is not feasible for functional reasons, then the • Exhaust gas aftertreatment unit with additional
body manufacturer must install suitable safety jacketing: 40 mm
precautions, e.g. covers, seals or trim pieces. • Heat sources with sheet metal shielding: 100 mm
The tailpipe outlet must not be directed towards other • Heat sources with sheet metal shielding and
components. additional insulation: 80 mm
Notes on design of electrical installations Individual cables are to be connected properly and
professionally, e.g. crimp-type connectors, end sleeves
There is also the risk of a vehicle fire if electric lines are etc. The corresponding parts can be procured from the
overloaded. When connecting electrical consumers, the local Mercedes‑Benz Service Partner.
electrical interfaces in the vehicle described in the Body/
Equipment Mounting Directives must be used and their End sleeves are not permissible on moving lines.
maximum power draws must be taken into account. Aftermarket connection to existing electric lines by
means of insulation piercing connectors (also known as
Electric lines in the body, particularly those with high vampire connectors or wire taps), or simply by twisting or
loads, must be appropriately dimensioned and fused. soldering, is prohibited.
Electric lines in the body, particularly those with high If any lines on the chassis, especially electric and
loads, must be appropriately dimensioned and fused. hydraulic lines, are damaged during the installation of
Electric lines must be routed so that the body, they must be replaced.
• they are protected from the effects of high Notes on the design of hydraulic installations
temperatures. If this is not possible, the lines must be
suitably insulated. • Retrofitted hydraulic lines or hoses must be fastened
and routed properly and professionally, e.g. taking
• there are no chafe points, particularly at crossovers, into account the minimum bending radii, chafe points,
sharp edges, bolt heads, protruding studs and nuts operating pressure and bursting pressure, etc.
etc.
Fire hazard
Damage prevention
• When using hydraulic lines, observe the shelf life and Hydraulic lines must be routed so that:
usage duration as per DIN 20066. • they are protected from the effects of high
• Hydraulic lines may not be fastened to existing lines temperatures. If this is not possible, the lines must be
of the chassis, e.g. hydraulic pipes, battery cables, suitably insulated.
brake lines, etc. • there are no chafe points, particularly at crossovers,
• The relative movements occurring during vehicle sharp edges, bolt heads, protruding studs and nuts
operation between the various components, e.g. the etc. If this is not possible, suitable holders should be
engine and the chassis or the body and the chassis, used to eliminate chafe points. If chafe points cannot
etc., and the resulting expansions and compressions be avoided despite suitable retainers, chafe
of the lines, must be taken into account when routing protection must be fitted. Non-chafing installation is
the lines. always preferable to the use of chafe protection.
---------------------------------------------------------------------------
Application Debris produced during use and when operating the
If combustible materials can come into contact with hot body or attachments (cuttings when mowing/mulching,
vehicle components due to the cargo carried or the wood chippings when chopping wood, flammable
loading process (bulk goods, etc.) or due to the materials in waste collection vehicles etc.) must be
operation of attachments, e.g. chopping, suitable prevented by means of suitable design measures from
protective covers must be provided by the body accumulating in the vehicle, particularly on hot vehicle
manufacturer. components.
---------------------------------------------------------------------------
Vehicles subject to the German regulation The GGVSEB/ADR regulations and country-specific
concerning the transport of dangerous goods by laws and regulations must be observed.
road, rail and inland waterways (GGVSEB/ADR)
i
For further information (see document "Electrical
interfaces → German regulation concerning the
transport of dangerous goods by road, rail and
inland waterways").
---------------------------------------------------------------------------
Environment the vehicle and body are absolutely essential in
When vehicles are operated in fire-sensitive addition to suitable design measures (covers, etc.).
environments, e.g. meadowland and agricultural land These eliminate deposits of combustible materials on
with dry vegetation, woodland, landfills, waste transfer the chassis and body and thus significantly reduce
stations, etc., the following additional measures are the risk of combustion caused by hot vehicle or body
required: components.
• Vehicles are to be fitted with the upright exhaust Examples of such high-contamination applications are:
tailpipe so that hot exhaust gas is not blown directly • Pesticide and fertilizer spreading: Contact with,
onto combustible materials. stripping off and accumulation of vegetation debris
• Insulation/shielding must be provided for hot vehicle (e.g. ears of wheat, etc.) in the chassis and body
components that may come into contact with • Landscaping, e.g. wood shredders or mulchers:
combustible materials due to the operating Accumulation of dust, grass and chippings in the
environment. chassis and body
• Furthermore, the body manufacturer must ensure • Waste disposal vehicles: Accumulation of
that, depending on the application, e.g. driving over combustible waste, e.g. paper, in the chassis
high vegetation, all vehicle and body components are • In such cases, in addition to the measures
adequately protected against damage, and chafing in described above, appropriate notices in the
particular, and that no flammable materials, operator's manual and maintenance instructions for
e.g. straw, crops, paper, etc., are deposited at the body/attachment must be provided to alert the
hazardous/hot points. operator to the importance of regular cleaning and
• In the case of high-contamination applications and maintenance of the overall vehicle.
environments, regular cleaning and maintenance of
Avoiding dirt in system circuit
Damage prevention
Residual dirt
If hydraulic lines, compressed-air lines, coolant lines, power-steering fluid
lines and fuel lines are modified, attached or detached, it must be ensured
that no dirt can enter the system. This means that as soon as a line is
detached, an appropriate protective cap (see the figure for comparison)
or another similar protective cover must be attached. This will prevent dirt
from entering the system circuit and causing failures.
N00.00-A010-02
Protective cap seals system and prevents
dirt from entering.
Trailer sockets
Damage prevention
The component can be damaged if water enters. To avoid this, brackets for
the trailer socket should be arranged at least vertically, or ideally facing
downwards.
N31.10-A000-02
Arrangement: Conforming arrangement of
bracket for trailer socket
Non-operational time longer than 4 months
Damage prevention
Service and maintenance Page 54

diagrams
i i
For information on storage and maintenance of the For the operator's manuals of various vehicle model
vehicle (see document "Service and designations, see document "Overview of
maintenance"). documents/catalogs/instructions/circuit
diagrams".
---------------------------------------------------------------------------
Where vehicles that have not been moved for longer 4.2 Check parking brake on test stand.
than 4 months are involved, it is necessary to perform a 4.3 Check trailer brake control.
function check before starting a journey:
5 Electrical components
1 Fluid levels
5.1 Check operation of all display systems and
1.1 Check oil level and perform visual inspection indicator lamps.
for leak tightness
5.2 Check entire vehicle lighting system incl.
1.1.1 Engine sockets
• For oil change intervals, see 5.3 Check operation of windshield wipers.
respective operator's manual.
5.4 Check the function of the horn.
1.2 Visual inspection for leak tightness; if leaks
are found, rectify the cause and top up the 5.5 Read out and reset fault memories.
operating fluid. 5.6 Presence of spare fuse?
1.2.1 Transmission 6 Vehicle accessories and documents
1.2.2 Axles 6.1 Depending on the installed codes, a check
1.2.3 Steering should be performed on all removable
accessory parts. It must also be ensured that
1.2.4 Central lubrication system the associated documents are complete.
1.3 Check brake fluid level for clutch operation 7 General appearance of vehicle
(replace after 1 year).
7.1 Clean inside and outside of vehicle
1.4 Battery state of charge/fluid (replace battery if
not functioning; it is permissible to charge 7.2 Visual inspection for mechanical damage
battery once) 7.3 Freshen up unpainted plastic exterior parts if
1.5 Check radiator fluid level and, for anti- necessary.
corrosion protection reasons, adjust to -38 ℃ 7.4 Check headlamp mirrors for blindness.
(±2- ℃) using an areometer.
7.5 Check paintwork on frame. Perform partial
1.6 Windshield washer system fluid level repair of paint flaws if necessary.
1.7 Check AdBlue® system and repair, if
necessary.
1.8 Check whether fuel is still pure (diesel bug).
2 Check leak tightness of pneumatic system using
display in vehicle (for specifications, see respective
operator's manual).
3 Tires
3.1 Check tire pressure.
3.2 Visual inspection for damage associated with
idle time
4 Brakes
4.1 Check service brake on test stand.
Non-operational time longer than 4 months
Damage prevention
8 Function test on test stand or road test 8.5.2 Transmission
8.1 Shift up/down through all gears incl. reverse 8.5.3 Drive axles
gear while driving. 8.5.4 Transfer case
8.2 Check oil pressure and coolant temperature 8.5.5 Power take-offs
after cold-running phase.
9 Additional attachments and modification parts
8.3 Check heating system for proper operation.
9.1 Check additional attachments and
8.4 Check auxiliary heating for proper operation. modification parts according to manufacturer
8.5 After test drive, check for leak tightness: specifications.
8.5.1 Engine
Redundant protection
Damage prevention
Ladders, wheel chocks, pressure distribution plates or The following examples show multiple options for correct
similar articles require double protection so that they do securing.
not get lost. If bolts or pins are used for this purpose,
then they must also be secured on the body with a
chain, for example.

N00.00-A011-01
Redundant securing by tensioning strap
and metal closure
N00.00-A012-01
Securing of the ladder by two independent
pins on both sides
Redundant protection
Damage prevention
W00.00-A078-76
Securing with a spring safety hook
W00.00-A079-76
Securing with a safety clip
Vehicle frame material
Modifications at frame
Modifications to wheelbase Page 153
For wheelbase and frame extensions, the material used The chassis has the following characteristics:
for the extension element and the reinforcing bracket • Web height, inner: 265 mm
must match the quality and dimensions of the standard
vehicle frame. • Flange width 70 or 80 mm

Frame material Thickness
S 500 MC 7 mm
S 600 MC 8..9 mm
S 700 MC 6 mm
Different versions are used depending on the vehicle drawings (offer drawings) in the Mercedes‑Benz
equipment, e.g. axle and axle load configuration, Bodybuilder Portal: http://bb-portal.mercedes-benz-
suspension type, wheelbase or intended purpose. trucks.com
The material and thickness specifications applicable to
your vehicle configuration are available in the 2D chassis
Drilling the vehicle frame
Drilling work on the longitudinal frame members existing bore in the longitudinal member. The smaller
The vehicle frame has a full-length hole pattern. screws and nuts must be centered by means of washers
(min. 5 mm thick, made of steel with an elongation at
Drilling on the vehicle frame is not permissible. If bolts fracture of Re = 355 N/mm²) or sleeves (see document
with a diameter of less than 16 mm are to be used, these "Threaded connections and weld joints").
bolts must be positively locked in the center of an

W31.30-A010-05
Longitudinal frame member hole pattern
Welding on vehicle frame
aDanger
Risk of death when working on component parts and Do not touch damaged or defective live component parts
systems with U >= 30 V alternating voltage (AC) or U >= and lines or non-insulated electrical connections and
60 V direct voltage (DC) lines.
aDanger
Welding Page 130
i i
Loss of certification, impairment of crash safety and Further information can be found in the documents
of high-voltage on-board electrical system: "Welding work" and "Threaded and welded
On model 983 vehicles, do not perform any welding connections" and in the Mercedes‑Benz Workshop
at the vehicle frame in the area between the axles Information System (WIS).
(e.g. wheelbase modifications).
---------------------------------------------------------------------------
Welding work on the vehicle frame may only be carried • Maximum current per mm electrode diameter is 40A.
out by trained personnel. We recommend an electrode with alkaline jacket:
Before carrying out welding, the frame must be situated • S500MC:DIN8529EY4664MoB
in the normal position and be free of preloads from • S380MC (only for model series
external forces. All attached equipment must be lowered 967):DIN1913E5154B10
to the floor and the operating lever of the hydraulic
system must be situated in the float position. Additional • Weld only with electrodes connected to the positive
weights and bodies must be removed. In principle, all terminal of a direct current source. Always weld from
relevant areas must be exposed. bottom to top.
Welding on the vehicle frame is not permitted (except for • Weld seams must be ground down and reinforced
wheelbase and frame extensions). with angle sections to prevent notching from fusion
penetration. Avoid weld seams in bending radii.
On model 983 vehicles, only make changes at the frame There should be at least 15mm between the weld
overhang. seams and the outer edges.
• Connect the welder ground clamp directly to the part • Fine grain steels with elongation at fracture Re
of the vehicle to be welded.
>380N/mm² in MC quality and in the sheet
• Mercedes-Benz recommends MAG welding with wire thicknesses used for frame parts should not be
electrode G69M Mn3NiCrMo with a wire diameter of preheated.
1...1.2mm.
• Use only completely dried alkaline jacket electrodes.
Electrode diameter 2.5mm.
Modifications to wheelbase
aDanger
aDanger
Risk of death caused by vehicle slipping or toppling off Only lift vehicle at the lift support points specified by the
during lifting vehicle manufacturer.
Reinforcements in frame Page 166
Modifications to frame overhang Page 159
Drilling the vehicle frame Page 151
Crossmembers and retrofitting crossmembers Page 164
Installation of propeller shafts Page 247
Electronic Stability Program ESP(R), center of gravity Page 445

heights, stabilizers
Steering-related modifications Page 254
Vehicles with steering, Servotwin (sales code C6G) are Take account of changes to the chassis weight and
only tested and designed within the standard wheelbase turning circle. Mercedes-Benz cannot vouch for the
limit. Therefore, only make changes within these limits. handling, braking and steering ability of vehicles that
If modifications are to be made to the wheelbase, use have undergone extreme modifications to the
the chassis whose standard wheelbase is closest to the wheelbase.
wheelbase required.
---------------------------------------------------------------------------
The specifications for the Stability Control Assist, sales If the wheelbase is modified, the wheelbase/overhang
code S1D, (see document "Electronic Stability ratio changes. Observe the limit values (see document
Program ESP(R), center of gravity heights, "Modifications to frame overhang").
stabilizers"), must be observed. On all-wheel drive vehicles, wheelbase shortenings can
If the wheelbase is modified, the required steering wheel only be made up to the shortest standard wheelbase.
diameter and the steering gear must always be checked Up to the maximum standard wheelbase, the subframe
as per national specifications, e.g.EC/UN-R79. If must be dimensioned according to the tables and
necessary, convert to the appropriate steering wheel diagrams in these Body/Equipment Mounting Directives,
diameter or steering gear (ratio). depending on the body.
For further information (see document "Steering- Above the maximum standard wheelbase, the specified
relevant modifications"). section moduli must be increased by at least 15%.
---------------------------------------------------------------------------
Certificate of non-objection for wheelbase standard wheelbase or longer than the longest standard
modifications wheelbase (cf. tables below) of the corresponding
Certificates of non-objection are not granted and are not vehicle, and if their implementation complies with these
required for modifications to the wheelbase if these do Body/Equipment Mounting Directives.
not make the wheelbase shorter than the shortest
If a wheelbase is required that deviates from those listed Either a certificate of non-objection or a written
here, this must be coordinated with the responsible agreement (email) with the responsible contact partner
contact person (see "Consultation for Body can be the basis for a necessary ESP parameter
Manufacturers" document). change.

Actros vehicle model Wheelbase [mm]
designations
963.002/.003 3700 to 6700
963.004 4900 to 6700
963.005 5500 to 5800
963.020 4000 to 6100
963.021 4000 to 5800
963.022 3250 to 4150
963.024 3700 to 5800
963.025 4000 to 6100
963.026 3700 to 5800
963.042 3850¹⁾
963.402/.403 3250 to 4000
963.404 3700
963.405 3850
963.406 3700
963.420 3250 to 3550
963.422/.423 2650
963.424 3250 to 4000
963.425 3250 to 3550
963.426 3250 to 4000
963.427 2990
¹⁾ Changes are only possible with 3850 mm wheelbase (sales code C1Y). Changes only after consultation with the relevant contact
person (see document "Advice for body manufacturers").

Off-road vehicle Wheelbase [mm]
model designation
964.000/.001/.002/.00 3600 to 6600

3
964.007/.008 3600 to 4500
964.014/.016 3600 to 5700
964.018 3600 to 5100
964.020 3900 to 6000
964.022 3150 to 4050
964.024/.026 3600 to 5700
964.025 3900 to 6000
964.030/.031 4250 to 6600
964.038 4250 to 6600
964.041 3600 to 5700
964.043 3750¹⁾
964.045 4250 to 6050
964.200/.201/.202/.20 3600 to 5400

3
964.207/.208 3600 to 4500
964.211 3600 to 3900
964.214/.216 3300 to 5400
964.218 3600 to 4500
964.224/.226 3300 to 5400
964.230/.231 4250 to 6600
964.232 4550 to 6050
964.233 4850 to 5450
964.238 4250 to 6600
964.241 3600 to 5700
964.314/.316/.324/.32 3300 to 4200

6
964.330/.331 4250 to 6050
964.338 4250 to 6050
964.341 3600 to 5700
964.401 3600 to 3900
Off-road vehicle Wheelbase [mm]

model designation
964.402/.403 3300 to 3900
964.407/.408 3600 to 3900
964.414/.416 3300 to 3900
964.418 3600 to 4200
964.420 3300 to 3450
964.422/.423 2550
964.424 3300 to 3900
964.425 3300 to 3450
964.426 3300 to 3900

¹⁾ Changes only after consultation with the relevant contact person (see document "Advice for body manufacturers").
Moving the rear axle assembly New flange head bolts and flange head nuts must be
It is possible to modify the wheelbase by moving the rear used for loosened threaded connections.
axle in the longitudinal frame member. Mandatory tightening method is the torque and
All the threaded connections of the axles are classified tightening angle tightening method.
as RA (safety relevant threaded connections). This is Do not add any additional bores in the frame.
therefore to be documented at the company carrying out
the modification (see document "Threaded and
welded connections").
---------------------------------------------------------------------------
Components for extending the longitudinal frame weld seams on the longitudinal frame member and the
members reinforcing bracket must be at least 300mm.
Existing reinforcements in the frame may be extended Adjust and weld the reinforcing bracket to existing frame
by welding. The offset of the weld seam between the inserts as appropriate to the position of the frame cut.

Longitudinal member part number Material Web height [mm] Flange width Thickness [mm]
[mm]
A9603112306 S600MC 265 70 9
A9603112305 S600MC 265 80 9
A9603112206 S600MC 265 70 8
A9603112205 S600MC 265 80 8
A9603112106 S500MC 265 80 7
A9603112105 S700MC 265 80 6
Cutting the longitudinal frame member frame must be supported (see the illustration "Vehicle
Before cutting the longitudinal frame members, the support").
chassis must be in a perfectly horizontal position and the

W31.00-A006-04
Supporting the vehicle
Making the cut

Make cuts in the vehicle frame according to the
following rules and the illustrated examples A and B of
the cutting point:
Not permissible in the area of:
• Force application points
• Axle guide, axle spring mounting
• Transmission suspension
• Areas of sectional change (front end frame drop,
tapering frame section)
• Up to 650 mm in front of the tubular crossmember
Cut the vehicle frame straight and centrally between two
rows of holes (hole spacing 50 mm).
Make the cut in the longitudinal member in the vicinity of
the second crossmember behind the transmission; if
necessary, remove the crossmember to do so.
If shortening the frame, make the cut in the vicinity/
center of a crossmember.
W31.00-A038-82
Example A for cutting point
W31.00-A039-82
Example B for cutting point
Reinforcement of weld seam • The bracket must overlap the weld seam by at least
• The weld seam at the cutting point must be 300 mm on the left and right and be bolted to the
reinforced with a bracket as per the specifications vehicle frame.
(see document "Reinforcements in the frame") • Fit a continuous subframe to the vehicle.
---------------------------------------------------------------------------
Adjustment of crossmember positions • The distance between tubular crossmembers and the
After modification of a longitudinal member, the original last crossmember immediately in front of them must
crossmembers, (see document "Crossmembers and not exceed 1650 mm.
retrofitting crossmembers"), must be reinstalled or • Any cross connections necessary for added
new crossmembers added according to the following equipment must be manufactured in accordance with
spacing rules: the specifications of these Body/Equipment Mounting
• The maximum permissible distance between Directives.
crossmembers (center to center) between the axles
is 1000mm.
• The distance between tubular crossmembers and the
last crossmember immediately in front of them must
be at least 650 mm.
---------------------------------------------------------------------------
Adjustment of propeller shaft All-wheel drive vehicles
Observe the specifications (see document "Installation For wheelbase modifications, the propeller shaft drive
of propeller shafts"). may only be modified behind the transfer case.
Modifications to frame overhang
aDanger
aDanger
Vehicle overhang and technical wheelbases Page 111
Reinforcements in frame Page 166
Repair and extension of plastic compressed-air lines of Page 455

the brake and air suspension system
Design of bodies, general Page 516
General • The first crossmember behind the rear axle in the

If you intend to change the frame overhang, the following overhang must not be modified.
specifications must be complied with: • The distance from the last-but-one crossmember to
• Do not cut the longitudinal member in the vicinity of the end crossmember may be reduced to 450 mm.
the crossmember of the last axle or the first • Modifications to the standard frame overhang are not
crossmember of the overhang. permissible on semitrailer truck chassis.
• To cut the longitudinal member, it may be necessary • Due to the modified vehicle geometry, the
to remove the crossmember. permissible axle loads, the gross mass and the
• Cut the frame straight and centrally between two minimum front axle load must be checked (see
rows of holes (hole spacing 50 mm). document "Steerability").
• After modification of the overhang, to guarantee • Fastening of the rear underride guard as on the
sufficient torsional rigidity in the rear frame overhang, series production vehicle
the original crossmembers must be reinstalled or new Riveted joints installed ex factory can be replaced with
crossmembers added according to the following threaded connections. For further information, see
spacing rules: document "Threaded and welded connections".
• Max. distance from crossmember to crossmember
1300 mm.

a Max. 1300 mm
W31.30-A025-75
Spacing of crossmembers in the overhang
Extension of the frame overhang • Modify electrical and pneumatic lines (see document
"Repair and extension of plastic compressed-air
lines of the brake and air suspension system"),
i • Extend the subframe to the end of the chassis frame.
Coordination required: On vehicle model • Weld seam with reinforcing bracket as per
designations 963.042, 964.043/211, before specifications (see documents "Reinforcements in
lengthening the overhang of the vehicle frame due to the frame"), overlapping on left and right and bolted.
the installed internal brackets, contact the relevant
contact person (see document "Advice for body • Only use frame sections of genuine materials and
manufacturers") original dimensions (see document "Modifications
to the wheelbase"). Mercedes-Benz genuine frame
sections are recommended.
Any extension of the frame overhang represents an • Use only one profile section on each side of the
intervention in the existing geometry of the vehicle, frame (no multiple extensions).
necessitating a re-evaluation of the technical and • Operational durability verifications of vehicle frame
licensing requirements. For this reason, the following and subframe (the section moduli specified in (see
points must also be observed: document "Design of bodies") for the subframe
• Maximum length of vehicle overhang (see chapter and in the subchapters for the respective body may
"Vehicle overhang and technical wheelbases → no longer be valid and may have to be verified)
Maximum vehicle overhang lengths") • All points are to be checked, in particular with loading
• National specifications with regard to vehicle equipment at the end of the frame and/or tongue
dimensions (e.g. overall vehicle length, shear-out weight.
dimension)
Trailer operation/tongue weight
• Technical and legal axle loads and the gross vehicle
mass If the ratio of frame overhang to (technical) wheelbase is
exceeded by more than 60 %, the ex-factory permissible
• Minimum front axle load (see document towing capacity must be reduced; see graph.
"Steerability"),

Permissible towing capacity (A)
R Wheelbase
Ü Overhang
Graue Fläche Invalid area
W31.30-A003-11
Reduced towing capacity with long frame overhang
Towing a rigid drawbar trailer (SDAH) or a center axle relevant conditions in the appropriate subchapters in
trailer (ZAA) and the tongue weights these introduce in (see document "Design of bodies") must be observed.
the vehicle have an effect on the operational durability The following operational durability verifications for
and handling characteristics. These effects are changed driving operation are available for download in the
by lengthening of the frame overhang. Mercedes‑Benz Bodybuilder Portal in the folder Body/
If the frame overhang exceeds the lengths available ex Equipment Mounting Directives/Additional information for
factory in combination with a trailer coupling for center Body/Equipment Mounting Directives, Calculation:
axle trailers, the anticipated handling characteristics of • For vehicles of axle configurations 4x2/4x4:
the tractor/trailer combinations have not been checked Document "NW 020216 Driving with additional loads,
by the vehicle manufacturer. 4x2".
Mercedes-Benz is unable to make any statement or • For vehicles of axle configurations 6x2 ENA/DNA or
assessment of this with regard to the anticipated 8x2/4 ENA: Document "NW 020216 Driving with
handling properties. additional loads, 6x2".
The calculation tools available in the Bodybuilder Portal • For vehicles of axle configurations 6x4/4, 6x6/4,
can be used to calculate the required operational 8x4/4, 8x6/4, 8x8x/4: Document "NW 020216 Driving
durability (dimensioning of the subframe). For other rear- with additional loads, 6x4".
mounted loads, e.g. a crane or cargo liftgate, the
---------------------------------------------------------------------------
Shortening of the frame overhang • Some model designations may be fitted with
• After shortening the frame overhang, the end reinforcing brackets which may have to be shortened
crossmember must be moved into the remaining part further.
of the end of the frame.

W31.30-A026-78
"Short" internal reinforcing bracket
Variant 1/"short" internal reinforcing bracket
Frame overhang 1050 mm (code COG) and
1350 mm (code COM)
Length of internal reinforcing brackets in frame Depending on the selected frame overhang (code),
overhang (vehicle model designation internal reinforcing brackets of various lengths are added
963.020/964.020) in the frame overhang at the factory.

W31.30-A027-78
"Long" internal reinforcing bracket and additional crossmember
Variant 2/"long" internal reinforcing bracket and additional crossmember
Frame overhang ≥ 1650 mm (code COT, COZ, C4F,
C4L, C4S, C4Y)
Frame overhang shortening, for refuse vehicles,
rear loaders, sales code C5N (model series 963, 964)
In the as-delivered state, vehicles with vehicle model
designations 963.003/964.003 and sales code C5N
have a frame overhang of 1200 mm; an end
crossmember is not installed. The body manufacturer
can shorten the overhang down to 600 mm. The
conditions specified in the illustration must be fulfilled.
1 Shortest series production frame
overhang = 1200 mm
2 1050 mm
3 Shortest frame overhang ≥ 600 mm
4 Shortening range without further measures
5 With a frame overhang > 1050 mm, it is
necessary to retrofit the end crossmember
A 960 312 07 35 (with frame track 834 mm)
or A 960 312 09 35 (with frame track 744 mm). It
is not possible to install a trailer coupling.
6 Shortening range
W31.30-A014-12
As-delivered state
Crossmembers and retrofitting crossmembers
Connecting devices Page 206
End crossmember If a trailer coupling or towing coupling is additionally

An end crossmember must always be installed, even if installed, the necessary reinforcements must be present
the vehicle is not used for trailer operation. (see document "Coupling devices").
Install the trailer coupling accordingly.

W31.30-A028-76
Example of crossmember
Retrofitting crossmembers Partners, but only as individual components. Threaded

If an additional genuine Mercedes-Benz crossmember is connections must be provided to replace the riveted
retrofitted in the area behind the front end frame joints between the crossmember and the gusset plates
drop, the following individual components (see the document "Threaded connections and weld
("crossmembers and gusset plates") can also be used joints")
depending on the variant required.
The complete crossmembers are not available as
assemblies (ZB) through the Mercedes-Benz Service

Crossmembers and retrofitting crossmembers

Rear axle suspension B [mm] 1 x crossmember 4 x gusset plate

system: Steel suspension
Without additional internal 744 A 960 312 66 01 A 960 312 45 88

reinforcement in longitudinal
frame member
With additional internal 732 A 960 312 49 87

reinforcing brackets (6 mm
per side) in longitudinal
frame member
Rear axle suspension B [mm] 1 x crossmember 4 x gusset plate

system: Air suspension
Without additional internal 834 A 960 312 77 01 A 960 312 45 88

reinforcement in longitudinal
frame member
With additional internal 822 A 960 312 49 87

reinforcing brackets (6 mm
per side) in longitudinal
frame member
Reinforcements in frame
Reinforcements • Bracket height at least 82 mm, width at least 68 mm

If the frame is modified, internal or external reinforcing (with 70 mm and 80 mm upper flange)
brackets must be installed. • Material thickness 6 mm
The reinforcing brackets should be bolted on and be • The bracket must be positioned so that the
flush with the end faces of the upper and lower flanges. longitudinal member weld is overlapped by at least
Use the existing holes in the longitudinal frame member 300 mm on each side (minimum length 600 mm).
where possible. • The bracket must always be bolted in the first two
A sufficient gap must be left between the upper and and last two hole patterns on the longitudinal
lower reinforcing brackets on the frame web. member.
Reinforcing brackets are to be manufactured and • The first two hole patterns on each side of the
fastened as follows: longitudinal member weld must be bolted.
• Material of internal bracket: Steel with elongation at • For the remainder of the length of the bracket, there
fracture Re ≥500 N/mm² must be a threaded connection with the longitudinal
member at least every 100 mm.
• On semitrailer trucks with frame in S 700 MC,
reinforcements must be made of steel with an
elongation at fracture of Re = 700 N/mm².

W31.00-A045-76
Example of reinforcing bracket A 960 312 5652 (L=598 mm)
Mounting on vehicle frame
Detachable parts at frame

Mounting compressors Page 195
i i
Avoid potential dangers to people or property Intended function impaired or operational safety of
damage due to lack of knowledge. Before starting to vehicle jeopardized. There is a heightened risk of
install other make bodies or equipment, please read accident and injury! Modifications or changes to the
the relevant documents of these Body/Equipment vehicle with non-approved parts are prohibited.
Mounting Directives, the instructions and information Ensure that only approved parts are used.
from the equipment supplier and the detailed
operator's manual for the base model vehicle.
---------------------------------------------------------------------------
Mounting on the vehicle frame • Install the holder and assembly near to a
• Mercedes-Benz recommends the use of flange head crossmember. Fitting additional crossmembers is not
bolts and nuts in line with Mercedes-Benz standard permitted. (Model 963, 964)
MBN 10105 and MBN 13023, strength class 10.9, • Alternatively, fit the reinforcement plate to the inside
thread pitch 1.5 mm. of the frame web.
• Use existing holes. • No force may be applied to the center of the web of
• Adjust the number of bolts to the load. the longitudinal member (diaphragm effect). If this is
unavoidable, make sure that there is a large area of
• Component parts must not jam up against the support on both sides of the web.
substructure frame or the longitudinal frame member.
For heavy attachments (heavier than 50 kg), refer to the
Lateral attachment specifications (see "Installation of compressors"
document (model 963, 964)).
• Install the holder and assembly near to a
crossmember. Install an additional crossmember if
necessary. (Model 967)
Front underride guard
All vehicles of class N2 (only for model 967) and N3, purpose of a vehicle is to a great extent determined by
which are put into circulation, require a front underride the body, so the vehicle equipment must be carefully
guard. Excluded from this are off-road vehicles of the considered both with and without the front underride
classes N2G (only for model 967) and N3G and vehicles guard. Mercedes-Benz recommends that the approval
whose intended use is not compatible with the and intended use be clarified with the authorities
regulations on front underride guards. The intended responsible beforehand.
Rear underride guard ex factory

i
Possible loss of eligibility for registration of the
vehicle. The height of the underride guard above the
ground changes due to the body and its mass
distribution. Therefore, especially for steel-sprung
vehicles, it is necessary to additionally check the
compliance with the height dimension after
installation.
---------------------------------------------------------------------------
General information Moving the original underride guards to a different
The following underride guards are available ex factory position is only permissible as part of overhang
(model designation and code specific): modifications in compliance with the following
specifications. The specifications in the chapter "Frame
• Code C7A Rear underride guard (ECE) modifications" must also be observed here.
• Code C7B Rear underride guard, folding, for air The underride guards as per codes C7B and C7C are
dump truck only permissible for the body type "Dump truck". The test
• Code C7C Rear underride guard, folding, for steel and certification as per UNECE 58 R03 was performed
dump truck at 80% of the corresponding proof loads for the body
type "Dump truck"
The underride guards installed at the factory correspond
to the specifications as per UNECE 58 R03. The national specifications with regard to the underride
guard must also be observed.
No modifications may be made to the components of the
underride guard itself.

X Horizontal distance
Y Vertical distance
Z Angle of approach/departure
W88.30-A040-82
Horizontal distance (X) Vertical distance (Y)

Rear edge of body to rear edge of underride guard bar Ground to lower edge of underride guard bar
Code C7A/C7B: max. 279 mm Vehicle class N3 with steel suspension: max. 500 mm (1),
Code C7C: max. 300 mm Vehicle class N3 with air suspension: max. 450 mm (1),
Vehicle class N3G: max. 550 mm (2)
1 Angle of approach/departure (Z) < 8⁰, max. 550 mm
2 Angle of approach/departure (Z) > 25⁰
i
The specifications in the currently valid version of
UNECE 58 R03 must be checked and must be
complied with.
---------------------------------------------------------------------------
Overview of variants (examples)

W88.30-A072-79
A1 Version 1: Code C7A A5 Version 5: Code C7A with B1 Version 8: Code C7B
Q8M
A2 Version 2: Code C7A A6 Version 6: Code C7A C1 Version 9: Code C7C
A3 Version 3: Code C7A A7 Version 7: Code C7A C2 Version 10: Code C7C with
code Q8M
A4 Version 4: Code C7A
Code Q8M: End crossmember, lowered, reinforced

i
The versions A1 to A7 show the different variants of
C7A depending on the frame height and version.

Mounting to vehicle frame/bar to mounting support
(examples)

W88.30-A042-79
A Code C7A B Code C7B 2 Bar to mounting support
A5 Code C7A with Q8M 1 Mounting support to frame 3 Contact surface
i
The contact surfaces (3) of the mounting supports/
reinforcements must make contact with the
substructure frame of the longitudinal frame
member.

Mount Number of threaded Screw Nut Torque controlled

connections tightening
(each side)
Mounting support to 8 - 17 (3) Flange head screw Flange head nut 225 Nm (3)
frame (1)
M16x1.5 class 10 (3)
Bar to mounting support 3 (4) Flange head screw Weld nut in bar 92 Nm
(2) (MBN10105)
N 0000 0000 8970
M12x1.5x40 10.9 (4)
3 The number of factory-fitted threaded connections and position must always be retained. For further information, see the chapter
"Vehicle frame threaded connections".
4 The factory-delivered flange head bolts can be reused.
W88.30-A043-77
C1 Code C7C 1 Mounting support to frame
C2 Code C7C with Q8M 3 Contact surface
i
The contact surfaces (3) of the mounting supports/
reinforcements must make contact with the
substructure frame of the longitudinal frame member
and with the frame end.

Mount Number of threaded Screw Nut Torque

connections controlled
tightening
Mounting support to 11 (3) Flange head screw Flange head nut 225 Nm (3)
frame (1) M16x1.5 class 10 (3)
M16x1.5 10.9 (3)
3 The number of factory-fitted threaded connections and position must always be retained. For further information, see the chapter
"Vehicle frame threaded connections".
---------------------------------------------------------------------------
Relative position of end crossmember and mounting
support on frame


Code C7A without code Q8M
A Code C7A without code Q8M
D Distance (50 mm to max. 350 mm)
W88.30-A068-81
Code C7A with code Q8M

W88.30-A051-77
Example pictures
4 Longitudinal frame member 6 Threaded connection
5 Reinforcement
• The factory-fitted relative position and the position the new frame end by the same amount. The
between the mounting supports of the underride specifications in the chapter "Frame modifications"
guard system, the end crossmember and the end of must also be observed.
the frame overhang must not be changed. • The reinforcement (5) must make contact with the
• In the case of a subsequent change to the overhang, lower flange of the longitudinal frame member (4).
the listed component parts must be moved toward

Mount Number of threaded Screw Nut Torque controlled

connections tightening
Reinforcement 2 (5) Flange head screw Flange head nut 225 Nm (5)
(5) M16x1.5 class 10 (5)
M16x1.5 10.9 (5)
5 For further information, see the chapter "Vehicle frame threaded connections".
Code C7B
B Code C7B
W88.30-A069-81
the frame overhang must not be changed.
• In the case of a subsequent change to the overhang,

Code C7C without code Q8M

C1 Code C7C without code Q8M
D Distance (50 mm to max. 200 mm)
W88.30-A070-81

Code C7C with code Q8M
C2 Code C7C with Q8M
W88.30-A071-81
the frame overhang must not be changed.
• In the case of a subsequent change to the overhang,
---------------------------------------------------------------------------
Permissible distance between mounting supports

The mounting supports are given

appropriate elongated holes at the
factory.
A Code C7A
D Distance (horizontal distance
between inner surfaces of
mounting supports)
W88.30-A047-75
Version Distance (D)
C7A - Vehicles with steel 760 to 782 mm

suspension
C7A - Vehicles with air 848 to 870 mm

suspension
corresponding elongated holes for mounting the

underride guard bar. (see mounting of bar to mounting
support).

Code C7B: Changing of the factory-delivered distance
(D) is not permissible.
It is therefore possible and permissible to subsequently Code C7C: It is not possible to subsequently adapt the
mount the underride guard mounting brackets of code distance (D) in combination with the factory-delivered
C7A on a crane side plate (max. t=10 mm), for example. scope.
For this purpose, the mounting supports have
---------------------------------------------------------------------------
Location of underride guard bar (code C7A)

W88.30-A048-77
E Adaptation of alignment G Adaptation of vertical position and alignment
F Adaptation of vertical position D Distance
Adaptation of the alignment (E) shows the permissible permissible locations of the underride guard bar in
location of the underride guard bar. combination with mounting supports:
Adaptation of the vertical position (F) and adaptation of A 966 520 08 33/09 33 or A 966 520 04 33/05 33.
the vertical position and alignment (G) show the

Mounting console Distance (D)
A 966 520 08 33/09 33 682 mm
A 966 520 04 33/05 33 592 mm

---------------------------------------------------------------------------
Adaptation of horizontal position of underride guard disassembling adapters, subject to compliance with the
bar following boundary conditions.
The horizontal position of the underride guard bar, as However, this is not permissible in combination with the
supplied ex works, can be changed by assembling/ following mounting supports K25: A 966 520 00 33/01 33


W88.30-A049-77
6 Bolts 8 Purely an assembly aid (only V2 Variant 2
for factory solution version)
7 Adapter part number V1 Variant 1 V3 Variant 3
- Variant 1 (V1) Variant 2 (V2) Variant 3 (V3)
Adapter part number (7) - Standard: A 966 520 00 32 Standard: A 966 520 01 32
For mounting supports K30 For mounting supports K30
and 35, use adapter A 966 and 35, no adapter with a
520 05 32. length of 130 mm is
available.
Length of adapter - 60 mm 130 mm
Screws (6) Flange head bolt Flange head bolt Flange head bolt
(MBN10105) (MBN10105) (MBN10105)
3x N 0000 0000 8970 3x N 0000 0000 8971 3x N 9101 0501 2044
M12x1.5x40 10.9 (4) M12x1.5x110 10.9 (7) M12x1.5x180 10.9 (7)
Nut Weld nut in bar
Torque controlled tightening 92 Nm

4 The factory-delivered flange head bolts can be reused.
7 Replacement part - to be procured separately.
W88.30-A073-77
K25 Mounting support 25 K35 Mounting support 35
K30 Mounting support 30 D Distance
Mounting console Part number Distance (D)
K25 A 966 520 00 424 mm

33/01 33
K30 A 966 520 32 477 mm

33/35 33
K35 A 966 520 33 548 mm

33/36 33
Code C7B: In combination with the factory-delivered scope, a

A subsequent change to the factory-delivered horizontal subsequent change to the horizontal position of the
position of the underride guard bar is not permissible. underride guard bar is not possible and is not
permissible.

Code C7C:
Rear underride guard

• When a body is mounted or when a rear underride
i guard is retrofitted or newly installed, the body
Currently there is the transitional agreement that UN manufacturer is responsible for ensuring that the
ECE R58.02 can continue to be used until statutory requirements are observed. The dimensions
01.09.2021. As of 01.09.2021, only UN ECE-R58.03 depend on the body and can only be determined on
will be valid. the complete vehicle with body.
• The rear underride guard must provide effective
underride protection across the entire width of the
According to Directive UN ECE-R58, an underride guard vehicle.
is a requirement if: • The underride guard must comply with Directive UN
• the distance from the end of the vehicle to the last ECE-R58 and have a corresponding approval mark.
rear axle is greater than 1000 mm and • The lights (also reflectors) and the license plate
• with the vehicle in its unladen condition, the distance number must not be concealed by the rear underride
between the roadway and the chassis or main parts guard.
of the body is greater than 550 mm across the entire • The underride guard must not be modified, e. g. by
width of the vehicle. welding, drilling or changing the angle of the
Exceptions to this are semitrailer trucks, working mounting consoles.
machines and special-purpose vehicles whose purpose • Any modifications will render the type-approval
cannot be fulfilled if the underride guard is fitted. certificate for the rear guard invalid.
Basic requirements:

Approval mark variants
W88.30-A019-76
Approval mark on mounting console of underride guard
Attachment dimensions for rear underride guard If, e.g. for the type approval for the protective rail, a
• The rear underride guard must be attached as far to maximum horizontal deformation of 121 mm is
the rear as possible. The maximum permissible determined, a maximum permissible distance is given
horizontal distance between the rear edge of the from the rear edge of the protective rail to the end of
protective rail to the rear edge of the body before the body of 279 mm (maximum permissible distance
applying the test force, may be a max. 300 mm, 400 mm – 121 mm deformation of rear underride
during and after the application of the test forces guard = 279 mm mounting dimension).
specified in directive UN ECE-R58, the distance may The specifications in the currently valid version of
not be greater than 400 mm. UNECE R58 must be checked and be complied with.
The new deformation value of the protective rail must
be taken into consideration when mounting the body.
Rear underride guard
• The distance from the lower edge of the guard to the In such cases, it is important to observe the following:
roadway, on an unladen vehicle, may not be more • The side clearance between component parts of the
than 550 mm or 450 mm at any point on the air- underride guard and elements of the cargo liftgate
sprung vehicles with an overhang angle > 8° (in that make interruption necessary, must not exceed
accordance with ECE-R58.03). 25 mm.
• The width of the rear guard must not exceed the • The approval mark must be visible and permanently
width of the rear axle and must not be less than attached next to the cargo liftgate identification plate.
100 mm. The outer edges of the tires on the widest
rear axle are the basis for determining the axle width. • If a lowerable cargo liftgate is installed, the cargo
liftgate can perform the function of the underride
• The profile height of the protective rail must be at guard.
least 100 mm (R58.02) or 120 mm (R58.03).
• Outer edges must be rounded off with a radius of at
least 2.5 mm.
Special considerations in combination with cargo

liftgate
The rear underride guard can be interrupted by
mechanical load-bearing elements.

W88.30-A020-79
Lowerable cargo liftgate performs the function of rear underride guard.
Possible locations for bolting on side protection device

In addition to the usual frame connections, the following • Fender carrier
detachable parts are also available for installing a side • Battery carrier
guard in accordance with the boundary conditions
described below: • Fuel tank
• Holder/mounting support for plastic AdBlue® tank • Sensor holder for Cornering Assist, sales code S1R
• Exhaust aftertreatment unit

AdBlue® 60 l/75 l/100 l: Welding on holders

The plastic AdBlue® tank must be removed during welding work. This will
prevent damage and allow effective anti-corrosion protection to be applied.
When reinstalling the mounting rail on the filler neck, remember that the
plastic tank loses its preload due to settling and can work loose if the
tension is too low.
• The welding zone is defined.
• No holes may be drilled in the mounting support.
• On vehicles with the 100 l tank, only the right rear holder (viewed in the
direction of travel) is present.
1 Holder spot weld
W88.00-A032-02
Holder for AdBlue® tank
AdBlue® 60 l/75 l/100 l: Specifications for position of

fastener
Maximum surface temperature for HDPE plastic
tank: 80 ℃/min.
W88.00-A033-12
Markings: Impermissible areas
Exhaust aftertreatment unit
W88.00-A037-11
Connection points M10 on exhaust gas aftertreatment unit, max.
15 kg
Front fender carrier with AdBlue® 60 l/75 l
W88.00-A038-11
Two M10 bores for fastening a protective rail of max. 15 kg

Front fender carrier with AdBlue® 100 l
W88.00-A104-81
Two bores for fastening a protective rail of max. 9 kg
W88.00-A067-11
Attachment points M10 on exhaust gas aftertreatment unit GATS
2.0, max. 15 kg
Wide battery carrier, end face

Maximum weight of parts to be attached: 15 kg
• Possible attachment points for a bore with a
maximum diameter of 11 mm
• Possible positions for two further bores with a
maximum diameter of 11 mm within the marked area
(2)
W88.00-A040-11
Wide battery carrier, end face
Wide battery carrier, right side

(2)
Minimum distance from existing bores: 30 mm
W88.00-A041-11
Wide battery carrier, right side

Wide battery carrier, left side
(2)
Minimum distance from existing bores: 30 mm
W88.00-A042-11
Wide battery carrier, left side
Stacked battery carrier, left and right sides

Longer bolts must be used according to the material
thickness of the component part to be attached.
W88.00-A043-12

1 Possible attachment points for fastening
additional component parts (applies to both sides
of the battery carrier)
No additional component parts may be fastened
to any other bolts or holes. No additional holes
may be drilled.
W88.00-A044-11
4-axle vehicle between front axles on left side

Attachment points for additional component parts or use of existing bores
for M10 screws.
W88.00-A045-02

W88.00-A046-02
W88.00-A047-02
W88.00-A048-02
Fuel tank
On the high 735x700 fuel tank, there are attachment points for 2 x M8 at
the bottom of the mounting support.
On other tank cross-sections, these holes must be drilled out by the body
manufacturer.
W88.00-A049-03
W88.00-A050-01

The marked bores can be used for fastening side underride guards up to a
maximum load capacity of 20 kg per mounting support.
The existing bores may be drilled to a maximum diameter of 12 mm.
Any existing cable connections must be suitably replaced.
The attachment points on the holder provided by the factory can be used
for securing.
The proportional weight pressure applied to the holder must not exceed a
maximum of 15 kg (See document GA54.00-W-0008-01A Side sensors).
W88.00-A051-03
Cornering Assist sensor holder, code S1R
Gap for accessibility to test connections

A 140 mm
B 360 mm
1 Gap
2 Brake air test connections
3 Air suspension air test connections
W88.30-A059-81
Vehicle with diesel engine (model designation 956.0xx):
A 250 mm
B 480 mm
1 Gap
2 Brake air test connections
3 Air suspension air test connections
W88.30-A060-81
Vehicle with gaseous fuel engine (model designation 956.4xx):
Side underride guard

According to UN-R73, a side underride guard is • Rivets, bolts or other parts must not project above the
stipulated for vehicles with a permissible gross mass in outer surface by more than 10 mm and must be
excess of 3.5 t. rounded off.
Exceptions to this are: • Brake, compressed air or hydraulic lines must not be
• Semitrailer trucks secured to the side underride guard.
• Working machines • The function and accessibility of all major assemblies

and maintenance-relevant components,
• Transfer chassis e.g. batteries, present on the vehicle must not be
• Vehicles on which, for practical reasons, it is not impaired.
possible to attach a side underride guard. • The deflector profiles must be secured sufficiently.
Folding and removable devices are permitted,
provided that they are strong enough to meet the
i requirements of the intended task.
All-terrain vehicles cannot be exempted from the • All outer edges and corners must be rounded off with
obligation to attach a side underride guard simply a radius of at least 2.5 mm.
because they are capable of off-road operation.
• The body manufacturer who installs the side
protective device is responsible for ensuring
compliance with the legal requirements.
Basic requirements
• The side underride guard must not increase the Attachment dimensions for side protective device
overall width of the vehicle. • The side protective device extends across the area
• The side underride guard can consist of a continuous between the front and rear axle of a vehicle. It begins
flat surface, rails or a combination of both. max. 300 mm behind the profile lines of the front
wheels and ends at a maximum distance of 300 mm
• Components such as e.g. battery boxes,
in front of the profile lines of the rear wheels.
compressed-air reservoirs, fuel tanks, spare wheels
and tool boxes, may be integrated in the side • The side underride guard can consist of one or more
underride guard provided that the specified deflector surfaces or rails arranged one above the
dimensions are observed. other. Their minimum height is as follows:
• The outer surface must be smooth, essentially flat or
horizontally corrugated. Where possible, it must be
continuous from the front to the rear.

Minimum height of rails/deflector surfaces
From 3.5 t to 12 t gross weight: 50 mm
Above 12 t gross weight: 100 mm
• If rails are used, the space between them must not of the guard must be level with the lower edge of
be more than 300 mm. the body or min. 950 mm above the roadway,
• If the side underride guard consists of several depending on which value is the lower of the two,
elements arranged in the longitudinal direction, the e.g. in the case of a roll-off dump truck, cement
interruptions resulting from the detachable parts must mixer vehicle, etc.
not exceed 25 mm. • If the lower edge of the body is higher than
• With the vehicle in its unladen condition, the lower 1300 mm above the roadway, the upper edge of
edge of the deflector elements must not be more the guard must be min. 950 mm above the
than 550 mm above the road surface. ground.
• The gap between the guard upper edge and the body The main part of the deflector surface must not be more
lower edge must not be greater than 350 mm. The than 150 mm inboard from the vehicle outer line. The
following cases are the exceptions: rear end must not be more than 30 mm inboard
measured from the outer edge of the rear wheels, over
• If the body is narrower than the outside tire at least the rearmost 250 mm. The front end may be
sidewalls on the widest rear axle, the upper edge turned inward.

Side underride guard
a Max. 300 mm
b Max. 350 mm
c Max. 100 mm
d Max. 550 mm
N31.30-A004-05
e Max. 150 mm
f Max. 25 mm
g Max. 30 mm
h 250 mm
N31.30-A005-05
Mount of fender

As far as the vehicle is concerned, there is nothing to fenders. It is not permissible to attach additional parts
stop the same attachment points being used as those such as shovel brackets and broom brackets or similar
used in series production. For the weight moment, to the factory-mounted fender. This is only permissible if
please refer to the series production version of the an additional support is provided.

1 Fender bracket with central

screw in only upper or lower
hole row and with anti-twist
lock as well as
2 Pressure distribution plate
W63.50-A000-05
Fender bracket
Basic requirements • If possible, secure the fender bracket to the body

• Use the correct bolt length. manufacturer auxiliary frame.
• The mounting points on the trailing arm bracket are • If mounting to the chassis frame, secure in the upper
not on one level; they must be aligned accordingly. and lower hole row (using the plate).
• Your are responsible for attaching your pipe to the • Mounting the fender bracket using the central screw/
plate and for dimensioning the plate. bolt (see the figure below) is only permissible in the
upper and lower hole row and with anti-twist lock as
• It would be of particular benefit to make a hole in the well as pressure distribution plate on the inside of the
plate, to feed through the fastening piece and to weld frame.
on both sides.

W63.50-A001-05
Introduction of forces into trailing arm bracket through three attachment points (available
ex factory).
Mount of fender

Overview of the available fender variants
Sales code Description
C8A Aluminum fenders, on rear axle
C8B Rear-axle fender, 2550 mm vehicle width
C8C Rear-axle fender, 2500 mm vehicle width
C8D Quarter-shell fender, for complete dumper
C8E Half-shell fender, for complete dumper
C8G 3-piece fender, without EC splash guard
C8H 3-piece fender, with EC splash guard
Mounting compressors

Compressor mounting • If the material thickness of the first crossmember is
Arrange compressor brackets in such a way that the 6 mm (as-built configuration in combination with
load application covers a large area on the vehicle clearance on right of frame, sales code C7R) and of
frame; use a pressure distribution plate if necessary. the gusset plates 7 mm, the reinforcement must be at
least 7 mm.
• Do not attach the compressor brackets in the middle
of the longitudinal member web (diaphragm effect). Mounting on semitrailer trucks
• The reinforcing brackets must have a minimum side If installed in front of the rear axle on a vehicle fitted with
measurement of 100 mm on the lower frame flange. a mounting bracket for a fifth wheel coupling, the
Use steel with an elongation at fracture Re = pressure distribution plate is not required. All that is
necessary is one external bracket on the lower frame
355 N/mm² (recommendation: Re = 500 N/mm²).
flange of the same thickness as the semitrailer bracket
For compressors with a weight > 100 kg, reinforcement (7 mm, reinforced 9 mm). The length of the bracket from
measures are required, depending on the installation the crossmember (in front of the rear axle) forwards
position: across the frame kink must be fastened with at least two
Design possibilities bolts (flange head bolts/nuts M16 × 1.5-10.9) in the
lower row of holes in front of the frame kink. Adjust the
Variant 1 material thickness of the semitrailer brackets.
The compressor bracket is located in the vicinity of the • Adjust the material thickness of the semitrailer
first or second crossmember after the transmission. brackets.
When installing compressors up to max. 400 kg on Variant 2
semitrailer trucks, the following exterior reinforcements
are necessary: Only part of the compressor bracket lies near a
crossmember (i.e. the compressor bracket can only be
• A pressure distribution plate under the entire partly bolted to the crossmember gussets).
compressor mounting and a reinforcing bracket on
the lower flange of the longitudinal frame member. Reinforcing brackets with a material thickness of at least
The reinforcing bracket must cover the area between 7 mm must be installed both at the top and bottom of the
the first and second crossmembers. An overlap of at longitudinal frame member, and extending at least
least two holes on the relevant crossmember gusset 300 mm beyond the compressor bracket.
plates is required. The pressure distribution plate and Mounting on semitrailer truck
the reinforcing bracket must be joined by welding or If installed in front of the rear axle on a vehicle fitted with
must be manufactured in one piece. a mounting bracket for a fifth wheel coupling, the
• The frame kink must be taken into account. pressure distribution plate is not required. The sheet
The required material thickness of the reinforcement thickness of the standard mounting angle is 7 mm/
depends on the following parameters: reinforced 9 mm.
• If the material thickness of the first crossmember is The compressor mounting bracket must always be
4 mm (standard for semitrailer trucks) and of the bolted to the upper and lower rows of holes in the
gusset plates 6 mm, the reinforcement must be at longitudinal frame member.
least 10 mm thick.

Mounting compressors
1 Pressure distribution plate

2 Reinforcing bracket
W88.00-A052-11
Threaded connection of compressor mounting bracket
Variant 3
The compressor mounting bracket lies outside the
gusset plate of the crossmember.
For torque support, install an additional standard
crossmember or as an alternative, two vertically-upright
panels, connected by an L bracket to the longitudinal
member.
Material thickness: At least 7 mm
Material: Steel with elongation at fracture
Re = 500 N/mm² W88.00-A053-10
Variant 4
The compressor mounting bracket lies near to a
crossmember (i.e. the compressor bracket is bolted to
the crossmember gusset plates).
No additional measures necessary.
W88.00-A054-10
Front attachments

Front sensors Page 422
i i
Risk of accident and possible malfunctions of Possible risk of accident and impairment of airbag
assistance systems: Observe further instructions system function (e.g. non-activation): Front-mounted
regarding front-mounted implements in combination implements, in particular, front brush guard brackets,
with the Lane Departure Warning System (LDWS)/ mean that the proper function of the system can no
Lane Keeping Assist, code S1H, Advanced longer be assured. Vehicles without airbag, order
Emergency Braking System (AEBS)/Active Brake code S3A or have airbag system removed by
Assist 5, code S1W and Proximity Control Assist, Mercedes-Benz Service Partner.
code S1I (see document "Front sensors").
i
i A drawing and 3D models of the pre-installation can
Potential risk of accident and impairment of the be found in the Mercedes‑Benz Bodybuilder Portal.
proper functioning of safety systems: With front- (http://bb-portal.mercedes-benz-trucks.com)
mounted implements, proper functioning of the
safety systems may be impaired. Front-mounted
implements are not permissible on vehicle model
designation 963, 983 (see document "Front
sensors").
i
Note the location of the attachment points: The
upper attachment points are identical on all vehicles
in terms of their design. The lower attachment
surfaces vary depending on their installation
position, location and design on the vehicle. See the
illustrations of variant 1 and 2 as well as the
assignment matrix table for information on the
assignment and dimensions.
Front attachments
W88.00-A055-12
pre-installation for front-mounted implements
Pre-installation, for special front-mounted The information below does not apply to additional front
implements, sales code C5O outriggers for loading crane bodies. This use case must
This pre-installation includes two attachment points at be coordinated with the contact person responsible (see
the top, two attachment surfaces with appropriate document "Advice for body manufacturers").
threads at the bottom, and one reinforced crossmember.
These attachment points can be used to fasten front
mounting plates for special installations, such as
snowplows, sweeper brushes, sprayers etc.

The following sales codes are not permissible in combination with the pre-installation for special front-
mounted implements
S3A Driver airbag
S1M Active Brake Assist 3
S1P Active Brake Assist
S1V Active Brake Assist 4
Front attachments

Assignment matrix table
Vehicle Variant 1 Variant 2
Non-AWD X -
Non‑AWD with F2M + (M2R/M2S) - X
Non‑AWD with Z5E + R0V - X
Non‑AWD with Z5F/Z5L/M3E - X
AWD - X

Legend
F2M Cab body floor height 420 mm
M2R Engine OM 470 R6, 10.7 l, 315 kW (428 hp), 2100 Nm
M2S Engine OM 470 R6, 10.7 l, 335 kW (455 hp), 2200 Nm
M3E Engine OM 471 R6, 12.8 l, 390 kW (530 hp), 2600 Nm
ROV Vehicle adaptation, large tires
Z5E Engine model series OM 471
Z5F Engine model series OM 473
Z5L Engine model series OM 460
AWD All-wheel drive vehicles (4x4, 6x6, 8x6, 8x8)
Non-AWD Non all-wheel drive vehicles (4x2, 6x4, 8x4) also in combination with Hydraulic Auxiliary Drive (HAD),
sales code A1H
A Distance to center of front axle

= 1110 mm
W88.00-A056-04
Variant 1 (example)
Front attachments
A Distance to center of front axle

= 1110 mm
W88.00-A057-04
Variant 2 (example)
Overview of attachment points

A Upper attachment points
B Lower attachment points
X Reinforced crossmember (not visible)
W88.00-A058-11
Attachment points for front-mounted implements
Upper attachment points (A)
W88.00-A059-11
Front attachments

C Fastening elements for plastic cover (cover not
illustrated)
D Ring surface for implement (ring surface ex
factory: Outside diameter at least 65 mm, inside
diameter 50 mm)
E Adapter socket (M45x3 to M24x2)
E1 Attachment point for implement, thread M24x2
inside adapter socket
F Edge
W88.00-A060-11
Shown in direction of travel, right
Additional information/specifications • Use of a high-strength washer under the bolt head,

The fastening elements (C) must be removed (no further with steel material, hardened and tempered – tensile
than edge F). strength at least 1100 N/mm² and/or hardness HV30
(350 + 80), outer diameter ≥ 48 mm, inner diameter
To enable the permissible operating forces and ≥ 26 mm, material thickness ≥ 5 mm.
moments to be transferred, a minimum preload force of
133 kN (max. 326 kN) must be permanently guaranteed • The minimum screw-in depth for the threaded
at each of these upper threaded connections. connection in the M24 × 2 thread is 1 x d = 24 mm.
The maximum screw-in depth must not exceed
This can be ensured by, e.g. : 32 mm. When selecting the bolt length, note the
• Hexagon head bolts with thread up to the head as clearance in the X-direction between the reducing
per DIN EN ISO 8676, M24 × 2, class 10.9 or bush (E) and the ring area (D) (see illustration).
• Hexagon head bolts with shank as per DIN EN ISO ¹⁾ Modified geometry of threaded socket
8765, M24 × 2, class 10.9 A 000 992 99 07/ZGS 02 for all vehicles as of
manufacturing date 01.02.2014, new maximum screw-in
• Tightening torque: MA = 790 Nm
depth 40 mm
• Total friction coefficient of threaded connection μtot =
0.08 to 0.14

E Adapter socket
D Ring surface for attachment
W88.00-A061-05
Clearance of adapter socket
Front attachments
The minimum grip length per M24× 2 threaded (D) is guaranteed. The implement must be made of steel
connection is 1 x d = 24 mm. with a yield strength of ≥ 355 N/mm².
Mercedes-Benz recommends the longest possible grip The adapter socket (E) must be checked for correct
length in order to counteract the losses in pre-load force seating every time the M24× 2 threaded connection is
due to settling effects. loosened.
The implement must be designed so that a uniform Check with tightening torque M = 100 Nm.
contact surface area of ≥ 1190 mm² on the ring surface

Lower attachment points (B)

G Thread M20 × 1.5
H Attachment/support surface for body
I Air conditioning system component (observe
installation space)
W88.00-A062-12
Example on left in direction of travel
Additional information/specifications The maximum screw-in depth must not exceed 42 mm.
To enable the permissible operating forces and The minimum grip length per M20 × 1.5 threaded
moments listed below to be transmitted, a minimum connection is 1 x d = 20 mm.
preload force of 97 kN must be permanently guaranteed Mercedes-Benz recommends the longest possible grip
at each of these lower threaded connections (G). length in order to counteract the losses in pre-load force
This can be ensured by, e.g.: due to settling effects.
• Use of M20 × 1.5 bolts as per MBN 10105, class 10.9 The implement must be designed so that a uniform
• Tightening torque: MA = 520 Nm (as per MBN 10130 contact surface area of ≥ 950 mm² under each threaded
connection (G) is guaranteed. The implement must be
class 2)
made of steel with a yield strength of ≥ 355 N/mm².
• Total friction coefficient of threaded connection μtot =
Mercedes-Benz recommends a design with the largest
0.08 to 0.14 possible contact surface.
The minimum screw-in depth per threaded connection in The three threads (G) must be used for attaching the
the M20× 1.5 thread is 1 x d = 30 mm. implement on each side.

Front attachments

Maximum permissible forces and moments
W88.00-A063-02
Directions of action My and Fz
W88.00-A064-02
Directions of action Mz
Front attachments
Abstand L ≤ 1720 mm
Statische Betriebskraft Fz ≤ 22 kN
Moment Mx ≤ 45 kNm
Moment My ≤ 22 kNm
Moment Mz ≤ 47 kNm
W88.00-A065-02
Directions of action Mx and Fz
These forces and moments can be transmitted into the If necessary, the forces and moments introduced must
vehicle frame via the fastening points (A) and (B). This be reduced according to these requirements, or other
guarantees the durability of the vehicle frame. suitable measures should be employed to ensure
All other limit values and boundary conditions must also compliance with all the limit values and boundary
be taken into account. This applies, in particular, to: conditions.
• Technically permissible individual axle loads Factory-fitted climbing aid
• Technically permissible wheel loads The climbing aid can be removed if necessary. This
allows the front mounting plate to be installed closer to
• Technically permissible gross mass the front end of the vehicle.
• Minimum rear axle load

W88.00-A066-11
K Climbing aid
The front-mounted implements are to be equipped with The manufacturer is responsible for demonstrating the
suitable overload safeguards. These overload fatigue strength of the front mounting plate and its
safeguards must act before the maximum operating components.
forces/moments are reached. The installation of a front mounting plate may mean that
the factory-installed climbing aids, lighting systems,
towing devices (coupling jaw) and license plate positions
Front attachments

etc. can no longer be used. Furthermore, the installation The installation of a front mounting plate/front-mounted
of a front mounting plate/front-mounted implements implements may reduce the cooling air flow onto the
changes the vehicle dimensions/weight. radiator. This may lead to increased operation of the
The manufacturer must take appropriate (substitute) engine fan.
measures to ensure that the relevant licensing
conditions, accident prevention regulations and other
national service specifications are complied with.
Connecting devices
Technical weights Page 250
Vehicle overhang and technical wheelbases Page 111
Positive rigid connection Page 496
Frame lowering on air-sprung vehicles Page 118

Doubling connections of trailer brake (2 and 3-axle Page 459

vehicles)
i i
Danger of the trailer breaking away, resulting in Inform users about the installation and permissible
serious accidents: parameters of the coupling device: Operating
Install the coupling device correctly. instructions indicating the special features and the
operation of the coupling device must be placed in
Do not make any changes to the trailer coupling,
the vehicle.
e.g. bending, welding or cutting.
i
i
Possible malfunctions: In combination with the
Vehicle model designations 963.042, 964.043 and
MirrorCam, code F6T, it is prohibited to mount a
964.211 are not homologated and designed for
fifth-wheel coupling on a vehicle without Electronic
trailer operation, e.g. with regard to brakes UN-R 13.
Stability Assist, code S1D. The panning function
Therefore, equipment intended for this purpose
(panning of the camera image when cornering)
e.g. trailer couplings or trailer brake connections are
cannot be guaranteed.
not available ex factory. Retrofitting/conversion to
trailer operation is not possible. Also, the installation
of a ball-type coupling for operating unbraked or
inertia-braked trailers is not permissible.
i
Expiration of operating permit and danger of service
brake overheating on model 983:
i Connecting devices (also trailer couplings) and
When a Mercedes-Benz genuine end crossmember trailer brake connections may only be attached to
is retrofitted in the end of the frame, or on vehicles vehicles with special equipment code B5G Battery
without trailer coupling ex factory (including omitted electric vehicle trailer brake.
trailer coupling, sales code Q9Z), no reinforcements
are installed on the end crossmember.
---------------------------------------------------------------------------
Connecting devices

General • The operating elements must be easily
Only use makes, types and end crossmembers accessible, simple, safe and there must be no risk
approved by Mercedes-Benz. of mix-ups.
Before a coupling device is installed, the following points • It must still be possible to open the coupling safely
must be checked: even with axial distortion of at least + 10°.
• The expected gross combination mass/towing • When the trailer is coupled up, it must be possible
capacity must always be achievable, e.g. drivetrain, without obstruction to determine whether the
cooling, brakes (see document "Technical coupling bolt is engaged and secured by means
weights"). of a visual check or a display.
• The frame overhang must be approved for retrofitted • Only use automatic coupling heads on the supply
end crossmembers/trailer couplings. pressure and brake lines.
• If retrofitted frame overhang extensions and/or • Design the trailer socket bracket so that the bracket
loading equipment are present on the frame end, the cannot be deformed if the plug is stiff.
documents "Modifications to the frame • The connection lines must not chafe against body
overhang", "Steerability" and "Vehicle overhang components. In the event of unfavorable space
and technical wheelbases" must also be observed conditions to the rear panel of the cab, e.g. on EURO
(essential for rigid drawbar trailer (SDAH) or center semitrailers, raise the coupling heads as per
axle trailer (ZAA) operation or tongue weights). ISO 1728 or attach a swivel arm.
• Any end crossmembers installed must be generally This must be approved by a technical inspection station.
suitable for supporting a trailer coupling (hole A manufacturer's certificate stating the technically
pattern). possible towing capacity is usually required for this
• For required drawbar ratio/Dc value/V value/tongue purpose. You can request this certificate from the
weight and hole pattern, refer to document relevant contact person (see document "Advice for
"Calculations". body manufacturers"), under specification of the
retrofitted parts.
• For semitrailer trucks, observe document
The following operational durability certificates are
"Electronic Stability Program ESP®, center of
available for download in the "Body/Equipment Mounting
gravity heights, stabilizers".
Directives/Additional Information on Body/Equipment
When doubling the trailer brake connections, observe Mounting Directives: Calculation" folder on the
document "Duplication of trailer brake Mercedes‑Benz Bodybuilder Portal:
connections on 2-axle and 3-axle vehicles".
- For vehicles of axle configurations 4x2/4x4. Document:
• Maintain the clearance dimensions and observe the NW 020216 Driving with additional loads, 4x2.
relevant national rules and regulations.
- For vehicles of axle configurations 6x2 E-NA/ DNA or
• If not all of the regulations regarding easy and safe 8x2/4 ENA. Document: NW 020216 Driving with
operation can be complied with, depending on the additional loads, 6x2.
attachment and body type, a remote-controlled
- For vehicles of axle configurations 6x4/4, 6x6/4, 8x4/4,
coupling that satisfies the following conditions must
8x6/4, 8x8/4. Document: NW 020216 Driving with
be installed:
additional loads, 6x4.
• The control unit must be permanently attached to
the vehicle and it must not be possible to remove
it.
---------------------------------------------------------------------------
Trailer coupling and end crossmember An example of the required reinforcements for installing
If a trailer coupling or maneuvering coupling is mounted a trailer coupling is provided below:
on an existing and suitable end crossmember or if an
entire end crossmember is to be installed, it is essential
to retrofit reinforcements.

Connecting devices
1 Reinforcement (lower left casting), may be

omitted if necessary
2 Outer reinforcement
3 Reinforcement (lower right casting), may be
omitted if necessary
W31.10-A014-11
Reinforcement on end crossmember
Parts shown in the example may differ from the

equipment actually installed.
In both cases, compile the required parts scope for your
particular vehicle equipment with the help of your
Mercedes-Benz Service Partner.
4 Upper inner reinforcement
5 Lower inner reinforcement
W31.10-A015-11
Reinforcement on end crossmember
Connecting devices

The following additional sales codes are available ex
factory:
• Q9B – Pre-installation for retrofitting trailer coupling
for SDAH or ZAA operation
W31.10-A016-11
Sales code Q9B
• Q9C – Pre-installation for retrofitting trailer coupling

for turntable drawbar trailer
When these sales codes are ordered, all of the
aforementioned reinforcements are installed ex factory.
The screw connections supplied are only for fastening
the reinforcements and must not be used for installing a
trailer coupling (observe the installation and assembly
instructions of the trailer coupling). The specifications
and clearances as per EC Directive 94/20/EC and UN-R
55 must be complied with.
W31.10-A017-11
Sales code Q9C
a 420 mm
b Min. 60 mm
c Min. 100 mm
W41.10-A004-10
Clearance dimensions
for handlever
Connecting devices
Ball-type coupling
All vehicles have a brake system certificate according to
ECE-R13, permitting an unbraked towing capacity of
750 kg and an inertia-braked towing capacity of 3500
kg.
W31.10-A013-11
Example of special equipment, sales code Q7D
Only type-approved coupling devices

and trailer brackets are to be used
(no aftermarket modifications
possible). The corresponding
drawbar ratio and the tongue weight
must be observed. With small
drawbar ratios it is possible that less
than 3500 kg inertia-activated braked
towing capacity is permissible.
When retrofitting, the clearance
dimensions as per DIN 74058 and
UN-R 55 must be observed (see
diagram):
a Min. 55 mm
b Min. 140 mm
c Max. 250 mm
d Min. 32 mm
e Min. 65 mm
f Max. 100 mm
g 350 mm to 420 mm
h 100 mm
k Max. 40 mm W31.10-A004-03 W31.10-A005-03
Ball-type coupling: Clearance dimensions Ball-type coupling: Clearance dimensions
m Max. 20 mm (top view)
n Min. 75 mm
Lowered trailer coupling • At least two bores overlapping the gusset plates of a
If the vehicle is to be fitted with a low coupling and/or a crossmember in the upper and lower hole row. If this
lowered end crossmember, the following must be is not possible, install a crossmember. For this
observed: purpose, see document "Modifications to the
frame overhang".
• Type approval for the low coupling system or end
crossmember must exist. • Only the existing holes may be used for installation.
The drilling of additional holes is not permissible.
• The trailer bracket must be bolted to the longitudinal
frame member at the upper and lower row of holes. • The manufacturer's installation instructions must be
followed.
• Mounting in vicinity of a crossmember.
Connecting devices

• The durability of the longitudinal frame member must system/trailer coupling has at least these values, then
be verified using the calculation guidelines listed in these are retained subject to the boundary conditions
the "General" tab. described above.
• If a towing capacity/tongue weight is already entered
in the vehicle documents and the low coupling

W31.10-A006-09
Fig. left: Example design of low coupling system; fig. right: lowered end crossmember)
1 Vehicle frame 3 Reinforcement 5 Profile
2 Crossmember 4 Gusset plate
1 Vehicle frame
2 Subframe
3 Mounting support
4 Crossmember
W31.10-A018-12
Lowered end crossmember
Connecting devices
W31.10-A009-11
Example design of a semi-lowered end crossmember
Vehicle use with a rigid drawbar trailer or center axle driving dynamic effect. We also recommend loading the
trailer towing vehicle first and unloading the SDAH/ZAA first to
A rigid drawbar trailer (SDAH) or center axle trailer ensure the best possible handling characteristics.
(ZAA) is a trailer with one axle or a group of axles, Always pay attention to an adapted driving style. See the
which: operator's manual of the trailer manufacturer for further
• is connected to the towing vehicle by a drawbar information.
connected rigidly to the trailer chassis. When using, pay attention to the following points:
• is designed in such a way that the towing vehicle • Bodies must be designed in such a way that placing
does not support a substantial proportion of the excessive load weight at the rear is prevented.
trailer's gross mass. Static vertical load of no more Otherwise, the necessary steering and brake forces
than 10% of the trailed mass or 1000 kg (whichever for safe vehicle operation cannot be transferred to
is lower). the road.
For this trailer design, which can vary in geometry, • The trailer tongue weight must also be considered in
tongue weight and axle load, we would like to point out the design. Therefore check the permissible axle
the following special driving dynamics characteristics: loads, the gross mass and the minimum front axle
An SDAH or ZAA behaves like a pendulum and can load.
develop a critical momentum of its own. • Check the trailer data, in particular the tongue weight,
Factors which encourage pendulum-like behavior can be and the Dc and V values. (The type plate affixed to
amplified, e.g. as a result of large side walls, a long the drawbar frequently lists only the maximum values
drawbar or a long overhang of the towing vehicle. Here, transferable by the drawbar. For this reason, always
the body type, drawbar length, load distribution, the observe the identification plate values of the entire
actual gross mass of the trailer and the driving speed are trailer structure and the vehicle documents).
decisive influencing factors. • Avoid operating a loaded trailer with an empty towing
In general, the longer the drawbar of the trailer and the vehicle. We recommend that the trailer weight does
heavier the gross mass of the trailer are, the more not exceed 1.5 times the mass of the tractor vehicle
energy is available for developing its own dynamics. in all load conditions.
Different loading conditions of the tractor/trailer • If retrofitted frame overhang extensions and/or
combination can additionally strengthen these natural loading equipment are present on the frame end,
dynamics. carry out operational durability verifications on the
vehicle frame and subframe.
Example
• On low frame model designations (identifiable by the
Carrying a fully loaded ZAA/SDAH with an empty towing vehicle frame taper over the rear axle), the
vehicle promotes critical handling characteristics. combination of rear-mounted loads (e.g. cargo
For this reason, when operating with SDAH/ZAA, we liftgate) and/or under-body or short trailer brackets
recommend a maximum tractor/trailer combination ratio and bodies without subframe (e.g. twist lock carriers
of 1 : 1.5 in every load condition as a safety-enhancing at the side of the frame) is not permissible.
---------------------------------------------------------------------------
Connecting devices

Fifth-wheel coupling/semitrailer trucks/semitrailers When mounting the fifth-wheel coupling, check and
Only use vehicle model designations (model comply with the following points:
963.4/964.4) of semitrailer trucks for the installation of a • Only use type-tested and type-approved fifth-wheel
fifth-wheel coupling, as the frame, springs, Electronic couplings and assembly plates.
Stability Program and brake system are adapted to this • To calculate the strength values (drawbar ratio D/fifth
application. wheel load U) of the fifth-wheel coupling and/or
Base model vehicles equipped with a steered trailing assembly plate, the tractor/trailer combination must
axle at the factory cannot in principle be used for a be taken into account in terms of the required gross
semitrailer application (semitrailer truck) (sales code vehicle mass and the gross combination mass.
A4Q, A4R, A4T, A4U, A4X, A4Y). This is due to the • Only use genuine parts and coupling brackets
failure behavior of the steering system and due to the approved for the vehicle model designation (observe
wheelbase range. In this case, please contact the coupling bracket height and total mass/weight
Mercedes-Benz Custom Tailored Trucks (CTT) division variant).
to coordinate possible implementation by using a special
steering system. • Mount the fifth-wheel coupling so that the coupling
joint is in the fifth-wheel coupling point.
The installation and operation of fifth-wheel couplings
are not permitted on vehicle model designations 963.042 • To determine the fifth-wheel lead, establish the
and 964.043. chassis weight by weighing it.
All other vehicle model designations may only be • Comply with the permissible weights, especially the
converted to semitrailer trucks after consultation with the permissible axle loads.
relevant contact person (see document "Advice for • The specifications and installation instructions of the
body manufacturers"). manufacturer of the fifth-wheel coupling must be
For vehicles equipped with ESP®, the following applies: observed.
If semitrailer trucks are to be used as towing vehicles • The semitrailer brackets provided ex factory are
with trailer operation, the Stability Control Assistant, generally suitable for the technically permissible
ESP® for trailer operation for semitrailer trucks, sales gross mass, technically permissible tongue weight
code S1E, is mandatory (see document "Electronic (fifth wheel load) and technically permissible gross
Stability Program ESP(R), center of gravity heights, combination mass entered in the CoC documents.
stabilizers". • For unperforated semitrailer brackets, the hole
The disabling of an existing stability program (sales code spacings given in the drawing below must be
S1D) is not possible due to the networking with other complied with:
driver assistance systems.
Depending on the application and eligibility for
registration, vehicles can be ordered without Stability
Control Assist, sales code S9Z.

W31.10-A019-07
Hole spacings in unperforated semitrailer brackets
A Min. 90 mm D Min. 50 mm
B Min. 35 mm E Max. ∅ 21 mm
C Max. 66 mm
• The specifications found in ISO standard 1726 must brackets. The fifth-wheel coupling plate must be
be complied with for EURO semitrailers. secured directly to these brackets.
• Vehicle model designations for use as semitrailer
trucks are supplied with external attachment angle
Connecting devices
• Ensure that the trailing arms and spring-loaded brake • On subframes with crossmembers, also bolt the
cylinders have sufficient clearance at maximum assembly plate to the crossmembers. If this is not
spring compression. If necessary, provide cutouts in possible, additional bolts must be provided to
the assembly plate around the trailing arms. connect the assembly plate to the attachment angle
• For most vehicle model designations, the protrusion brackets.
of the wishbone control arms of the rear axle(s) over • Semitrailer brackets with hole pattern ex factory
the top edge of the vehicle frame (OKR) with the (sales code Q6W/Q6Z) are provided with elongated
suspension compressed is indicated in the 2D holes for screw connections (M20).
chassis drawings (offer drawings) in the Mercedes- • The assembly plate must be fastened with flange
Benz Bodybuilder Portal head bolts MBN 10105 M20x1.5 10.9 and flange
http://bb-portal.mercedes-benz-trucks.com head nuts MBN 13023 (Ma = 530 Nm + 90°) (for
. additional specifications see document "Threaded
and welded connections").
• Never drill holes in the upper flange of the vehicle
frame or the subframe, if present, for the purpose of • If this is not possible, e.g. if, depending on the
attaching the fifth-wheel coupling or the assembly manufacturer and design, only countersunk bolts can
plate. The fifth wheel must not rest on the longitudinal be used in the superstructure area of the fifth-wheel
frame members but instead on the semitrailer coupling for assembly plates with a thickness of
brackets. 12 mm, then fastening must be carried out according
to the specifications of the system manufacturer.
• Screw the fifth-wheel coupling and attachment angle
bracket to the assembly plate. • The fifth-wheel coupling and assembly plate must
also be connected according to their specifications.
• In the case of fifth-wheel couplings without an All of the threaded connections are classified as RA
additional assembly plate, an extra cross connection (safety-relevant threaded connections). These are
must be installed between the vehicle longitudinal therefore to be documented at the company carrying
frame members in the area of the fifth-wheel out the modification.
coupling.
• On 2-axle vehicles, the installation height of the fifth-
wheel coupling and the assembly plate together must
not exceed 300 mm.

If you intend to combine a fifth-wheel

coupling with drive-on ramps, the
operator must be advised of the
possibility of a restricted incline angle
as per ISO 1726.
If tilting semitrailers are to be
operated in combination with air-
sprung semitrailer trucks, these must
be equipped with frame lowering as
per the specifications (see
document "Frame lowering on air-
sprung vehicles") because this
includes the integrated "compulsory
lowering" function.
W31.10-A010-06
Example design of a fifth-wheel coupling with assembly plate on the coupling side
bracket
Semitrailer acceleration of 0.3 g so that the semitrailer truck does

Semitrailers with air suspension must not lean over by not have to bear the entire force caused by the lateral
more than 3° to 4° when subjected to a lateral inclination of the semitrailer.
Connecting devices

The manufacturer of the semitrailer is responsible for • The fifth-wheel coupling is secured on an assembly
compliance with the regulations concerning driving the plate or profile plate with attachment angle brackets.
tractor/semitrailer combination in a circle (in Germany, • Ensure that the trailing arms and spring-loaded brake
this is Section 32 (BO Kraftkreis) of the German vehicle cylinders have sufficient clearance at maximum
licensing regulations (StVZO)): spring compression. If necessary, provide recesses
• Check the front and rear swivel radius on the in the assembly plate.
semitrailer and the vertical swivel range. • The attachment angle brackets must end at least
• If necessary, observe the minimum height of the fifth- 150 mm before or after the fifth wheel.
wheel coupling according to ISO standard 1726 • The subframe must have at least one crossmember
(sales code Q0Y, incline angle not as per DIN ISO in the vicinity of the fifth-wheel coupling. The
1726). longitudinal members must be continued as far
• Ensure sufficient space inside the vehicle frame and forward as possible.
above the fuel filler neck. • Fasten the longitudinal members in the area of the
Installation of fifth-wheel coupling on subframe fifth-wheel coupling rigidly (see document "Positive
rigid connection") to the vehicle frame. Provide at
Subframe with dimensions: 100 x 70 x 7 mm least four tabs per side.

1 Vehicle frame
2 Subframe
3 Profile plate/assembly plate
4 Attachment angle bracket
W31.10-A011-06
Standard chassis as semitrailer truck
Intake air system
i
Risk of engine damage, possible loss of vehicle's
registration eligibility:
Modifications to the intake air system can change
not only the external noise but also the flow and
pressure conditions in the intake tract. Such
interventions are not permissible.
Mount of fuel tank

The following points must be observed when attaching should be positioned over the beads of the fuel tank
the fuel tank to the frame: (picture 4) because the stability of the fuel tanks is at
• The number and strength of the mounting supports its greatest at the beads. In exceptional cases it is
must be adapted to the size and weight of the fuel permissible, e.g. if there is not enough installation
tank (picture 1). Only genuine Mercedes-Benz fuel space, to move a tensioning strap so that it is
tank mounting supports or fuel tank mounting positioned as close as possible to the marking
supports provided by the tank manufacturer for the (picture 5). It is not permissible to leave two beads
specific tank size should be used. free (picture 6). If fuel tanks that do not have beads
are installed, the mounting supports must be
• If Mercedes-Benz fuel tank mounting supports are positioned symmetrically relative to the center of the
not used, the strength must be verified by means of tank. Three mounting supports may be necessary.
calculation.
• Maintain a minimum clearance of 20 mm to other
• Position the mounting supports as close as possible components and major assemblies or between tanks
to crossmembers. The threaded connection must be in case of a double tank.
made at the upper and lower hole pattern row of the
longitudinal member rib. • The torque to be applied in the case of tensioning
straps with nuts is 40 ±5 Nm, irrespective of the
• If fuel tanks are mounted at the wide section of the material of the fuel tank (plastic, steel or aluminum).
frame, special mounting supports will be required. It New self-locking nuts with polyamide insert must
must be ensured that the slopes are compensated for always be used. (The tensioning strap nuts of
and that the fuel tank lies flat against the mounting AdBlue® tanks must be tightened to 92 ± 18 Nm.)
supports (picture 2).
• Additional fuel tanks can be added or tanks can be
• Fuel tank mounting supports must be installed replaced with others with a larger capacity.
parallel and vertical.
• According to the ADR guideline, the maximum
• Rubber pads are required between the fuel tank and permissible total volume must not exceed 1500 l.
the mounting supports/tensioning straps.
• If multiple fuel tanks are connected, it must be
• The tensioning straps and rubber pads must follow ensured that the connections of the fuel lines are
the outline of the tank. It must be ensured that the positioned in such a way that they do not project
rubber pads are seated correctly at the mounting above the mounting supports. There is a risk of the
supports and straps. connecting lines being pulled off.
• The beads (picture 3) on the fuel tank provide a • If existing fuel tanks are replaced by different ones or
visual indication as to the correct position of the tank additional fuel tanks are installed, reparameterization
tensioning straps. Usually, both tensioning straps will be necessary.

W47.10-A018-75
Correct: Fuel tank mounting supports at
wide section of frame (picture 2)
N47.10-A000-01 N47.10-A002-01
Correct: Attachment according to fuel tank Arrow: Fuel tank with beading (picture 3)
size (picture 1)
Mount of fuel tank
N47.10-A003-01 W47.10-A036-01 N47.10-A005-01

Correct: Both tensioning straps over beads Still permissible: One tensioning strap next Incorrect: All tensioning straps next to bead
(can also be asymmetrical) (picture 4) to bead (picture 5) (picture 6)
This sheet metal causes rigidity ruptures in the fuel tank and at the weld
seams. Furthermore, the tensioning strap and the rubber element at the top
in the metal sheet will be indented at the transition. There is a risk of
breakage and the tank can move.
N47.10-A006-01
Not permissible: Tank protection made of
grooved sheet metal is also pinched under
the tensioning straps.
Clearance between fuel filler cap and body

To ensure easy refueling of the fuel tank or AdBlue® delivery nozzle can be performed (without having to
tank, it is important to provide sufficient clearance permanently hold the nozzle in place).
between the tank cap and body. These conditions apply to the following systems:
The gap must be such that there is not only enough • AdBlue® tank
space for the actual delivery nozzle and the refueling
procedure, but also refueling using the automatic • Fuel tank

W47.10-A015-11
Sufficient clearance to body; refueling can be performed without
restriction.
Tank surface
Painting Page 76
i
To avoid damage to fuel tanks, they must be
protected during work on the body.
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The surface of the fuel tank is divided into three quality
zones. This division applies to aluminum fuel tanks and
painted fuel tanks.

Quality zones
A Quality zones 1
B Quality zones 2
C Quality zones 3
N47.10-A007-05

Fault description in quality zones
Permissible Not permissible
Quality zone 1 (top and front Flaws caused during manufacturing Intrusions/dents
surfaces) process, e.g. draw marks
Slight chafe marks Scratches causing chip removal
Quality zone 2 (side surfaces) Flaws caused during manufacturing Intrusions/dents

process, e.g. draw marks
Slight chafe marks Scratches causing chip removal
Slight scratches causing chip removal
Quality zone 3 (bottom and rear Flaws caused during manufacturing Intrusions/dents
surfaces) process, e.g. draw marks
Chafe marks Cluster of scratches causing chip

removal
Isolated scratches causing chip removal
Tank surface

N47.10-A008-01 N47.10-A009-01 N47.10-A010-01
Draw marks: Permissible in quality zones 1 Slight chafe marks: Permissible in quality Slight scratches caused by machining:
to 3 zones 1 to 3 Permissible in quality zones 1 to 3
N47.10-A011-01 N47.10-A012-01 N47.10-A013-01

Slight scratches caused by machining: Chafe marks: Permissible in quality zone 3 Cluster of scratches: Not permissible in
Permissible in quality zones 2 and 3 quality zones 1 to 3
Example
N47.10-A014-01
Protect fuel tank against damage using
fabric or leather cover.
Painted fuel tanks fuel tank; the requirements of paint quality zone 4 must
The criteria described in document "Paintwork" must be taken into account for paint quality zone 3 of the fuel
be applied. Here, the criteria for paint quality zone 2 tank.
must be applied for paint quality zones 1 and 2 of the
Extension of fuel lines
If fuel tanks are moved, the feed line and return lines to ISO 7628, version 2 3A can be used. Fuel lines have an
the fuel tank will usually also be changed. Fuel lines also outside diameter of 13 mm with a wall thickness of
need to be reinstalled, extended or modified if filters or 1.5 mm. In comparison, brake lines have the dimensions
fuel tanks are retrofitted. 12x1.5 mm.
Retrofitted lines must correspond to version PA12‑PHLY
according to DIN 73378. Alternatively, lines according to

N47.25-A000-01 N47.25-A002-01 N47.25-A001-01

Racor filter and fuel tank for auxiliary PA line for fuel according to DIN 73378 - Extended fuel line
heating 13x1.5 - PA12-PHLY
Connection of PA lines
The VOSS connection system 246 allows fuel lines (plastic pipes) to be
connected quickly and securely. This corresponds to the Mercedes-Benz
standard and must be used for subsequent modifications to the fuel
system.
The VOSS connection system 246 is designed for a temperature range of –
40 ℃ to +100 ℃ and can be used for a maximum operating pressure of
20 bar.
The connection can be pressed onto the PA line using the press-in tool
used for compressed-air lines in combination with an appropriate tool
insert.
N47.25-A005-03
VOSS connection system 246 for diesel
fuel systems in automotive construction
Extension of fuel lines

N47.25-A003-10
Connector without removal element with counterpart
N47.25-A004-01
Connector with removal element
Fuel tapping for additional assemblies
Generally speaking, the fuel tank is a certified the tank. Depending on the situation, fuel should be
component and this certificate will be rendered invalid in tapped via connections 1 to 4 at the fuel level sensor.
the case of fuel tapping directly through a hole made in

Actros/Arocs, Zetros, Unimog, Econic
Without auxiliary heating
Fuel system feed: Use of connection 3 at fill level sensor
Fuel system return: Use of connection 4 at fill level sensor
If a fill level sensor with only two connections (without auxiliary heating) is
installed in the basic vehicle, fuel tapping is via a T-piece on the feed line
and on the return line. Note that fuel tapping must take place as close as
possible to the fill level sensor. The maximum distance from the fill level
sensor should not exceed 1000 mm.
Fuel tap
1 Fuel tapping via connection 3 at fill level sensor (without auxiliary
heating)
2 Fuel tapping via connection 4 at fill level sensor (without auxiliary
heating)
N47.10-A015-01
Barbed hose profile A 001 990 83 78, for
connection 3 and 4 at fill level sensor.

With auxiliary heating
Fuel system feed: Tapping via T-piece at engine return connection 2
Fuel system return: Use of connection 4 at fill level sensor (sealed at factory and must be opened)
With additional tank system

i Here, fuel tapping must always take place at the blind
A pressure of 0.1 bar to 0.3 bar can exist in the fuel flange of the additional fuel tank. PA lines (polyamide
feed and a vacuum of up to 0.38 bar in the return lines) are positioned on the blind flange. Alternatively, a
line. fuel level sensor can also be installed.
i
Fuel tapping must take place as close as possible to
the fuel level sensor (the maximum distance from
the fuel level sensor should not exceed 1000 mm).

1 Engine feed
2 Engine return
3 Auxiliary heating feed
4 Auxiliary heating return
N47.50-A000-01
Fill level sensor
There are two barbed connections for the connections at • Barbed hose profile A 001 990 74 78, this may only
the fill level sensor: be connected at connections 1 and 2 of the fill level
• Barbed hose profile A 001 990 83 78, for connection sensor of an additional fuel tank.
3 and 4 at fill level sensor.

Atego
Without auxiliary heating
Fuel system feed: Fill level sensor for auxiliary heating must be installed here. Fuel level
sensor A 970 542 02 17 Rising pipe A 970 470 00 26
Fuel system return: In engine feed, without air bubble formation

With auxiliary heating
Fuel system feed: Fuel tapping in engine feed with T-piece A 004 990 90 70
Fuel system return: In engine return or feed with T‑piece A 004 990 90 70
Overview of T-pieces
i Table 1 below provides an overview of the available T-
Fuel tapping must take place as close as possible to pieces.
the fill level sensor (the maximum distance from the
fuel level sensor should not exceed 1000 mm).
A Form A (DIN 475 ‑ size a ‑ 2)

B Form B (DIN 475 ‑ size a ‑ 2)
N47.25-A006-04

Table 1: T-piece, can be used for all model series
11 12 13 14 15 16 a Barbed hose profile to N Item number
15 049
1 2 3
22 16 25 16 22 16 12 6 4 4 A 001 997 20 74
29 22 29 22 29 14 16 10 10 10 A 005 990 03 70
29 22 29 22 23 16 14 9 9 4 A 004 990 94 70
31 22 31 22 33 25 16 8 8 12 A 004 990 70 70
33 25 33 25 24 16 16 12 12 6 A 004 990 32 70
29 22 29 22 22 16 14 9 9 6 A 003 990 44 70
22 16 22 16 22 16 12 6 6 4 A 003 990 43 70
29 22 22 16 22 16 14 9 6 6 A 003 990 41 70
33 25 33 25 33 22 16 12 12 9 A 002 990 73 70
29 22 33 25 33 25 16 9 12 12 A 002 990 60 70
22 16 22 16 22 16 12 4 6 6 A 002 990 57 70
33 25 33 25 33 25 16 12 12 12 A 002 990 53 70
23 16 29 22 29 22 14 4 9 9 A 002 990 10 70
23 16 29 22 29 22 14 6 9 9 A 002 990 09 70
28.5 22 28.5 22 22.5 16 12 8 8 6 A 001 990 54 70
23.5 16 29.5 22 29.5 22 16 6 9 9 A 001 990 47 70
22 16 22 16 22 16 12 4 4 6 A 001 990 29 70
28.5 22 29 22 29 22 14 9 9 9 A 000 990 78 70
29 22 29 22 29 22 14 9 9 9 A 001 990 39 70
28.5 22 28.5 22 28.5 22 12 8 8 8 A 001 990 02 70
22 16 22 16 22 16 12 6 6 6 A 000 990 79 90
22 16 22 16 22 16 12 6 6 6 A 000 429 42 37
Note i
The following generally applies for all types of fuel The body manufacturer must check whether the
tapping: Fuel must always be tapped upstream of available delivery rate is sufficient for the application
the vehicle-mounted fuel filter (exception: engine in question, and whether the cross-sections of the
return). existing lines/connections (e.g. return, etc.) are
Maximum volumetric flow of tapped fuel 100 l/h. sufficient.
If a higher volumetric flow is required, the
department responsible must be consulted. The
maximum fuel return temperature can be up to Color of pipes
120 °C. The pipes can be supplied in transparent (TR) or in black
(BK).
Installation of automatic snow chains

aDanger
Risk of death when loosening nuts of axle for attaching Do not loosen nuts of axle assembly simultaneously!
automatic tire chains
aDanger
Risk of death from lowering vehicle when working Testing and repair work between the wheel and wheel
between wheels and body. Risk of injury from pinching arch or in the wheel well should only be performed if the
or crushing when working on the air suspension. vehicle is secured using suitable support fixtures to
prevent it from lowering.
Adjustment operations should only be performed from
underneath the vehicle.
Use only suitable support fixtures to secure the vehicle
frame or vehicle axles in order to prevent them from
lowering.
If necessary, additionally use suitable support fixtures in
order to prevent other moving vehicle parts that are in the
working area from lowering, or use suitable retaining
devices to prevent these parts from moving suddenly and
without warning.
Secure areas with moving vehicle parts against
unauthorized access.
aDanger
aWarning
Risk of injury from being trapped in the swivel range of Ensure that no persons or objects are in the swivel range
steered axles of all steered axles when turning the steering wheel. Do
not stand in the swivel range of the additional steering
axle when the engine is running.
i i
Possible damage due to electrostatic charge: Possible damage to safety-relevant components:
With the automatic tire chains switched off, the The threaded connections marked with "RA" are
distance between the automatic tire chains and safety relevant and must be treated separately.
roadway must be at least 50 mm. Observe document "Threaded and welded
connections".
Mounting the adapter on the vehicle

• The nuts of the axle attachment must be removed
individually and immediately replaced by the
fasteners provided by the automatic snow chain
supplier ("double nuts").
It is not permitted to mount the automatic snow chain
manufacturer's fasteners on the mounting nuts of the
axle assembly.
W40.10-A002-11
Automatic snow chains
The hexagon spring U-bolts can be reused if there is adequate thread

protrusion.
If the thread protrusion is not adequate, spring U-bolts of various lengths
are available as accessories.
W40.10-A001-01
Nut and counternut

Hexagon head bolts for air-suspension vehicles
M24 x 2 - 10.9 Overall length (without height of head)
A 006 990 27 00 272 mm
A 006 990 08 00 280 mm
A 005 990 34 00 270 mm
A 005 990 33 00 260 mm
A 005 990 32 00 240 mm

Spring U-bolts for steel-suspension vehicles
M24 x 2 – 10.9t Length
A 960 325 02 47 465 mm
A 960 325 03 47 510mm
A 960 325 04 47 540mm
A 960 325 05 47 490mm
This list only contains a selection of the spring U-bolts The tightening torques and contact surface for the
available. spacer nuts are given in the table in the following
section.

Specifications for double nut (contact surface)
M24x2 652mm²
Property class: 10
The following tightening torques must be complied

with

Steel-sprung vehicles
Spacer nut M24 x 2 750 Nm ± 60 Nm RC

Air-sprung vehicles
Nut and counternut M24x2
With axle sales code A2E¹⁾ 750 Nm RA
With axle sales code A2F/A2G/A2H/A2I 690 Nm± 56 Nm +90° ±10° RA

1) The threaded connection must be made in a crosswise pattern in 4 stages. The tightening torque must be increased to the values
specified in the table at each stage.
Stage Increase tightening torque
1 100 Nm
2 300 Nm
3 500 Nm
4 750 Nm
It must be ensured that automatic snow chains operate

without colliding with other parts (e.g.brake lines/brake
cylinders)!
Chocks

Redundant protection Page 148
Wheel chocks must be carried on the vehicle at all times. Hooks and chains must not be used for holding the
They are usually kept in a suitable holder mounted on wheel chocks.
the vehicle. To prevent loss of the wheel chocks, they must be
If the wheel chocks are supplied loose by Mercedes- secured on Mercedes-Benz trucks by means of two
Benz, the body manufacturer must attach a suitable separate locking devices, e.g. vertical mounting in
holder at an easily accessible location in or on the combination with a retaining spring, (see document
vehicle. "Redundant locking devices").
The holder must be designed such that the wheel

chocks do not rattle in it during vehicle operation.

i
Apart from the requirements
stipulated in Section 41 of the
StVZO (German vehicle licensing
regulations) and DIN 76051,
additional requirements may
arise depending on the
application of the vehicle (e.g.
fire-fighting vehicle with cable
winch), country-specific
requirements and, if applicable, N00.00-A013-01 N00.00-A011-01
customer requirements. Wheel chocks secured adequately by Wheel chock secured adequately by means
means of spring and safety bolt. of spring and rubber tensioning strap.
Temporary spare wheel mounting for vehicle transfer
Fastening: • In the event of deviations from the standard

• Observe legal requirements fastening, approval from the body manufacturer
management TE/ORB-B is required.
• It must be easily accessible and easy to handle
• Doubly secured against loss

If the vehicle is delivered with a provisional spare wheel holder, either the
body manufacturer must attach a suitable holder or the spare wheel must
be supplied as a load in the cargo area. If the spare wheel is delivered in
the cargo area, it must be secured in the cargo area in a state of the art
manner (see VDI guideline VDI 2007). Mounting on the vehicle frame or
the subframe using only tensioning straps (e.g. pallet strap) is not
permitted.
N40.10-A001-01
Incorrect: Spare wheel is provisionally
secured to the body or chassis using only
parcel tape
N40.10-A002-01 N40.10-A003-01 N40.10-A004-01

Correct: Spare wheel is provisionally Incorrect: Spare wheel lies unsecured in Correct: Spare wheel is securely attached
secured to the body using screwed on cargo area (load securing). in cargo area (load securing).
holder.
Hydraulic oil reservoir K6Y/K6W/K2P

aWarning
Risk of injury to skin or eyes from hydraulic fluid Depressurize hydraulic system completely before starting
spraying out under pressure.Risk of poisoning from any work on it. Wear protective clothing and safety
swallowing hydraulic fluid. glasses.
i
Safeguarding durability and operational safety:
Only hydraulic hoses and the required screw
connections may be installed between the
connecting points on the hydraulic oil reservoir and
the frame-side mounting. Additional components
e.g., switchover valves are not permissible in this
area. The specifications of the component
manufacturer (e.g., return filter/hydraulic hose) must
also be taken into account.
---------------------------------------------------------------------------
For selected vehicle model designations it is possible to The geometric representation of the hydraulic oil
configure the special equipment hydraulic oil reservoir reservoir and the position on the vehicle can be found in
200 l hydraulic oil, right, 650 x 565 x 750 mm, aluminum, the 2D chassis drawings (offer drawings) in the
code K6W and hydraulic oil reservoir 200 l hydraulic oil, Mercedes-Benz Bodybuilder Portal:
left, 650 x 565 x 750 mm, aluminum, code K6Y or the http://bb-portal.mercedes-benz-trucks.com
combined diesel tank 390 l +130 l hydraulic oil, left,
650x700x1365 mm, aluminum, code K2P. Technical data of hydraulic oil reservoir:
In combination with codes K6Y/K6W/K2P, the • Material: AL alloy EN 485-2 AW-5754 (AlMg3)
connection/oil supply for the desired body application is • Maximum usable volume (vehicle is horizontal/flat,
simplified by ex-factory installation of the hydraulic oil fuel tank filled to maximum):
reservoir.
• Code K6Y/K6W 180 liters
The delivery package consists of an aluminum hydraulic
• Code K2P 115 liters
oil reservoir and the corresponding tank brackets. An oil
level display is not installed. • Permissible positive pressure/vacuum: 0.3 bar
The hydraulic oil reservoir, or combined diesel/hydraulic • Maximum permissible operating temperature: 80 ℃
oil reservoir, is factory-mounted on the longitudinal frame Appropriate measures must be taken to avoid contact
member. corrosion between the aluminum tank and connecting
The additional connecting components required components, e.g. material selection, coatings, seals, etc.
(e.g., return filter, intake connection etc.) are not (see the "Damage prevention" document).
included/supplied under the sales code. These
component parts can be obtained, e.g., from our service
organization (included in code P0H Semitrailer truck
hydraulics, delivery package ex factory).

Connection options A1 to A3 are sealed with covers ex

factory (not shown).
The covers and screws for connections A1 and A3 are
merely transport covers/screw connections for
preventing soiling of the hydraulic oil reservoir during
transfer. The parts must not be reused.
The screw plug installed ex factory on connection A2 is
suitable for continuous operation provided that it is not
modified.
A1 Pre-installation of upper double flange for filler
neck/return filter
A2 Pre-installation of upper connection for leak oil
line
A3 Pre-installation of lower connection for intake
connection/stopcock
W55.00-A008-82
Overview of connection options
A1: Detailed view of connection

Thread M10:
• Clearance hole
• Thread length 15 mm
W55.00-A001-11
Connection dimensions

W55.00-A009-75
Example: Retrofitting with filler neck/return filter
A1: Requirements for attachment

of hydraulic line/return line to
vehicle frame
1 Routing of hydraulic lines/
return lines
a Max. 500 mm
W55.00-A010-76
A2: Detailed overview

1 Reversibly sealed at plant for continuous
operation
2 Connection option: Internal thread R3/8
a Ø = 30 mm
b Ø = 40 mm
W55.00-A004-11
A3: Detailed overview of

connection
W55.00-A005-06
Connection dimensions

W55.00-A011-78
Example: Retrofitting with intake connection/shutoff valve
A3: Requirements for attachment

of suction line/hydraulic lines to
vehicle frame:
1 Routing of suction line/
hydraulic lines
a 200 to 500 mm
W55.00-A012-76
Example
The suction line/hydraulic lines to the intake connection 200 to max. 500 mm relative to the central axis of the
(connection A3) must be attached at a distance of min. tank on the frame side.
Code C8B/C8C rear axle fender, vehicle width 2500 mm/2550 mm
C8B-Rear axle fender, 2550 mm vehicle width C8C-

Rear axle fender 2500 mm vehicle width
The rear fenders are made in three parts and are
available on request with the code C8H with EC splash
guard or with code C8G without EC splash guard.
The components are mounted in such a way that the
specified vehicle width is not exceeded (dimension over
fender outer edges).
For semitrailer trucks, a lower rear axle fender center
section can be ordered additionally with the code C8M.
Depending on the tires, the center of the fender is
lowered by up to 30 mm with C8M.
For selected semitrailer and platform model
designations, which require a higher fender center
section due to the vehicle design, a fender center
section that is about 30 mm higher can be added with W88.10-A018-81
the equipment code C9A. Rear axle fender with EC splash guard
Code Q9A - Pre-installation, for low coupling system

Q9A Pre-installation for low coupling system
The equipment can be ordered for selected air-sprung
vehicles of the Actros 5 (BM 963) model series.
The pre-installation for the low coupling system reduces
the conversion time for the body manufacturer and at
the same time supports the quality of the conversion
work.
The scope of equipment includes:
W31.30-A023-81
Scope on chassis frame of the equipment Q9A with trailer hitch ex
factory
• Bolted crossmember in overhang for fastening the

low coupling system
• Trailer brake connections on frame overhang routed
to the right
• Wiring harness pre-installed, plug X177.4 in right
frame overhang
• Indicator lamp for trailer hitch in Classic Cockpit (J6A)
or Multimedia Cockpit (J6B/J6C)
W54.30-A054-81
Low coupling indicator lamp (A) in instrument cluster on Classic
Cockpit (J6A)
Code Q9A - Pre-installation, for low coupling system
i
The pre-installation Q9A can also be ordered ex
factory together with a trailer coupling on the end
crossmember. In combination with a trailer coupling
ex factory, Duo-Matic trailer brake connections are
also installed at the end of the frame!
W54.30-A055-81
E.g. Low coupling indicator lamp in Multimedia Cockpit (J6B/J6C)
Circuit diagram of pre-installation, for low coupling PE54.30-W-2064F (J6A Classic Cockpit)
system for model series Actros 5 (963.0x) PE54.21-W-2162FD (J6B/J6C Multimedia Cockpit)

W31.19-A002-79
Leading/trailing axle
Modifications to basic vehicle

Connecting devices
Connecting devices
i i
Possible loss of control while driving: Impairment of proper functioning:
Do not use a base model vehicle with a steered The subsequent attachment or removal of axles is
trailing axle (sales code A4Q, A4R, A4T, A4U, A4X, not permissible, particularly in combination with the
A4Y) for a semitrailer application (semitrailer truck) ESP® functionality present in the vehicle.
(see document "Coupling devices").
---------------------------------------------------------------------------
The lift function can be disabled by changing the Additional information can be found in the Mercedes-
parameters in the level control (CLCS) control unit. This Benz Workshop Information System (WIS).
must be carried out if, with the vehicle unladen and the Customer special requests can be realized through the
trailing axle in the lift position, more than 80% of the Mercedes-Benz Custom Tailored Trucks (CTT) business
permissible axle load of the drive axle(s) is already unit. Customer special requests can be recognized in the
reached. Contact your Mercedes-Benz Service Partner vehicle's order data by the four-digit sales code (Jxxx).
for this.
Retrofitting an automatic transmission
i
Potential risk of accident and impairment of the
proper functioning of the brake system:
It is therefore not permissible to retrofit an automatic
transmission that is not available ex factory.
Retarder

It is not permitted to retrofit a retarder.
Hydraulic auxiliary drive (HAD)
aWarning

i i
Possible failure of the system and risk of injury for Possible overheating of the system:
the user or other persons: The components and lines of the HAD system
The system operates with hydraulic system become hot during operation. The air flow to the
pressures up to 400 bar, and modifications can hydraulic oil cooler/additional fan and the
result in leakages or burst hoses. It is not components of the HAD system must not be
permissible to modify components or modules of the impeded by the body/implement.
HAD system. It is not permissible to mount or attach
additional components to the pipes, hoses and
components of the HAD system.
The Hydraulic Auxiliary Drive (HAD)

special equipment package with
sales code A1H is an engageable
hydraulic additional drive system
which powers the front axle on
demand.
An additional hydraulic pump is
installed on the rear of the timing
case.
It is driven by the vehicle's engine via
the gearwheel drive.
The hydraulic oil reservoir, the oil
cooler and the controller units are
located on the right side of the
vehicle.
Wheel hub motors are installed on
the front axle.
Appropriate supply lines are also
installed.
Please see the vehicle operator's
W43.00-A000-06
manual for information on activating
and deactivating the HAD and for
further information.

W43.00-A001-01 W43.00-A002-01
Wheel hub motors Supply lines
W43.00-A003-01 W43.00-A004-01
Pump Oil container and oil cooler
A horizontal clearance of at least 100 mm must be

maintained behind the hydraulic pump (4) to allow for its
removal.
¹⁾ Rear engine power take-off, b, flange 100 mm,
650 Nm
1 Engine power take-off special equipment N7I¹⁾
2 Hydraulic oil reservoir, oil cooler and controller
unit
3 Supply lines
4 Pump
W43.00-A005-12
Overview of HAD components in the body area
Relocating components If special applications require the complete HAD side

Subsequently relocating HAD components, in particular module to be relocated, for example, they can be
the complete HAD side module (2), is not permissible implemented via Mercedes Benz-Custom Tailored
and will no longer be supported. Trucks (CTT) if required.
This must be coordinated and checked beforehand when

configuring the vehicle (see "Advice for body
manufacturers" document).
---------------------------------------------------------------------------
HAD in combination with rear engine power take-off If these specifications are ignored, damage to the
Regarding the rear engine power take-offs, only sales gearwheel drive/engine can be expected.
code N7I, Propeller shaft connection ∅ 100 mm, is Control signals of "active" HAD
available in combination with the HAD, sales code A1H.
The following signals are provided for any necessary
With the combination of sales code A1H and sales control system for torque reduction added by the body
code N7I, the following supplemental/deviating manufacturer when the HAD system is "active":
specifications/boundary conditions must be adhered to:
• Signal acquisition and actuation module (ASAM):
• With the HAD "active", the torque tapped at the Active pin X2 52/49, maximum permissible power
power take-off flange may not exceed 450 Nm. draw 0.7 A
• The torque tapped at the PTO flange must be • SAM with additional functions (XMC): Active
reduced if necessary to the maximum limit value of pin X2 52/40, maximum permissible power draw 1 A
450 Nm within two seconds after activation of the
HAD. • Body manufacturer CAN of the SAM with additional
functions (XMC):
• The torque tapped at the PTO flange may be
increased if necessary back to the maximum limit Message GPM1K, byte 2, bit 5 + 6
value of 650 Nm no earlier than two seconds after
deactivation of the HAD.
Installation of propeller shafts

General
i Propeller shafts are used to transmit the engine output to
Propeller shafts can produce unwanted vibrations or the transmission or to the axles. Propeller shafts are
can snap. This can cause damage to other major used in the same way in the case of power take-offs. A
assemblies or lead to accidents. sliding piece with splined profile compensates for vertical
Do not attempt to adapt or modify propeller shafts. movements (length compensation).
Pay attention to correct dimensioning and working
angles.
Use Mercedes-Benz GenuineParts only.
a Working length
b Permissible shaft length
W41.10-A005-10
Propeller shaft with sliding piece
a Working length
W41.10-A001-10
Propeller shaft without sliding piece - Intermediate shaft with
bearing
Types of angular offset

ß1 = ß2
Top = Z-type offset
Bottom = W-type offset
The working angles must be identical at both joints (ß1
= ß2) (the absolute differential angle between the
working angles ß1 and ß2 of a shaft (including all
measurement tolerances) must be < 1°. A value of 0°
should be aimed for). They must not exceed 6°. Angular
offsets greater than 6° and flange angle errors (ß1 ≠ ß2)
cause vibrations in the drivetrain. They shorten the
service life of major assemblies and may cause
damage.
W41.10-A002-11
Angle in one plane (two-dimensional offset)
ß1 = ß2
With three-dimensional offset, the power input and
power output shafts intersect in different planes
(combined W and Z-offset). In order to compensate for
any irregularities, the inner joint forks must be offset. To
determine the offset angle phi, observe specifications of
propeller shaft manufacturer.
W41.10-A003-11
Angles in two planes (three-dimensional offset)
Wheelbase modifications bbe@daimlertruck.com

When changing the wheelbase, always use the standard At this address you can obtain support for requests
wheelbase as a guide (same type, same wheelbase and relating to the layout of a new propeller shaft drive. If the
same drivetrain design), see also chapter "Changing response is positive, you will be told the new part
the wheelbase". numbers of the propeller shaft drive.
The correct layout of the propeller shaft drive prevents At least the following information must be provided for
noise and the development of vibrations. Make sure that your request to be processed:
the marks are aligned on the propeller shafts during • Chassis number
installation.
• Description of the modifications to the vehicle
Work carried out incorrectly on propeller shafts could
cause damage to major assemblies or result in serious • Chassis drawing
accidents due to total failure. To avoid this, always use • Contact person for any queries
genuine Mercedes-Benz parts.
If wheelbases other than the standard wheelbases are
required, contact the following email address for the
layout of a new propeller shaft drive:
---------------------------------------------------------------------------

Installation of propeller shafts with power take-off • Ensure that the markings coincide when assembling.
• Observe the rules of installation from the propeller • Always eliminate any vibrations that may occur.
shaft manufacturer. • If necessary, use several propeller shafts with
• Observe the permissible moments of inertia. intermediate bearings.
• Observe the rotational speeds that are critical with • Make sure that flanging faces are flat.
regard to bending stress. • Do not remove any balancing plates.
• Observe the rigidity of the propeller shaft. • Observe the required clearances.
• Only use balanced propeller shafts. • Rotating parts must be covered.
• Working angle max. 6°
Technical weights
i
In the case of vehicles that are not registered in
Germany, please contact your national general
distributor. You can find your respective contact
person in the Mercedes‑Benz Bodybuilder Portal:
---------------------------------------------------------------------------
In the case of changes in weight (towing capacities, axle drivetrain for the desired gross combination mass. If
loads, gross masses), contact the department named these sales codes are not installed, it may only be
below. After a check, a corresponding manufacturer's possible to realize a slight increase in the gross
certificate for modification of the vehicle documents will combination mass after testing of the existing
be issued if necessary. components.
Model 963, 964 If you have any questions about the topics above, or to
The special equipment sales codes G0A/G0B/G0C and obtain a manufacturer's certificate for submission to a
G0D are available for higher gross combination weights. technical inspection station, please contact the address
These sales codes automatically add a suitable below.

Contact for weight changes, alternative tires and towing capacities for the German market:
Mercedes-Benz Sales Germany
Department: VDS
In-house post code: HPC V620
Location: 10787 Berlin
Email: hebeo-truck@daimlertruck.com
Tel.: +49 900 1844 559 (€1.99/min)¹⁾

1) Valid for calls from Germany.
• Please have the vehicle identification number ready • For written queries, please use the request form
for telephone queries. available from the Mercedes-Benz Workshop
Information System (WIS).
Engine preheaters

The pre-installation for engine coolant preheating, sales coordinated with the relevant contact person (see
code M9A, is available as additional equipment ex document "Advice for body manufacturers") before
factory. If engine preheaters are to be retrofitted and installation.
integrated into the cooling circuit, this must be
Coolant tap for external heat exchanger
Any tapping of coolant for external heat exchangers

i must be coordinated with the relevant contact person
Model 963, 964, 967 (see document "Advice for body manufacturers")
Possible damage to the engine from excessively before installation.
high or low coolant temperature: High heating Heat exchangers with low volumes (3 l) and low heating
outputs and/or high additional volumes of coolant in outputs, e.g. for heating instrument cabinets or valves,
the additional heat exchanger system, e.g. for can be integrated into the circuit of the cab heat
heating the body, cannot be implemented. exchanger. You can request the relevant documents
from the respective contact person (see document
---------------------------------------------------------------------------
i
Model 983
Tapping of coolant for external heat exchangers is
unavailable and not permissible.
Tire pressure monitoring system

The tire pressure monitoring system, sales code S1Y, is

installed in the vehicle to monitor tire pressures and tire
temperatures.
The package consists of a control unit in the electrical
compartment, wireless tire pressure sensors with
electronics in the rims, and the antennas for receiving
the data from the tire pressure sensors.
Depending on the body installed and modifications
made to the vehicle, it may be necessary to relocate the
antennas in the longitudinal direction. This is possible to
a limited extent. Further information can be obtained
from the relevant contact person (see document
Avoid shielding the antennas with metallic attachments
and body components.
If proper functioning of the system is no longer assured W40.15-A017-11
after the modification, a configuration should be Antenna (1) for receiving data from the tire pressure sensors
produced that is as close as possible to the original
condition.
Steering-related modifications
i i
Possible loss of eligibility for registration of the Possible loss of eligibility for registration of the
vehicle. Compliance with UN-R 79 (Steering vehicle. Observe the cornering characteristics of the
System) is mandatory for all modifications to the vehicle including body as governed by national
base model vehicle that affect steering kinematics or legislation.
steering ability.
i
Possibility that assistance systems, such as Active
Drive Assist, react incorrectly, the power steering
reacts incorrectly and steering forces are too high
according to ECE R-79: Vehicles with steering,
Servotwin (sales code C6G) are only tested and
designed within the scope approved ex factory (axle
loads and configurations, wheelbases, tires, etc.).
Modifications to such vehicles may only be carried
out within these limits/approved conditions. Any
modification requires a parameterization of the
vehicle.
Shown on model 964
W46.00-A004-11
Steering linkage
UN-R 79 is relevant for registration and describes the In the case of these changes, care must be taken to
steering. It includes: ensure that they remain within the specified limits of the
• the control device, system approvals. It may be necessary to replace the
steering gear and/or install a steering wheel with a
• the transmission device, diameter of 500 mm. Modification of the steering wheel
• the steered wheels, may entail further restrictions (e.g. removal of the driver's
airbag, no leather steering wheel possible). If
• if applicable, the energy supply device.
conversions not described here are carried out, the tests
The following main changes to the base model vehicle required for registration must be carried out by the body
have an influence on the steering kinematics: manufacturer itself (individual acceptance).
• Axle load increase All parts that transmit force are safety components,
• Tires i.e. any change requires new proof of their strength
suitability and a durability test (hydro-pulse). The
• Wheelbase modifications connection between the steering wheel and the steering
• Changing the number of axles and steering type gear must be retained without change, including all the
components.
Cab
Modifications at cab
Cab contact person (see document "Advice for body

Subsequent modifications to the cab are possible to a manufacturers").
minor extent only. The arrangements and calculations The tilt cab must not be rigidly connected to the body.
required for this can be coordinated via the responsible
---------------------------------------------------------------------------
i
Take the additional space required for opening the
roof hatch/roof ventilation flap into consideration
when designing the body application.
See the offer drawing for further information.
W60.80-A013-78
Roof hatch/roof ventilation flap, code D8A
Cab
W60.80-A014-79
Roof hatch/roof ventilation flap, code D8A
Fastening points for retrofitting the wind deflectors on the...
Permissible roof loads Page 120
i i
Drill carefully so that the nuts in the roof are not Roof variants BigSpace, StreamSpace and
damaged. GigaSpace are not described. The fastening points
All the edges of the holes must be deburred and can be requested from the responsible contact
coated with a suitable anti-corrosion paint. person (see document "Advice for Body
Manufacturers").
i
The M8 weld nuts are always only present on the
respective connection point!
The hole diameter is max. 12 mm.
---------------------------------------------------------------------------
General between 9 mm and 12 mm. The anti-corrosion
The familiar outer punch marks in the roof paneling are protection must then be restored professionally.
no longer present in the new Actros and Arocs model • Moreover, a suitable seal must be installed between
series (model series 963/964). They mark the positions the roof attachment and roof paneling.
of the weld nuts for securing the wind deflectors on the Further specifications can be found in (see document
cab roof. "Permissible roof loads")
• The positions of the weld nuts can be found in the
following sub-chapters. The bore hole diameter is

S cab standard roof

(ClassicSpace)
A Front fastening points for
wind deflector
B Attachment of wind deflector
to rear roof flange
W60.80-A035-76
a 28.5 mm
b 90 mm
c 42.3 mm
d 46 mm
e 47.2 mm
f 35.2 mm
N65.00-A001-75
View perpendicular to the contact surface
M cab standard roof

(ClassicSpace)
wind deflector
to rear roof flange
N65.00-A002-76
a 168.4 mm
b 25.8 mm
c 90 mm
d 43.4 mm
e 35.2 mm
N65.00-A003-74
L cab standard roof
(ClassicSpace)
wind deflector
to rear roof flange
N65.00-A004-76
a 26.8 mm
b 90 mm
c 65 mm
d 59 mm
N65.00-A005-76
Fastening parts of left and right

front wind deflectors
1 Screw M8x20,
A 016 990 18 01
2 Mounting console with M8
thread, A 960 793 28 31
A Direction of travel
N65.00-A006-74
Attachment of left and right front mounting console (figure left), attachment of left and
right front mounting console on roof (figure right)
3 Washer A 000 987 50 41
N65.00-A007-71
Assembly sequence:
1 Place hinge on the mounting console in the z-direction.
2 Slide in the x-direction until the hinge engages.
3 Subsequently screw the hinge to the mounting console.
1 Screw M8x20, A 016 990 18 01
4 Washer N 000000 005058
N65.00-A008-73
Fastening parts of wind deflectors on rear roof

flange (ClassicSpace)

1 Spacer A 973 793 00 96
2 Washer A 004 990 25 82
3 Screw M8x25,
A 016 990 17 01
4 Holder A 941 793 24 14
N65.00-A009-75
Seats and bench seat
i
Possible risk of injury to vehicle occupants and loss
of registration eligibility:
Modifications to restraint systems or their wiring are
prohibited. They could cause restraint systems to no
longer function correctly.
---------------------------------------------------------------------------
Comply with all national regulations and directives! tensile tests) is required. This must also be presented to
The retrofitting of original seats and/or bench seats is the relevant contact person (see document "Advice for
only permitted and possible if the necessary pre- body manufacturers") as part of a non-objection check.
installations exist in the vehicle, such as suitable floor Not all the seats can pass the head impact test from
assembly, reinforced cab/cab suspension. For all other behind according to UN-R 17/…25 (only required for the
seat retrofits, corresponding evidence (belt checks, 2nd seat row = seat/bunk(s) combination).
Exhaust gas aftertreatment system for Euro III Standard
Exhaust gas aftertreatment system

aWarning
Risk of burn injuries, suffocation and poisoning when Wear protective clothing and safety glasses. Use the
working on the exhaust system and the components extraction system. Move people out of the danger zone.
connected to it. Risk of suffocation and risk of poisoning
caused by inhalation of gaseous and solid components of
the exhaust. Risk of poisoning caused by skin contact
with solid components of the exhaust.
Extension of insulated exhaust gas lines Page 359
(Emissions standard Euro III, code M5W) • The maximum permissible exhaust gas back
pressure may not exceed the values.
Moving the muffler on engine OM 460 - Euro III
The muffler may be relocated under the conditions listed
below:

Table for OM 460 (code M5W)
Engine Output Sales code condition Exhaust gas back
pressure [kPa]*
OM 460LA.III/1 350 kW/1600 rpm M3L+M5W 12.5
OM 460LA.III/2 330 kW/1600 rpm M3K+M5W 12.0
OM 460LA.III/3 310 kW/1600 rpm M3J+M5W 11.0
OM 460LA.III/4 290 kW/1600 rpm M3I+M5W 10.5
OM 460LA.III/5 265 kW/1600 rpm M3H+M5W 9.5

* + 1.0 kPa
• Stainless steel pipes (material 1.4301) must be used • Correct installed length.
for lengthening. Observe welding specifications in • The free masses introduced at the engine must be
document "Extending insulated exhaust gas kept as small as possible. For example, the chassis-
lines". side exhaust pipe downstream of the decoupling
• The original mounting supports are to be used to element must be fixed on the chassis side for pipe
fasten the muffler on the vehicle frame. lengths of 1200 mm and longer (incl. decoupling
The following points must be observed when installing element).
the decoupling element: • With a pipe length of 2000 mm or longer (without
• The flexible pipe section with decoupling element decoupling elements), a second decoupling element
must not be installed until after the engine and/or the must be installed immediately upstream of the
muffler has been installed. muffler.
• The decoupling element must not exhibit any

damage on the outer shell.
• The decoupling element must be installed in a
straight line (coaxially), i.e. with no bends or S-shape
deformation.

Exhaust gas aftertreatment system for Euro III Standard
A Installed length
B Installation control length
C Pipe insertion depth
W49.20-A201-10
Decoupling element can be removed from exhaust pipe assy.
A 960 492 15 59
Moving the muffler on engine OM 473 - Euro III • The maximum permissible exhaust gas back
The muffler may be relocated under the boundary pressure must not exceed the following values for the
conditions listed below. entire exhaust system from the engine interface.

Table for OM 473
Engine Output Sales code condition Exhaust gas back
pressure [kPa]*)
OM 473LA.3-4 425 kW/1600 rpm M3P+M5W 14.5
OM 473LA.3-5 380 kW/1600 rpm M3N+M5W 11.8

*) + 1.0 kPa
A Installed length
B Installation control length
C Pipe insertion depth
W49.20-A202-11
Decoupling element can be removed from exhaust pipe
assy. A 960 490 04 20
Exhaust gas aftertreatment system Euro V Standard

aWarning
Risk of burn injuries and scalding when working on Only fill AdBlue(R) in suitable containers. Wait until the
AdBlue(R) lines and the component parts attached to pressure is released before starting any work on the
them. Risk of injury to skin and eyes when handling exhaust aftertreatment system.
AdBlue(R). Risk of poisoning caused by swallowing
AdBlue(R)
aWarning
Power take-off via externally installed transfer case Page 416
Exhaust gas aftertreatment system Euro VI Standard Page 268
i
Loss of eligibility for registration and emissions
certificate:
The specified criteria must not be exceeded.
---------------------------------------------------------------------------
Exhaust gas aftertreatment system (emissions • The angular sum of the pipe must not exceed 4x90°.
standard Euro V, code M5S) • The maximum permissible pipe lengths are limited for
The specifications from document "Euro VI Standard the power categories available in Euro V, analogous
exhaust gas aftertreatment system" should also be to the specifications for the Euro VI engines (see
applied accordingly to the version which complies with document "Exhaust gas aftertreatment
the Euro V Standard. However, this system works solely system Euro VI Standard → Exhaust gas line
according to the principle of selective catalytic reduction between engine and exhaust gas aftertreatment
(SCR). An additional soot particle filter is not installed. unit"). (Certification: SC 2100)
Deviating from the information in the Euro VI system, the • The maximum back pressures listed in the tables
specifications below must be complied with. (see the table "OM 470 (code M5S), table OM 471
Exhaust gas line between engine and exhaust gas (code M5S) and table OM 473 (code M5S) below")
aftertreatment unit must always be observed.
• A decoupling element (A9484904719) must be

installed in the exhaust pipe between the exhaust
gas aftertreatment unit and the first bracket on the i
chassis. If one of the above criteria is exceeded, the exhaust
gas certificate will be rendered invalid. The vehicle
• The exhaust pipe shall be insulated for at least will no longer be eligible for registration!
80%of the total length behind the engine interface.
• Use certified pipes and insulating material with
certification number RA 2002 see document "Euro
VI Standard exhaust gas aftertreatment system".
---------------------------------------------------------------------------
Modifications to the exhaust tailpipe facing inwards (codeK7I). Here, the following points
In combination with the engine model series OM47x, must be observed:
there is only one exhaust outlet variant with the tailpipe
• In the case of bodies that prevent hot exhaust gas high engine outputs while stationary, the tailpipe
from flowing away under the vehicle, e.g.integrated must likewise be modified so that the exhaust gas is
bodies (fire-fighting bodies or similar),the exhaust directed outward.
outlet pipe must be modified so that the exhaust gas • Vehicles with increased gross combination masses
can stream outwards on the left side. An exhaust operated at low speeds may also require modification
outlet to the right is not possible for noise reasons. to an exhaust outlet towards the left.
• On vehicles with transmission-independent power • The tailpipe can be detached from the exhaust gas
take-offs (codeN4X, N4Y or power take-offs aftertreatment unit (the band-type clamp can be
retrofitted in the propeller shaft drive, cf. N6P), (see reused).
document "Pre-installation of power take-off via
externally installed transfer case") which draw
---------------------------------------------------------------------------
Limit values for exhaust gas back pressure The data refer to the entire exhaust system from the
(emissions standard Euro V, code M5S) engine interface.
• The maximum permissible exhaust gas back
pressures must not exceed the values listed below.


Table for OM 470 (code M5S)
Engine Output Code Exhaust gas back
pressure [kPa]*
OM 470LA.5-1 290kW/1600rpm M2Q 9.7
OM 470LA.5-2 265kW/1600rpm M2P 8.7
OM 470LA.5-3 240kW/1600rpm M2N 7.6
OM 470LA.5-4 315kW/1600rpm M2R 10.9

pressure [kPa]*
OM 471LA.5-8 375kW/1600rpm M3D 15.6
OM 471LA.5-12 350kW/1600rpm M3C+M0E 14.0
OM 471LA.5-9 350kW/1600rpm M3C 13.9
OM 471LA.5-13 330kW/1600rpm M3B+M0E 12.8
OM 471LA.5-10 330kW/1600rpm M3B 12.6
OM 471LA.5-14 310kW/1600rpm M3A+M0E 11.8
OM 471LA.5-11 310kW/1600rpm M3A 11.7

pressure [kPa]*
OM 473LA.5-1 460kW/1600rpm M3V 20.4
OM 473LA.5-2 425kW/1600rpm M3P 17.6
OM 473LA.5-3 380kW/1600rpm M3N 14.7

* +1.0kPa
Exhaust gas aftertreatment system Euro VI Standard
aWarning
AdBlue(R)
aWarning
Extending electric lines Page 615
Fire hazard Page 142
Basic vehicle, general Page 110
Exhaust gas aftertreatment system GATS 2.0, Euro VI Page 306

Standard

Platform and swap body Page 521
i i
Possible mechanical and electrical damage: Possible damage to or detachment of the exhaust
Ensure protection against mechanical damage with gas aftertreatment unit:
a stone chipping guard. Ensure protection against No additional detachable parts may be attached to
splash water. Protect connector plug and wiring the exhaust gas aftertreatment unit or its
harness from water entry. Strain relief of the wiring components. Make sure that only genuine
harness and electrical connectors must be ensured. Mercedes-Benz components are used and that the
Attachment of the wiring harness using a cable tie components are mounted and secured as described.
must be implemented by the body manufacturer, If the series-production holder is not used, this can
taking strain relief into consideration. result in unpredictable effects on the exhaust gas
aftertreatment unit support structure. This may be
attributable to, for example, a change in the flow of
forces or in the vibration behavior.

i i
Loss of eligibility for registration: Risk of burn injuries for the user or persons in the
The documentation for the exhaust gas vicinity:
aftertreatment unit refers specifically to the Make sure that exhaust gas discharged via the outlet
respective vehicle. The anti-tamper seal and the is cooled down sufficiently or that the outlet area is
labels on the filters must not be damaged or not accessible to persons.
removed. The position of the exhaust gas
aftertreatment unit is an essential part of the engine
and noise certificate. Any modifications, even if they
comply with the specifications given in these
guidelines, require the acceptance inspection to be
repeated by the technical service.
i
Risk of fire:
If combustible material (e.g. fluids, combustible
objects or gases) come into contact with hot parts of
the exhaust system or with the exhaust flow, these
materials can ignite. Make sure that the level of
safety provided at the installation space corresponds
to the respective vehicle application profile; refer to
the "Fire hazard" document. During active
regeneration of the diesel particulate filter (DPF),
diesel fuel is injected into the exhaust gas line. If the
exhaust gas line is not leak-tight, diesel fuel and
exhaust gas can escape at high temperatures.
Escaping diesel fuel can ignite. To avoid this, it is
essential to ensure that the piping is made of
stainless steel and that it is gas-tight and liquid-tight.
If the exhaust outlet is covered by the body
(e.g. dropsides) during loading and unloading, hot
exhaust gases can heat up the body. The exhaust
outlet must not be directed at other components
(e.g. the side underride guard). Otherwise, the
engine must be switched off before loading. This
must be noted in the operator's manual for the body.
---------------------------------------------------------------------------
Exhaust gas aftertreatment system MCS/SCS The exhaust system with two-piece mounting support,
(emissions standard Euro VI Standard d, code M5C) sales code K7P, allows the exhaust gas aftertreatment
Modifications to the exhaust gas aftertreatment unit unit to be removed to the side. Otherwise the system is
should be avoided. Various versions are available ex removed upward and requires a clearance of
factory. The position of the exhaust gas aftertreatment min. 100 mm to the bottom edge of the body. Its use is
unit is an essential part of the engine and noise recommended especially in combination with bodies with
certificate. Any modifications, even if they comply with no subframe, see "Platform and swap bodies"
the specifications given in these guidelines, require the document.
acceptance inspection to be repeated by the technical
service.

Minimum clearances from exhaust gas

aftertreatment unit to avoid thermal damage
Prerequisite: The adjacent component must be resistant
to long term temperatures of 80 ℃. A limit temperature
of 60 ℃ applies to batteries.
1 Metering device
2 Distance a: ≥ 50 mm, heat shield absolutely
essential
W49.20-A089-11
Exhaust gas aftertreatment unit for engine OM 936
a Distance a: ≥ 30 mm Heat shield required if

30 mm < a < 150 mm from exhaust gas
aftertreatment unit
W49.20-A134-11
Exhaust gas aftertreatment unit for engine OM 47x without right
rear exhaust outlet (not sales code K7D)

2 Exhaust outlet
a Distance a: ≥ 30 mm Heat shield required if
30 mm < a < 150 mm from exhaust gas
aftertreatment unit
W49.20-A135-11
Exhaust gas aftertreatment unit for engine OM 47x with right rear
exhaust outlet, sales code K7D
Maintain the following distances from heat sources: Minimum clearances must also be observed during
• Exhaust pipe without shielding 200mm maintenance and repair.
• Exhaust gas aftertreatment unit without shielding The following temperature limit values apply for the
150mm components listed below:
• Heat source with sheet metal shielding 100 mm

• Heat source with sheet metal shielding and additional
insulation 80 mm

Tires 80℃
Brake cylinder 80℃
Brake hoses 80℃
Modifications to the exhaust gas aftertreatment unit • Replacement of the exhaust gas aftertreatment unit
If modifications need to be made, it is essential to with a different third-party exhaust system is not
observe the points listed below: permitted.
• The tailpipe/exhaust outlet directly on the exhaust • The exhaust gas back pressure may not exceed the
gas aftertreatment unit may not be modified. maximum permissible limit values for exhaust gas
back pressure.
• Following modification, Daimler Truck AG cannot
guarantee that the specifications stipulated by law • The installation position of the sensors (temperature,
and trade associations will be met; the person who pressure, NOx) must not be changed.
makes the modifications is responsible for this. • All maintenance tasks (diesel particulate filter
• If the exhaust routing is changed, the exhaust outlet replacement, disconnection of electrical connectors,
must be positioned in such a way that the exhaust replacement of sensors, etc.) must be feasible, which
gas never flows directly over any components on the is why sufficient accessibility must be guaranteed. If
vehicle and never heats up these components to a necessary, replace the hexagon socket head bolts of
temperature higher than 80 °C, as exhaust gas the top cover with hexagon head bolts with washers.
temperatures of up to 600 °C can occur during
regeneration mode. The body manufacturer is
responsible for ensuring this!
• It is possible to move the exhaust gas aftertreatment • Body manufacturers must ensure that the maximum
unit to the left side of the vehicle. In this case, the permissible component temperatures are observed.
same conditions and specifications given in these • Daimler Truck AG cannot provide information on or
Body/Equipment Mounting Directive apply. The guarantee operational durability. Operational
following must also be considered: durability must be ensured by the body manufacturer.
• To protect the exhaust gas aftertreatment unit and • The details concerning part numbers, length
its detachable parts against stone chipping, information and certificates given in the (see
suitable protection (protective metal sheets) must "Exhaust gas line between engine and exhaust
also be fitted to the front and/or rear side of the gas aftertreatment unit" document) must be
exhaust gas aftertreatment unit. observed when extending pipes and with regard to
• Use the fan-type outlet (Exhaust system, outlet the permissible lengths.
below, fan-type to right, sales code K7B). • The exhaust gas aftertreatment unit can only be
• Checking compliance with noise certificate moved to the area between the last front axle and the
• If the exhaust gas aftertreatment unit is moved, a front of the first rear axle and on the left or right side
side protection device which fulfills the legal of the vehicle.
requirements may have to be attached at this • The exhaust gas should always flow to the outside of
position. the vehicle. Vehicle components such as brake
• If modification parts not approved by cylinders, tires, axles and lines, must never be
Daimler Truck AG are used, the exhaust gas and directly exposed to the exhaust flow.
noise certification will be rendered invalid. • Accessibility for maintenance (e.g., opening of
• Modifications are not permissible to any individual electrical plugs) must be ensured.
components of the entire exhaust gas aftertreatment System overview
system! Only the position of the complete exhaust
gas aftertreatment unit may be changed.

W49.20-A136-09
Illustration shows example of OM 47x

W49.20-A137-09
Component connections
1 Nozzle unit for DPF regeneration B37 Exhaust pressure sensor upstream of
diesel oxidation catalytic converter
2 Pump module B38 Exhaust pressure sensor downstream of
diesel particulate filter
3 AdBlue®tank B67 Exhaust temperature sensor upstream of
diesel oxidation catalytic converter
4 Exhaust gas aftertreatment unit B68 Upper exhaust temperature sensor
downstream of diesel oxidation catalytic
converter
5 Ammonia slip catalytic converter B69 Exhaust gas temperature sensor
downstream of lower diesel oxidation
catalytic converter (not present on
exhaust gas aftertreatment unit generation
II)
6 SCR (Selective Catalytic Reduction) B70 Exhaust temperature sensor downstream
catalytic converter of diesel particulate filter
7 Diesel oxidation catalytic converter (DOC) B73 Exhaust temperature sensor downstream
of SCR catalytic converter
8 Diesel particulate filter (DPF) B74 AdBlue®fill level sensor/temperature
sensor
9 Diesel fuel metering unit (for DPF B625 Fuel pressure sensor (outlet)
regeneration)
A4 Engine management control unit (MCM) B626 Fuel pressure sensor (inlet)
A57 NOxsensor control unit, exhaust gas M25 SCR delivery pump
aftertreatment unit outlet
A57 b1 Exhaust gas aftertreatment unit outlet Y627 AdBlue®heater coolant solenoid valve
NOxsensor
A58 SCR control unit Y628 Fuel metering valve
A60 Exhaust gas aftertreatment (ACM) control Y629 Fuel shutoff valve
unit
A67 AdBlue®metering device CAN 3 Frame CAN
A70 NOxsensor control unit, exhaust gas CAN 4 Drive train CAN
aftertreatment unit inlet
A70 b1 Exhaust gas aftertreatment unit inlet CAN 13 NOxCAN
NOxsensor
AdBlue® supply
i
Possible failure of the AdBlue® metering device
i (A67):
Premature wear and possible serious damage to the Ensure the required level of cooling at the injection
engine system: nozzle of the AdBlue® metering device (A67).
Installation spaces carrying medium must be clean
when installed. The body manufacturer is
responsible for ensuring that all components that are
modified by them meet the requirements of technical i
cleanliness. The AdBlue® temperature must not Damage to the pump due to crystallization of
exceed 60 ℃ under any operating conditions. AdBlue®:
Seal the pump module and the separated lines air-
tight and liquid-tight after removal. The maximum
storage time for the sealed pump is 2 months.

AdBlue®circuit - System description
2 Pump module
3 AdBlue®tank
A67 AdBlue®metering device
S AdBlue®suction line
D AdBlue®pressure line
R AdBlue®return line
W49.20-A100-11
Illustration showing metering system
AdBlue® circulates in the line system between the A system run-on is required depending on the
AdBlue® tank (3), pump module (2), AdBlue® metering installation position, operating status and ambient
device (A67) and back to the AdBlue® tank (3). temperature in order to provide adequate cooling.
The AdBlue® metering device (A67) is mounted on the The power supply must be maintained during the entire
exhaust gas aftertreatment unit and is therefore exposed run-on time (max. 45 min). (The length of the run-on time
to high temperatures. can be displayed on the driver's instrument panel. This is
provided as standard on vehicles with battery disconnect
To cool the circuit, AdBlue® therefore circulates switch).
continuously as soon as the engine is started and, if
necessary, for a certain period of time after the engine AdBlue® circuit - Installation specifications
has been stopped (run-on time).

Installation position of components

2 Pump module
3 AdBlue®tank
B74 AdBlue®fill level sensor/temperature sensor
h₁ Height difference on suction side
h₂ Height difference on pressure side
h₃ Height difference at return
W49.20-A101-11
Example illustration
The permissible installation position of the components The permissible pressure loss must not be exceeded.
depends on the line length, the height difference (h₁, h₂)
and the line cross-sections.


Requirement Suction line (S)
Line cross-section D 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm
(internal)
Line length 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm 4000 mm 5000 mm
Maximum height 500 mm 1000 mm 1200 mm 1200 mm 1200 mm 900 mm 200 mm 0 mm

difference h₁
The body manufacturer must keep the suction line length The length of the suction line can also be shorter than
and the height difference (h₁) as small as possible. the minimum specified length.

Requirement Pressure line (D)
Line cross-section D (internal) 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm
Line length 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm
Maximum height difference h₂ 500 mm 1000 mm 1500 mm 1620 mm 1500 mm 1490 mm

Line length 4000 mm 5000 mm 7500 mm 10,000 m 12,500 m 15,000 m

m m m
It is essential to observe the minimum length of the

pressure line.

Requirement Return line (R)
Line cross-section D (internal) 4 mm
Line length 20000 mm
Maximum height difference h₂ 3200 mm
Refer also to the following sections concerning the

AdBlue® lines.
---------------------------------------------------------------------------
AdBlue® lines - Installation specifications • It must be ensured that the lines are secured
General correctly; the distance between the fastening points
must not exceed 300 mm.
• There must not be any narrowing of the cross-section
along the lines. It must be ensured that the lines are • The max. permissible pressure loss must not be
not pinched or kinked. exceeded.
• The minimum bending radii selected during routing

must be such that no narrowing of the cross-section
occurs.

• The pressure loss in the line is determined by the line • No air or dirt is allowed to enter the system via the
cross-section and the line length. If the individual suction line.
components are arranged at different heights, this
height difference must be taken into account as an
additional pressure difference.

Suction line
Max. permissible pressure loss: 0.35 bar (where Q = 0.25 l/min)
Operating pressure: 0.5 to 1.1 bar absolute
Material: PA, NBR, EPDM
A prefilter with mesh width of min. 100 µm is required in

the fuel tank (already integrated in the delivered
Daimler AdBlue® tank).

Pressure line
Operating pressure: 10 bar
Max. burst pressure: 60 bar
Material: EPDM, NBR

Return line
Technical cleanliness for AdBlue® lines If the pressure line is replaced, the filter of the AdBlue®
metering device must be changed.
The AdBlue® lines are subject to high requirements with
regard to cleanliness. If these requirements are ignored, It is not permitted to use lubricants (silicone-based) as
it is no longer possible to guarantee reliable operation an assembly aid.
and functioning of the AdBlue® circuit.
If the suction line is replaced, the prefilter of the AdBlue®
pump module must be changed.

AdBlue®heating - System description

2 Pump module
3 AdBlue®tank
A4 Engine management control unit (MCM)
A60 Exhaust gas aftertreatment (ACM) control
unit
Y627 AdBlue®heater coolant solenoid valve
C1 Coolant feed from engine
C2 Coolant feed to AdBlue®tank
C3 Coolant feed to pump module
C4 Coolant return to engine
R AdBlue®return line W49.20-A102-11
AdBlue® heater - Installation specifications It is important to make sure that the coolant line and the
AdBlue® line are lying tight against each other, which
The AdBlue® tank (3) and the pump module (2) are
can be achieved using, e.g. fabric tape. The attachment
heated by means of coolant, for which approx. 140 l/h of
with fabric tape (e.g. A 001 989 63 85) should be carried
coolant is removed from the engine cooling system.
out at least every 100 mm or over the entire length.
The vehicles are supplied with coolant-heated AdBlue®
It must also be ensured that both lines are additionally
lines.
enclosed in a hose (corrugated hose or "zipper hose",
The following basic principle applies: If system e.g. from Zipper Technik GmbH). This outer cover or
modifications are carried out, the body manufacturer hose increases the heat transfer between the two lines.
must ensure the prescribed rapid condensing of AdBlue® Alternatively, a sleeve with Velcro fastener can also be
and the subsequent, correct circulation of AdBlue®. used. In all cases, the ends of the outer cover must be
fixed in place using fabric tape and/or cable ties so that
It is essential to ensure:
the cover cannot move and to maximize the heat
• Fulfillment of the legal requirements/certification. The transfer between the coolant and the AdBlue® line at
system must be ready for metering after a defrosting these points.
time of max. 60 min.
After extending the lines, the body manufacturer must
• Cooling of the AdBlue® metering device (A67) and ensure that system leak tightness is given.
prevention of thermal overloading of the injection
nozzle.
Heating of AdBlue® lines by means of integrated

coolant lines – Installation specifications
The AdBlue® lines heated by coolant can be extended in
accordance with the suggestions below.


V Delivery package of connection
components, Kunzer order number HAVS49
(Note: The component assignment supplied by
Willy Kunzer GmbH must also be observed.)
S1 AdBlue®hose A 967 476 05 01
S2 Coolant hose, inside diameter 12 mm, wall
thickness 3.5 mm (Note: Compatibility with the
1-ear clamps supplied with the connection
components (V) is only guaranteed with the
listed hose inside diameter and wall thickness.)
W49.20-A140-11
Extension component overview
The delivery package of connection components (V) can Willy Kunzer GmbH, Römerstrasse 17,
be ordered with the number HAVS49 from 85661 Forstinning, Tel. +49 (0) 8121 220-0.

• • Separate lines with special tool.

• Push outer corrugated pipe back.
• Secure with cable ties to prevent it slipping back.
W49.20-A138-11
W49.20-A139-11
W49.20-A141-12
Double union in special drive-in bushing
• Example: Double union in smooth tube (with an

external diameter of 6 mm), knock in with a sleeve or
similar.
W49.20-A142-10
Double union

W49.20-A143-10
Fitting
• Knock in special bushing.

This bushing also forms the raised bead for the coolant
hose, which is installed over it.
W49.20-A144-11
Fitting in special drive-in bushing
W49.20-A146-11
Push on coolant hose (internal ∅ 12 mm and wall
thickness 3.5 mm) by approx. 20 mm.
W49.20-A145-11
Attach hose clamps
W49.20-A147-10
Protective hoses (insulating hoses)
W49.20-A148-10
Join with fabric tape at least every 100 mm in order to ensure
sufficient thermal contact.

Example:
Protective hose with Velcro:
• A 000 821 06 97, ∅ 30 mm
• A 000 821 05 97, ∅ 40 mm
W49.20-A149-10
Protective hoses (insulating hoses) mounted and secured with
cable ties.
AdBlue® supply • A clearance of 130 mm in a downward direction at an

angle of ±45° from vertical (in all directions) is
AdBlue® tank - Installation specifications necessary for maintenance (detaching and attaching
The AdBlue® tank should only be used in combination filter housing).
with the intended genuine Mercedes-Benz AdBlue® fill • A guard to protect against dirt and stone chippings
level sensor/temperature sensor and the genuine may be necessary.
Mercedes-Benz heater.
General information on attaching/detaching:
If a different tank size (Mercedes-Benz genuine parts
only) is installed, the parameters valid for the new tank • Do not spill any AdBlue®.
must be transferred to the vehicle. Please contact your • Do not allow AdBlue® to come into contact with plug
Mercedes-Benz Service Partner. contacts and plugs.
The surface temperature of the tank must not exceed • Do not place the detached pump module on the
80 ℃. cover; seal the connections.
AdBlue® pump module • Escaping AdBlue® can damage the electrical plug
contacts.
AdBlue® pump module - Installation specifications
Attaching pump module
Temperatures
The standard holder of the pump module is attached to
Operating temperatures: ₋40 ℃ to +85 ℃ the vehicle frame with two M16 screws (see document
"Threaded and welded connections").
Installation position
• The holder is bolted to the frame.
• The filter housing must face downward.
• The pump module is mounted to the holder with two
• ±45° in all directions is permissible. vibration dampers and secured using two screws.

Bolts: M8×25 (for 5 mm holder)
Classification: 8.8
Torque: 18 Nm ±20 %
If the standard holder has to be replaced, it must be version and fastened to the vehicle frame/body
dimensioned in the same way as the factory supplied accordingly.
---------------------------------------------------------------------------
Exhaust gas aftertreatment unit
The following basic variants are used.


Exhaust gas aftertreatment unit table
Engine Exhaust certification Exhaust gas aftertreatment unit Equipment
OM 936 Euro VI Standard d SCS (Small Cross System) 1 diesel oxidation catalytic converter
1 diesel particulate filter
1 SCR catalytic converter
1 ammonia slip catalytic converter
OM 470 Euro VI Standard d MCS (Medium Cross System) 2 diesel oxidation catalytic converters
OM 471 2 diesel particulate filters
OM 473 2 SCR catalytic converters
2 ammonia slip catalytic converters
Task function as muffler, it also ensures that noise emissions

In the vehicle, the exhaust gas aftertreatment unit is the remain within the legally prescribed limits.
primary component for limiting pollutant emissions. In its

Retrofitting a heat shield

If the exhaust gas aftertreatment unit is moved toward
the rear, a heat shield must be attached at the front end.
The heat shield including fastening parts is available as
a genuine accessory under the number B6 684 8600.
W49.20-A150-12
Exhaust gas aftertreatment unit with shield
Exhaust gas aftertreatment control unit Electrical connection

Location 120-pin plug (A60X2): Wiring harness for sensor system,
The ACM (exhaust gas aftertreatment control unit (A60)) pump control, AdBlue® tank and AdBlue® heater lines
is rigidly attached to a holder on the exhaust gas 21-pin plug (A60X1): Wiring harness for frame and cab
aftertreatment unit.
Installation specifications
• Maximum protection against mechanical damage is
Temperatures necessary.
Ambient temperature of control unit: • Ensure stone chipping protection.
- 40 ℃ ... max. 85 ℃ (body manufacturer must ensure • Ensure protection against splash water.
that sufficient air cooling is provided)
• Protect connector plug and wiring harness from water
entry.

• Wiring harness strain relief must be ensured. The This must be ensured by the body manufacturer, taking
body manufacturer must attach the wiring harness strain relief into consideration.
using cable ties, taking strain relief into consideration.
(120‑pin plug by means of holder bolted to the control Electric lines and electrical connectors to the
unit). exhaust gas aftertreatment unit control unit
• The control unit must be installed above the fording Depending on the vehicle model designation used, the
line. wiring harnesses are dimensioned so that one wiring
harness can be used for different wheelbases. For this
Holder for supporting wiring harness of 120-pin plug reason, the body manufacturer must check whether,
on ACM after the cable ties have been removed, the wiring
The holder is attached to the control unit at the provided harnesses routed in the frame can possibly be used for
support points using screws. The body manufacturer the newly selected position of the components.
must attach the wiring harness using cable ties, taking If it is necessary to change the length of the wiring
strain relief into consideration. harnesses, however, the specifications in the Body/
Equipment Mounting Directives, see GA82.00-
Supporting wiring harness of 21-pin plug on ACM W-0002-01B, and alternatively the specifications stored
The wiring harness is secured to the support point on the in the Workshop Information System (WIS) must be
control unit using the cable tie. observed.

A Frame
B Exhaust gas aftertreatment unit
1 Power supply
2 CAN
3 AdBlue®heater line
4 Pin 1: Switched supply (pump)
Pin 2: GND
Pin 2: GND Pin 3: Required engine speed
Pin 4: Actual engine speed
5 Pump module
6 Electrical connector
7 EDU functionality
8 Sensors at exhaust gas aftertreatment unit
9 Pin 1: DV LS
Pin 2: DV HS
Pin 3: HE LS
Pin 4: Switched supply
Pin 5: Sens. supply 5 V
Pin 6: (T-Signal)
W49.20-A091-12
Pin 7: Sen. ground
Component connections
Pin 8: P-signal
10 AdBlue®metering device
X42: CAN line (ASAM Cab plug) X208: Exhaust gas aftertreatment unit pump module
X160: AdBlue® heater suction line A80: Pump module
X157: AdBlue® heater return line B100: AdBlue® quality sensor
X174: AdBlue® heater pressure line B74: AdBlue® fill level sensor/temperature sensor

Overview of plugs and mating connectors
Plug designation Number of pins Socket housing Plug housing
X42 40 A 168 545 09 28 A 057 545 22 28
Contacts 0.75 mm² A 005 545 76 26 A 026 545 84 28
X208 (OBD‑B + OBD‑C) 8 A 027 545 41 26 A 055 545 79 28
Contacts 0.75 mm² A 000 982 00 26 A 000 982 84 28

(1.6 mm)
ELA A 003 997 75 49 A 003 997 75 49
Blind plug A 002 997 60 86 A 002 997 60 86
Protective cap 180°, NW10 A 002 545 68 83 A 002 545 68 83
Reducing piece 13/10 A 000 153 24 66 A 000 153 24 66
Cable tie A 002 997 68 90 A 002 997 68 90
A80 (OBD‑B + OBD‑C) 4 A 026 545 11 26 A 054 545 66 28
Contacts 0.75 mm² A 013 545 54 26 A 030 545 46 28

(2.8 mm)
ELA A 000 545 28 39 A 000 545 28 39
Blind plug A 001 545 66 80 A 001 545 66 80
Protective cap 180°, NW8.5 A 001 546 01 35 A 001 546 01 35
B100 (OBD‑C) 4 A 026 545 10 26 A 030 545 65 28
Contacts 0.75 mm² A 013 545 54 26 A 030 545 46 28

(2.8 mm)
ELA A 000 545 28 39 A 000 545 28 39
Blind plug A 001 545 66 80 A 001 545 66 80
B74 (OBD‑B) 4 A 026 545 10 26 A 030 545 65 28
Contacts 0.75 mm² A 013 545 54 26 A 030 545 46 28

(2.8 mm)
ELA A 000 545 28 39 A 000 545 28 39
Blind plug A 001 545 66 80 A 001 545 66 80
Dates: OBD-B since 06/2015; OBD-C as of 10/2016
CAN line (between exhaust gas aftertreatment unit Electric lines to sensors
and ASAM) It is not permitted to modify the electric lines to the
The CAN line (4-core, twisted-pair cable) should never sensors. The wiring harness may not be modified at the
be extended. If a different length is required, the existing exhaust gas aftertreatment unit end!
CAN line must be replaced with a new line.

Electric lines • The new positions of the mounting supports must not
All electric lines, provided that they do not lead to the be at the center of the longitudinal member rib
sensors and are not the 4-core CAN line, can be (diaphragm effect). The threaded connection points
extended. For this, also see document "Extending must be positioned at the top and bottom row of
electric lines". holes in the longitudinal member. (Make the
connections using series-production mounting
Sensors supports corresponding to the series-production
configuration!)
It is prohibited to change the (installation) position of the
sensors on the exhaust gas aftertreatment unit. The information in document "Installation of
compressors" regarding the installation of compressors
Exhaust gas aftertreatment unit operational applies equally to the installation of the exhaust gas
durability - Installation specifications aftertreatment unit.
If the exhaust gas aftertreatment unit is moved, • Attachment is carried out with the approved genuine
Daimler Truck AG is unable to make any statement Mercedes-Benz mounting support. The shims and
regarding its operational durability. The body inner reinforcement plates must also be reused.
manufacturer is therefore responsible for providing Important: New flange head bolts and flange head
information on service life. nuts.
Other notes: • M16×1.5 - 10.9, MBN 10105 and MBN 13023)

must be used for attachment,
• Lifting the vehicle, e.g. using a vehicle jack, salvage
crane, at the exhaust gas aftertreatment unit is not Tightening instructions:
permissible. • MA = 225 Nm +90°
• It is not permitted to stand on the exhaust gas • Attachment is carried out using defined and secured
aftertreatment unit. mounting points on the exhaust gas aftertreatment
• If the exhaust gas aftertreatment unit is installed at unit
exposed positions, it is important to note that these • Make sure that the components are in perfect
positions are not suitable for bearing loads which condition when attaching.
occur, e.g. in the case of impacts or when obstacles
• Make sure that the contact surfaces of the
are set down on or are dragged against the unit. The
components are clean.
unit must therefore be provided with sufficient
protection if installed at exposed positions on the • Make sure that the components are attached and
vehicle! secured correctly before the exhaust gas
aftertreatment unit is mounted to the vehicle and that
• Welding and other modifications (drill holes, etc.) on
the mounting points are designed for the intended
the exhaust gas aftertreatment unit are not
purpose.
permissible.
Installation position and incline angle of exhaust gas
Mounting to the vehicle longitudinal frame member
aftertreatment unit in vehicle
• Attachment is only permissible at the secured
It is not permitted to perform installation at a position
mounting points and using the series-production
rotated about the X and Y-axis. Rotation about the Z-
bracket. Only the mounting supports available from
axis is only permitted by 180°. In the case of installation
Mercedes-Benz are permissible.
rotated about the Z-axis, it is important to note that the
• To ensure that force influences, e.g. torsion from the local coordinates system must also be rotated
chassis, are not transferred to the unit, the mounting accordingly.
supports must be attached to the longitudinal
member.

Definition of vehicle coordinates system:

x Positive in vehicle longitudinal direction
y Positive from right to left (viewed in direction of travel)
z Positive in upward direction
W49.20-A103-01
Attachment of detachable parts to exhaust gas • Exhaust pipe connections (clamp connections) must
aftertreatment unit be gas-tight.
Additional points of load application resulting from • To prevent potential thermal events, appropriate
additional detachable parts are generally not permitted. covers, seals or trim pieces must be attached to the
Exceptions are specifically approved series-production body.
detachable parts: Surface temperatures of exhaust gas aftertreatment
• Heat shields unit.
• Exhaust baffles The information applies to, e.g.:

• Free-standing unit without detachable parts, e.g. heat
Temperatures at the exhaust gas aftertreatment unit shield, contact guard
Owing to the high temperatures and the high heat • Ambient temperature < 25 ℃
retaining capacity, it is important to observe the following
points: • Exhaust gas temperatures and mass flows occurring
with the OM 936 (SCS) and OM 471 (MCS) engine in
• The exhaust gas aftertreatment unit must not come typical truck applications
into contact with combustible objects, fluids or gases.
The insulation must be designed such that, under the
• If combustible objects, fluids or gas are located above-mentioned boundary conditions, a max. surface
above or close to the exhaust gas aftertreatment unit, temperature of approx. 250 ℃ is not exceeded even in
appropriate measures must be taken to ensure that the case of full-load operation and/or correctly performed
the temperature of these materials remains at a non- active DPF regeneration.
critical level.
Exceptions are areas with limited insulation, e.g. at joints
• When the exhaust gas aftertreatment unit is installed, and sensor positions. These areas can reach surface
it must be ensured that adequate free convection of temperatures of up to 480 ℃. This also applies to the
cool ambient air is provided in order to prevent area at the service flap. Additionally, in this area and in
overheating of components on the unit and in the the area around the rear mounting point, air heated up to
surrounding area. 480 ℃ can be discharged from the inside.
If in doubt, observance of the maximum temperatures Owing to the high heat capacity, the surface temperature
must be ensured by implementing appropriate also remains at a high level for a relatively long time
measures, and this must be verified by means of after operation. This also applies to the exhaust outlet
appropriate measurement. This particularly applies in temperature.
the case of restricted installation space and if
additional components are attached to the unit, It is important to note that additional detachable parts,
e.g. contact guards. such as heat shields, or installation in a space with
limited ventilation increase the temperatures
• Particular attention must be paid to operating ranges considerably. This can result in permissible
with high load and to the active regeneration of the temperatures of the detachable parts being exceeded.
diesel particulate filter (DPF). This must be avoided by implementing appropriate
• Maintenance operations must only be carried out measures.
when the system is cold (including removal of service
flap).


Typical surface temperature values with full load
A Insulated surface approx. 250 ℃
B Edge area approx. 450 ℃
C Sensor opening approx. 480 ℃
D Gap and joint openings approx. 480 ℃
W49.20-A104-03
Example showing SCS exhaust gas
aftertreatment unit
Temperatures of the exhaust flow • The actual alignment of the exhaust flow and the
The exhaust flow at the outlet opening can reach occurring temperatures are influenced by the outlet
temperatures up to 600 ℃. variant, the ambient boundary conditions (wind,
temperatures, etc.) as well as the vehicle model,
The body manufacturer must therefore observe the e.g., ground clearance, and the driven speed.
following points:
• When the power take-off is in operation, it is
• Precautions must be taken to ensure that exhaust important to ensure that the discharged hot exhaust
gases leaving the outlet do not come into contact gases do not pose a hazard for the surrounding area.
with combustible or heat-sensitive objects or with Here, the actuated load points, the local conditions
persons. and the wind situation must be taken into
• The exhaust gas should always flow to the outside of consideration. It must also be ensured that active
the vehicle. Vehicle components such as brake regeneration can take place when the vehicle is
cylinders, tires, axles and lines, must never be stationary.
directly exposed to the exhaust flow.
• The exhaust outlet must be such that the exhaust
flow is horizontal or pointing downward at an angle of
max. 20° relative to the horizontal.

Typical temperature ranges at exhaust outlet:
Range 120 ℃ Range 250 ℃
Stationary regeneration at v = 0 m/h Up to approx. 100 cm Up to approx. 40 cm
Full load at v = 30 km/h Up to approx. 110 cm Up to approx. 60 cm
Temperature limit values for electrical detachable

parts
Maximum ambient temperatures:


NOx sensor
Exhaust gas aftertreatment unit NOx sensor control –40 ℃ ... 105 ℃
unit
Exhaust gas aftertreatment unit NOx sensor cable –40 ℃ to 200 ℃

Temperature sensor
Flat plug housing –40 ℃ to 120 ℃
Electric line and corrugated pipe –40 ℃ to 260 ℃
Exhaust gas aftertreatment control unit –40 ℃ to 85 ℃
Pressure sensors –40 ℃ to 125 ℃
Exhaust gas line between engine and exhaust gas element must be installed immediately upstream
aftertreatment unit of the exhaust gas aftertreatment unit.
The following aspects must be taken into consideration • Permissible sectional loads on exhaust gas
for the connection: aftertreatment unit
• Modifications to the factory-fitted exhaust pipe layout • Use of certified pipe extensions or, alternatively, use
are only permissible downstream of the decoupling of specified insulation and observance of permissible
element (EKE). pipe lengths
• The vehicle-side component parts must be • Work and installation instructions for processing
decoupled from the engine-side component parts. certified pipe extensions (see document "Extension
• To compensate for stress in static and dynamic of insulated exhaust gas lines")
mode, the genuine Mercedes-Benz decoupling • Compliance with exhaust gas back pressure limits
element must be installed downstream of the • Possible surface temperatures are approx. 110℃ at
transition point. It must be ensured here that the the insulated exhaust gas line, approx. 300℃ at the
decoupling element is not overloaded in its static uninsulated exhaust gas line and approx. 200℃ at
and dynamic working range. the decoupling element.
• The free masses introduced at the engine must • The exhaust must be routed such that the max.
be kept as small as possible. For example,the permissible temperatures of the adjacent
chassis-side exhaust pipe downstream of the components parts are not exceeded (frame wiring
decoupling element must be fixed on the chassis harness: 100℃, compressed-air line: 120℃,
side for pipe lengths of 900mm and longer (incl. compressed-air connector: 100℃, transmission
decoupling element). control unit: 80℃ (further limit values available on
• With a pipe length of 2000mm or longer (without request).
decoupling elements), a second decoupling

Overview of transition points along exhaust gas

line
A Engine
C Vehicle frame
1 Transition point "engine/exhaust pipe"
2 Decoupling element (EKE)
3 Connection "decoupling element to exhaust pipe"
4 Transition point "exhaust pipe/exhaust gas
aftertreatment unit" W49.20-A125-10
5 Second decoupling element, if required

Overview of clamps and connections
Item Part designation OM 47x vehicle of OM 47x vehicle of OM 936
model series 963 model series 964
2 Decoupling element A 960 492 14 59 ¹⁾ A 960 492 23 59 ²⁾ A 960 492 16 59 ³⁾
1 1 Parts kit (V-band Seal A 002 995 22 02 -

clamp, seal)
1 V-band clamp (no seal - A 001 995 84 02

necessary)
3 Welded connection (V-seam)
4 Parts kit (clamp, A 003 995 07 02 A 003 995 09 02

clamping disk, sealing
ring)
1) Part is not available as a separate replacement part (i.e. the item number cannot be procured separately from the Mercedes-
Benz Service Partner). The part can be taken from, e.g. the exhaust gas line assembly with the item number ZB A 960 490 12 20.
Benz Service Partner). The part can be taken from e.g., the exhaust gas line assembly with the item number ZB A 960 490 49 47.
Benz Service Partner). The part can be taken from, e.g. the exhaust gas line assembly with the item number ZB A 960 490 88 20.
"Engine exhaust gas/chassis" transition point Connection to exhaust nozzle

The exhaust gas is fed from the engine at the transition A decoupling element is screwed directly to the exhaust
point "engine exhaust gas/chassis" to the chassis-side nozzle.
exhaust pipe.

Assembly operations on OM 47x

On engine OM47x, a V-band clamp must be used for connection to the
exhaust nozzle.
• Place the seal (4) over the exhaust nozzle (5). Push the clamp side with
the folded edge (2) over the connector (3) in the direction of the engine.
• Position the connector (3) with clamp (1) over the exhaust nozzle (A).
1 Clamp
2 Folded edge
3 Connector (chassis-side exhaust pipe with decoupling element)
4 Seal N49.10-A004-01
5 Exhaust nozzle (engine-side exhaust pipe) Structure of connection
Before the clamp (1) is tightened, it must be ensured

that the maximum permissible installation angle of the
connector (B) relative to the exhaust nozzle (A) is not
exceeded.
The seals and clamps on the exhaust nozzle must be
replaced with new ones each time they are
disassembled.
Bending moment on OM 47x

If the exhaust nozzle is not supported at the engine on
the OM 47x, the body manufacturer must take measures
to limit the permissible bending moment which acts on
the flange of the exhaust gas turbocharger due to the
exhaust pipes.
The permissible bending moment of the exhaust nozzle
(not supported at engine) is 2 Nm.
W49.20-A126-11
A Exhaust nozzle (engine-side exhaust pipe)
Max. permissible installation angle
B Connector (chassis-side exhaust pipe with
decoupling element)
"Engine exhaust gas/chassis" transition point • Push the clamp side with steeper side (2) over the
The exhaust gas is fed from the engine at the transition connector (B) in the direction of the engine.
point "engine exhaust gas/chassis" to the chassis-side • Position the connector (B) with clamp (1) over the
exhaust pipe. exhaust nozzle (A).
Assembly operations on OM 936

On engine OM936, a V-band clamp must be used for
connection to the exhaust nozzle.

1 Clamp
2 Steeper side
B Connector (chassis-side exhaust pipe with decoupling element)
W49.20-A094-01
Structure of connection

exceeded.
disassembled.
decoupling element)
W49.20-A126-11
Max. permissible installation angle
Welding consumable for connector The subsequently used material must be made of the
If the connector is used, Daimler Truck AG recommends same stainless steel as the connector, or of a higher
using the welding consumable alloyed stainless steel.
1.4430(SGX2CrNiMo19-12).

Decoupling element
The exhaust gas line from the transition point "engine
exhaust gas/chassis" up to the transition point "chassis/
exhaust gas aftertreatment unit" must have at least one
decoupling element.
1 Marking on exhaust manifold
2 Marking on decoupling element
W49.20-A154-11
Markings
W49.20-A155-11
Alignment
The following points must be observed when installing • The decoupling element must be aligned coaxially
the decoupling element: with the flange of the exhaust gas turbocharger.
• The flexible pipe section with decoupling element • The permissible mounting angle must not be
must not be installed until after the engine and/or exceeded.
exhaust gas aftertreatment unit has been installed. • The two arrow markings on the decoupling element
• The decoupling element must not exhibit any and engine-side exhaust pipe must be in alignment.
damage on the outer shell.
---------------------------------------------------------------------------
Exhaust pipes must be approved by the relevant contact person (see
To prevent excessive cooling by external influences, the
i uninsulated areas of the exhaust pipe should be
Leaks in piping due to corrosion and possible protected against splash water.
consequential damage to other components of the The length of the exhaust pipe from the connecting point
exhaust system: at the engine to the inlet of the exhaust gas
Prevent the accumulation of condensation and aftertreatment unit is part of the certification.
ingress of moisture. The body manufacturer must
A pipe extension with insulation will be necessary
ensure that the insulation on the piping is dry and
depending on the pipe length between the engine and
leak-tight.
exhaust gas aftertreatment unit. Only pipes with certified
insulation are permitted to be used.
The exhaust pipe between the engine and decoupling Daimler Truck AG provides certified pipe extensions with
element must not be changed. certification number.
The exhaust pipe must be made of stainless steel and Depending on the certificate of the engine, a specified
must be gas-tight and liquid-tight. Fuel loss during active insulation can be used if necessary.
regeneration must be avoided.
Transition point "chassis/exhaust gas aftertreatment
The exhaust pipe must not have any bends on the unit"
following lengths downstream of HC injection of the
At the transition point "chassis/exhaust gas
nozzle unit for DPF regeneration:
aftertreatment unit", the exhaust gas is fed from the
• OM936 with SCS: 100mm chassis-side exhaust pipe to the exhaust gas
• OM47x with MCS: 300mm aftertreatment unit.
To prevent the accumulation of fuel in the exhaust pipe, The body manufacturer must provide a clamp, clamping
a siphon trap in the piping must be avoided. If this is disk and sealing ring for this transition point.
unavoidable for installation reasons, the use of a siphon


Example illustrations
2 Clamp
6 Clamping disk
7 Sealing ring
C Slot in sealing ring
D Slot in clamping disk
E Opening in clamp
W49.20-A097-01
Example illustration of transition point
1 Clamp
2 Clamping disk
3 Seal
4 Exhaust gas aftertreatment unit inlet pipe
5 Exhaust pipe
A Insertion dimension for exhaust pipe (min.
17 mm)
X Transition point "chassis/exhaust gas
aftertreatment unit"
W49.20-A096-10
Transition point in detail
The following points must be observed when carrying disk must be on the exhaust pipe during this
out work on the transition point: procedure.
• The sealing ring, clamp and clamping disk must be • The slot of the clamping disk must be on the same
replaced each time they are disassembled. side as the opening of the clamp.
• When the clamp is installed, the exhaust pipe must • A pipe bend ≥ 90° can be installed after the straight
be aligned coaxially with the inlet pipe. The clamping pipe section of at least 160 mm in length.

Certified pipe extensions

The approved certification number is punched on the
pipe extensions certified by Daimler Truck AG.
During installation, the work and installation instructions
for certified pipe extensions must be observed (see the
"Extension of insulated exhaust gas lines"
document). At least one certification number must
remain on each welded pipe.
The drawing "Specification of exhaust pipe extension"
contained in the certificate contains the specification and W49.20-A098-10
the thermal resistance of the pipe insulation to be used.
If necessary, a pipe extension with insulation can also
be manufactured individually. The body manufacturer is
obliged to provide proof that the insulation specifications
contained in the certificate have been observed.
A pipe bracket must be positioned at the weld joints.
The max. spacing between the pipe brackets is
1100mm.
W49.20-A099-11
Dimensions for pipe extension

Engine Certification External Wall Insulation Piping Pipe bend Mercedes-Benz
number ∅ thickness length radius no.
c d a b
OM 47x RA 2002 130 mm 1.5 mm 15 mm 1000 mm - A 960 490 67 10

2000 mm - A 960 490 68 10
- 180 mm A 960 490 05 23
- 85 mm A 960 490 06 23
OM 936 RA 2005 90 mm 1.5 mm 15 mm 1000 mm - A 960 490 65 10
2000 mm - A 960 490 66 10
- 120 mm A 960 490 03 23
- 60 mm A 960 490 04 23
1) Not insulated
Insulation for pipe extensions thermal resistance of the pipe insulation to be used. This
Depending on the certification of the engine system, the allows a pipe extension with insulation to be
drawing "Specification of exhaust extension" contained manufactured according to the individual requirements of
in the certificate contains the specification and the the system.

Example excerpt from the certificate:
Insulation material with certification number: RA 2002 ¹
Stainless steel foil t = 0.15 mm
Silicate fiber t = 15 mm
1) Optionally thermal resistance of silicate fibers, values correspond to minimum requirements.

Thermal resistance of insulation
℃ 100 200 300 400 500 600 700 800 900
m²K/W 0.042 0.052 0.065 0.082 0.098 0.119 0.148 0.175 0.190
If certified insulation is required, this must be applied to

at least 80 % of the pipe length.

OM 936 Euro VI Standard d (sales code M5C)
Exhaust gas SCS 236 SCS 226/223
aftertreatment
unit
Certification SC2132 SC 2134
Engine output 260 235 220 200 175

[kW]
Length of 0.82 m to No insulation

exhaust pipe ¹⁾ 1.00 m
1.00 m to No insulation
1.51 m
1.51 m to RA 2005 RA 2005 RA 2005 Not permissible Not permissible

2.42 m
2.42 m to RA 2005 RA 2005 RA 2005 Not permissible Not permissible

2.75 m
2.75 m to Not permissible Not permissible Not permissible Not permissible Not permissible
5.50 m
1) Extended length with max. 4 x 90°

OM 936 Euro VI Standard e (sales code M4X)
Exhaust gas SCS 236 SCS 226/223
aftertreatment
unit
Certification SC2159 SC 2161
Engine output 260 235 220 200 175

[kW]
Length of 0.82 m to No insulation

exhaust pipe ¹⁾ 1.00 m
1.00 m to No insulation RA 2005 RA 2005 RA 2005

1.51 m
1.51 m to RA 2005 RA 2005 RA 2005 RA 2005 RA 2005

2.42 m
2.42 m to RA 2005 RA 2005 RA 2005 RA 2005 RA 2005

2.74 m
2.74 m to RA 2005 ²⁾ RA 2005 ²⁾ Not permissible Not permissible Not permissible

3.07 m
3.07 m to Not permissible Not permissible Not permissible Not permissible Not permissible
5.50 m
2) Only permissible with special approval following a successfully completed PEMS measurement

OM 470 Euro VI Standard D (sales code M5C)
Exhaust gas MCS Truck Min. vehicle curb
aftertreatment unit weight
Certification SC 2101
Engine output [kW] 240 265 290 315 335
Length of 0.40 m to 1.10 m No insulation No access

exhaust pipe restrictions
¹⁾
1.10 m to 2.00 m RA 2002 No access
restrictions
2.00 m to 3.50 m Not RA 2002 12 t

permissibl
e
3.50 m to 4.50 m Not permissible RA 2002 24 t
4.50 m to 5.00 m Not permissible RA 2002 24 t


Exhaust gas MCS Truck Min. vehicle curb
aftertreatment unit weight
Engine output [kW] 310 330 350 375 390
Length of 0.50 m to 1.10 m No insulation No access

exhaust pipe restrictions
¹⁾
1.10 m to 2.00 m RA 2002 No access
restrictions
2.00 m to 3.50 m Not RA 2002 12 t

permissibl
e
3.50 m to 4.50 m Not RA 2002 24 t

permissibl
e
4.50 m to 5.00 m Not RA 2002 24 t

permissibl
e

Exhaust gas MCS Truck Min. vehicle curb weight
aftertreatment unit
Engine output [kW] 380 425 46o
Length of 0.40 m to 1.10 m No insulation No access restrictions

exhaust pipe
¹⁾ 1.10 m to 2.00 m RA 2002 No access restrictions
2.00 m to 3.50 m RA 2002 12 t
3.50 m to 4.50 m RA 2002 24 t
4.50 m to 5.00 m RA 2002 24 t

Exhaust gas back pressure consideration here. Modifications to the exhaust pipe
The length and routing of the exhaust pipes influences layout are therefore only permissible within the scope of
the exhaust gas back pressure. The exhaust gas line the boundary conditions described here. Modifications to
between the engine and exhaust gas aftertreatment unit the exhaust tailpipe/exhaust outlet are not permissible.
as well as the exhaust tailpipe must be taken into

Exhaust system, tailpipe to right and outwards,

sales code K7D
The exhaust outlet must not be directed at other
components (e.g. the underride guard). The exhaust
outlet can be adjusted to 0° or 20° by means of three
screws. Additional holes may not be made. If the
exhaust outlet is welded (low frame and low fifth-wheel
coupling), it must not be adjusted.
W49.20-A156-11
Adjustment range of exhaust outlet
Dump truck body heating connection pre- The exhaust outlet is behind the exhaust gas
installation, sales code K7G aftertreatment unit on semitrailer trucks and above it on
This exhaust gas aftertreatment unit is optionally dump trucks.
equipped with an exhaust gas connection for a dump The outlet pipes are flange-mounted and can be
box heater at the top or rear. The hot exhaust gases can exchanged for right-pointing outlets in the summer
be directed from there into the various cavities/firewall of months or when operating in hot countries.
dump truck/dumper semitrailer and into the surrounding
floor ducts.

Version K7G for semitrailer trucks

The exhaust gas aftertreatment unit corresponds to the
exhaust system, tailpipe to right and outwards, sales
code K7D. The K7D adapter for connection of the dump
truck body heating system is also supplied.
The adapter is fastened to the longitudinal frame
member with a bolt and is supplied for the body
manufacturer. The body manufacturer can attach his
exhaust tailpipe to the adapter.
X 1976 (to center of front axle)
Z - 50 (from first upper row of holes of longitudinal
frame member)
P Position of right longitudinal frame member
F Direction of travel
W49.20-A157-11

Version K7G with dump truck chassis
The exhaust gas aftertreatment unit corresponds to the exhaust system,
upward tailpipe, sales code K7A. The tailpipe is provided only for the
purpose of vehicle transfer. An example is shown in the illustration (exhaust
system, upward tailpipe, sales code K7A, on the L cab)
W49.20-A158-02
Exhaust system, upward tailpipe, sales
code K7A, on L cab
Mechanical connection The body manufacturer must ensure that all national
The same fasteners must be used as on production registration and accident prevention regulations are
vehicles. complied with.
The transition from the vehicle exhaust pipe to the inlet A single reuse of the seal and bolts is permissible after
of the dump truck bed heater must be non-contact even the transfer of the vehicle to the body manufacturer. If
under torsion. modified again, the seal and bolts must be renewed.

Connection fitting on exhaust system, tailpipe to right and outwards,

sales code K7D
• Adapter (connecting pipe Ø 130x2): A 960 490 84 21 (mounted on
frame)
• Screws: A 001 990 97 03 (used on flange)
• Seal: A 960 492 03 80 (used on flange)
A single reuse of the seal and bolts is permissible after the transfer of the
vehicle to the body manufacturer. If modified again, the seal and bolts must
be renewed.
W49.20-A159-02
Dimensions of connection fitting on exhaust
system
1 Inner
Clamp: A 942 492 05 40
Bolt: N 910105 010007
Nut: N 913023 010002
W49.20-A160-11
Dimensions of connecting pipe to exhaust gas aftertreatment unit
Recommended material for pipe connection to electronic components. Leakages through which the
adapter: 1.4301 exhaust gas can escape are to be avoided.
The acoustic limits must not be exceeded, even with The minimum clearances for adjacent components and
dump truck body heating. lines must be taken into account (see the "Fire hazard"
Water and bulk cargo must be prevented from entering document).
the exhaust gas aftertreatment unit. The static and dynamic peak loads at the outlet of the
The exhaust gas temperatures at the outlet of the exhaust gas aftertreatment unit must not exceed the
exhaust gas aftertreatment unit can reach 580 °C. values below:
When designing the dump truck body heating system,

always pay attention to the potential risk of heating

FX [N] FY [N] FZ [N] MX [Nm] MY [Nm] MZ [Nm]
Axial Radial Radial Torsional Flexural Flexural
Outlet pipe K7D 1500 1500 1500 450 60 60
Outlet pipe K7A 500 500 500 80 30 40
Decoupling elements may have to be used after the Unless only a short, straight tailpipe extension is used, a
flange in order to guarantee compliance with the decoupling element must always be fitted in the outlet
strength values. pipe of the exhaust gas aftertreatment unit in order to
Any additional connection of the dump truck body meet the described sectional load limit values.
heating system to the exhaust gas aftertreatment unit is
not permitted.
---------------------------------------------------------------------------
Limit values for exhaust gas back pressure The modification should be coordinated in advance with
MCS/SCS Euro VI Standard d the relevant contact person (see document "Advice for
The body manufacturer must ensure that, after body manufacturers").
installation of the dump truck body heating system, the The exhaust gas back pressures and conversion
exhaust gas back pressures described below are not instructions described below must be observed for the
exceeded and that the modification instructions are installation/assembly of the dump box heater.
complied with.
The data for the exhaust gas back pressure limit values
is based on the EC type-approval certificate.

Table for OM 936
Engine Output Exhaust gas back pressure [kPa]
OM 936LA.6-1 260 kW/2200 rpm 32.9 ¹⁾ ²⁾
OM 936LA.6-2 235 kW/2200 rpm 27.3 ¹⁾ ²⁾
OM 936LA.6-3 220 kW/2200 rpm 19.3 ¹⁾ ²⁾
OM 936LA.6-4 200 kW/2200 rpm 18.8 ¹⁾ ²⁾
OM 936LA.6-5 175 kW/2200 rpm 16.6 ¹⁾ ²⁾

1) +1.0 kPa
2) Optionally with exhaust pipe extension +2.0 kPa

Table for OM 470 Euro VI Standard d (sales code M5C)
OM 470LA.6-6 335 kW/1600 rpm 22.1 ¹⁾
OM 470LA.6-7 315 kW/1600 rpm 20.6 ¹⁾
OM 470LA.6-8 290 kW/1600 rpm 18.5 ¹⁾
OM 470LA.6-9 265 kW/1600 rpm 16.8 ¹⁾
OM 470LA.6- 10 240 kW/1600 rpm 14.9 ¹⁾

1) +1.0 kPa

Table for OM 471 Euro VI Standard D (sales code M5C)
OM 471LA.6-8 390 kW/1600 rpm 25.8 ¹⁾
OM 471LA.6-9 375 kW/1800 rpm 24.7 ¹⁾
OM 471LA.6- 10 350 kW/1800 rpm 22.4 ¹⁾

OM 471LA.6- 11
OM 471LA.6- 12 330 kW/1800 rpm 20.6 ¹⁾

OM 471LA.6- 13
OM 471LA.6- 14 310 kW/1800 rpm 18.8 ¹⁾

OM 471LA.6-15
1) +1.0 kPa

Output Exhaust gas back pressure [kPa]
OM 473LA.6-4 460 kW/1600 rpm 34.2 ¹⁾
OM 473LA.6-5 425 kW/1600 rpm 29.3 ¹⁾
OM 473LA.6-6 380 kW/1600 rpm 25.5 ¹⁾

1) +1.0 kPa
Exhaust gas back pressure measurement Preparation of vehicle and engine for measurement
The maximum permissible exhaust gas back pressure is
measured at rated speed and at full load in accordance
with the work instructions. i
Possible fault entry and necessary recalibration in
Procedure for a measurement to determine the vehicles with camera system MPC2:
exhaust gas back pressure with a heated dump box
Cover the camera lens before the test is started on
the chassis dynamometer. Remove the cover again
after the test. If this instruction is ignored, a fault
i entry will occur and the camera system will be shut
Possible shortening of exhaust gas regeneration down.
intervals:
In vehicles with the facility to switch the dump truck
body heating system between summer and winter Remark: The exhaust pipes on vehicles with AdBlue®
operation, the heating must be switched to winter supply are made of stainless steel.
operation before performing the teach-in process. The exhaust gas back pressure value measured at this
Otherwise the system could detect an inadequate measuring point is the one which must be lower than the
back pressure. The changeover between summer value in the certification.
and winter operation can then be made by the
operator without having to consider further actions. Another measuring point, for reference, should be
installed immediately before the inlet to the heated dump
box.
The steps described below must be strictly adhered to in Parameterization of outlet variant
order to ensure that the certification of the affected
vehicles and their engines is not invalidated: The following points must be considered when installing
a dump box heater:
• It is essential that the vehicle be tested on a
dynamometer, generally a roller dynamometer. Roller Variant 1
dynamometers are installed e.g. at certain Bosch The vehicle is equipped ex factory with exhaust system
service centers. with connection for dump truck heating, sales code K7G,
• At least one measuring point, the rated output at and was transferred to the body manufacturer under its
rated speed, must be run up to. These values can be own power. The procedure here is as follows:
obtained from the Bosch service center. • After installation, a Mercedes-Benz Service Partner
• The measurement must be carried out several times: must temporarily parameterize a different exhaust
variant and then parameterize it back to sales code
The measured exhaust gas back pressure with the K7G. A mechanical modification is thus recognized
dumper body lowered (production configuration) must and a new teach-in process is initialized.
always be lower than the value listed in the certification.
If the value is higher, you must contact the Daimler Variant 2
Truck AG department responsible for body/equipment The vehicle is equipped with sales code K7G and was
approval certificates. not transferred under its own power but on a low loader
and the engine was only started for loading and
unloading:
• Initial startup is carried out after installation of the
dump box heater and reparameterization is not
required.
Variant 3

The vehicle was not delivered with sales code K7G • In this case, the Mercedes-Benz Service Partner
(e.g. exhaust system, upward tailpipe, sales code K7A) must perform parameterization to sales code K7G
and was equipped with a dump box heater by the body after installation of a dump truck body heating
manufacturer: system.

Positioning of the measuring point for measuring

the exhaust gas back pressure for OM 936 and
OM 47x
1 Compensator
A Approx. 100 mm ... 20 mm after the
compensator
2 Measuring point: Measuring point connection
M14 x 1.5 Do not install measuring point on
convex or concave surface.
W49.20-A161-11
Exhaust gas back pressure measuring point of OM 936
1 Compensator
A Approx. 100 mm ... 20 mm after the compensator
2 Measuring point: Measuring point connection
M14 x 1.5 Do not install measuring point on
convex or concave surface.
W49.20-A162-11
Exhaust gas back pressure measuring point of OM 47x
Exhaust gas aftertreatment system GATS 2.0, Euro VI Standard
aWarning
aWarning
AdBlue(R)
Fire hazard Page 142
Extension of insulated exhaust gas lines Page 359

Soundproofing Page 53
i i
Possible damage to or detachment of the exhaust Loss of eligibility for registration:
gas aftertreatment unit: The documentation for the exhaust gas
No additional detachable parts may be attached to aftertreatment unit refers specifically to the
the exhaust gas aftertreatment unit or its respective vehicle. The anti-tamper seal and the
components. Make sure that only genuine labels on the filters must not be damaged or
Mercedes-Benz components are used and that the removed. The position of the exhaust gas
components are mounted and secured as described. aftertreatment unit is an essential part of the engine
If the series-production holder is not used, this can and noise certificate. Any modifications, even if they
result in unpredictable effects on the exhaust gas comply with the specifications given in these
aftertreatment unit support structure. This may be guidelines, require the acceptance inspection to be
attributable to, for example, a change in the flow of repeated by the technical service.
forces or in the vibration behavior.

i i
Possible mechanical and electrical damage: Risk of burn injuries for the user or persons in the
Ensure protection against mechanical damage with vicinity:
a stone chipping guard. Ensure protection against Make sure that exhaust gas discharged via the outlet
splash water. Protect connector plug and wiring is cooled down sufficiently or that the outlet area is
harness from water entry. Strain relief of the wiring not accessible to persons.
harness and electrical connectors must be ensured.
Attachment of the wiring harness using a cable tie
must be implemented by the body manufacturer,
taking strain relief into consideration.
i
Fire hazard: If combustible materials (e.g. fluids,
combustible objects or gases) come into contact with
hot parts of the exhaust system or with the exhaust
flow, these materials can ignite. Make sure that the
level of safety provided at the installation space
corresponds to the respective vehicle application
profile. Also observe the document "Risk of fire".
During active regeneration of the diesel particulate
filter (DPF), diesel fuel is injected into the exhaust
gas line. If the exhaust gas line is not leak-tight,
diesel fuel and exhaust gas can escape at high
temperatures. Escaping diesel fuel can ignite. To
avoid this, it is essential to ensure that the piping is
made of stainless steel and that it is gas-tight and
liquid-tight. If the exhaust outlet is covered by the
body (e.g.dropsides) during loading and unloading,
hot exhaust gases can heat up the body. The
exhaust outlet must not be directed at other
components (e.g.the side underride guard).
Otherwise, the engine must be switched off before
loading. This must be noted in the operator's manual
for the body.
---------------------------------------------------------------------------
Exhaust gas aftertreatment unit GATS2.0 (EuroVI d factory. The position of the exhaust gas aftertreatment
emissions standard, sales code M5C) and (Euro VI e unit is an essential part of the engine and noise
emissions standard, sales code M4X) certificate. Any modifications, even if they comply with
All the procedures described here apply to the exhaust the specifications given in these guidelines, require the
gas aftertreatment unit GATS 2.0, code U2G (GATS - acceptance inspection to be repeated by the technical
Global Aftertreatment System). service.
Modifications to the exhaust gas aftertreatment unit

should be avoided. Various versions are available ex

Disassembly of exhaust gas aftertreatment unit and

mounting supports from the longitudinal frame
member
• Disassembly of the exhaust gas aftertreatment unit
and its fasteners requires a clearance of at least
100mm to the bottom edge of the body. This must be
considered especially in combination with bodies
with no subframe (see document "Platform and
swap bodies").
• Disconnect the threaded connections (1) and remove
the exhaust gas aftertreatment unit. The threaded
connections (2) of the mounting supports to the
longitudinal frame member can then be
disassembled.
Do not reuse any disassembled flange head bolts and
nuts. New flange head bolts and nuts must be used.
W49.20-A120-11
Tightening procedure Disassembly of exhaust gas aftertreatment unit
• Tightening torque 225Nm
• Tightening torque 225Nm+torque angle 90°
For information about this, see document "Threaded
and welded connections".
Minimum clearances from exhaust gas dimension is undershot (see the following figure), the
aftertreatment unit to avoid thermal damage adjacent component may have to be disassembled
In order to ensure accessibility for maintenance and additionally during maintenance work. This results in
repair (e.g.replacement of sensors), a minimum distance higher costs and time requirements.
of ≥80mm (a) must be maintained between the exhaust Prerequisite: The adjacent component must be resistant
gas aftertreatment system (exhaust gas aftertreatment to long term temperatures of 80℃. A limit temperature of
unit) and the adjacent component, e.g.fuel tank. If this 60 ℃ applies to batteries.

1 Rear exhaust gas aftertreatment unit cover

2 Example: Fuel tank
a Distance a: ≥50mm
Heat shield required if 50mm<a<150mm
W49.20-A121-11
Maintain the following distances from heat sources: • Heat source with sheet metal shielding and additional
• Exhaust pipe without shielding 200mm insulation 80 mm
• Exhaust gas aftertreatment unit without shielding Minimum clearances must also be observed during
150mm maintenance and repair.
• Heat source with sheet metal shielding 100 mm The following temperature limit values apply for the
components listed below:

Tires 80℃
Brake cylinder 80℃
Brake hoses 80℃
Modifications to the exhaust gas aftertreatment unit These protective metal sheets must be open at
If modifications need to be made, it is essential to the top and bottom and mounted at a distance of
observe the points listed below: approx.100mm from the exhaust gas
aftertreatment unit or its detachable parts. This
• The tailpipe/exhaust outlet directly on the exhaust ensures the required temperature dissipation.
gas aftertreatment unit may not be modified.
• Checking compliance with noise certificate
• Following modification, DaimlerTruckAG cannot
guarantee that the specifications stipulated by law • If the exhaust gas aftertreatment unit is moved, a
and trade associations will be met; the person who side protection device which fulfills the legal
makes the modifications is responsible for this. requirements may have to be attached at this
position.
• If the exhaust routing is changed, the exhaust outlet
must be positioned in such a way that the exhaust • If modification parts not approved by
gas never flows directly over vehicle components and DaimlerTruckAG are used, the exhaust gas and
never heats up these components to a temperature noise certification will be rendered invalid.
higher than 80°C as exhaust gas temperatures of up • Modifications are not permissible to any individual
to 600°C can occur during regeneration mode. The components of the entire exhaust gas aftertreatment
body manufacturer is responsible for ensuring this! system! Only the position of the complete exhaust
• Replacement of the exhaust gas aftertreatment unit gas aftertreatment unit may be changed.
with a different third-party exhaust system is not • Body manufacturers must ensure that the maximum
permitted. permissible component temperatures are observed.
• The exhaust gas back pressure may not exceed the • DaimlerTruckAG cannot provide information on or
maximum permissible limit values for exhaust gas guarantee operational durability. Operational
back pressure. durability must be ensured by the body manufacturer.
• All maintenance tasks (diesel particulate filter • The details concerning part numbers, length
replacement, disconnection of electrical connectors, information and certificates given in the (see section
replacement of sensors, etc.) must be feasible, which "Exhaust gas line between engine and exhaust
is why sufficient accessibility must be guaranteed. If gas aftertreatment unit") must be observed when
necessary, replace the hexagon socket head bolts of extending pipes and with regard to the permissible
the top cover with hexagon head bolts with washers. lengths.
• It is possible to move the exhaust gas aftertreatment • The exhaust gas aftertreatment unit can only be
unit to the left side of the vehicle. In this case, the moved to the area between the last front axle and the
same conditions and specifications given in these front of the first rear axle and on the left or right side
Body/Equipment Mounting Directive apply. The of the vehicle.
following must also be considered: • The exhaust gas should always flow to the outside of
• To protect the exhaust gas aftertreatment unit and the vehicle. Vehicle components such asbrake
its detachable parts against stone chipping, cylinders, tires, axles and lines, must never be
suitable protection (protective metal sheets) must directly exposed to the exhaust flow.
also be fitted to the front and/or rear side of the
exhaust gas aftertreatment unit.

AdBlue® supply
i
Premature wear and possible serious damage to the
engine system:
Installation spaces carrying medium must be clean
when installed. The body manufacturer is
responsible for ensuring that all components that
are modified by them meet the requirements of
technical cleanliness. The AdBlue® temperature
must not exceed 60 ℃ under any operating
conditions.
i W49.20-A100-11
Possible failure of the AdBlue® metering device Illustration showing metering system
(A67):
Ensure the required level of cooling at the injection
nozzle of the AdBlue® metering device (A67).
i
Damage to the pump due to crystallization of
AdBlue®:
Seal the pump module and the separated lines air-
tight and liquid-tight after removal. The maximum
storage time for the sealed pump is 2 months.
AdBlue®circuit - System description

2 Pump module
3 AdBlue®tank
AdBlue® circulates in the line system between the A system run-on is required depending on the
AdBlue® tank (3), pump module (2), AdBlue® metering installation position, operating status and ambient
device (A67) and back to the AdBlue® tank (3). temperature in order to provide adequate cooling.
The AdBlue® metering device (A67) is mounted on the The power supply must be maintained during the entire
exhaust gas aftertreatment unit and is therefore exposed run-on time (max. 45 min). (The length of the run-on time
to high temperatures. can be displayed on the driver's instrument panel. This is
provided as standard on vehicles with battery disconnect
To cool the circuit, AdBlue® therefore circulates switch).
continuously as soon as the engine is started and, if
necessary, for a certain period of time after the engine AdBlue® circuit - Installation specifications
has been stopped (run-on time).


Installation position of components
2 Pump module
3 AdBlue®tank
B74 AdBlue®fill level sensor/temperature sensor
h₁ Height difference on suction side
h₂ Height difference on pressure side
h₃ Height difference at return
W49.20-A101-11
The permissible installation position of the components The permissible pressure loss must not be exceeded.
depends on the line length, the height difference (h1, h₂)
and the line cross-sections.

Requirement Suction line (S)
Line cross-section D 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm 4 mm
(internal)
Line length 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm 4000 mm 5000 mm
Maximum height 500 mm 1000 mm 1200 mm 1200 mm 1200 mm 900 mm 200 mm 0 mm

difference h₁
The body manufacturer must keep the suction line length The length of the suction line can also be shorter than
and the height difference (h1) as small as possible. the minimum specified length.

Line length 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm

Line length 4000 mm 5000 mm 7500 mm 10,000 m 12,500 m 15,000 m

m m m
It is essential to observe the minimum length of the

pressure line.

Requirement Return line (R)
Line cross-section D (internal) 4 mm
Line length 20000 mm
Maximum height difference h₂ 3200 mm
Refer also to the following sections concerning the

AdBlue® lines.
---------------------------------------------------------------------------
AdBlue® lines - Installation specifications • The max. permissible pressure loss must not be
General exceeded.
• There must not be any narrowing of the cross-section • The pressure loss in the line is determined by the line
along the lines. It must be ensured that the lines are cross-section and the line length. If the individual
not pinched or kinked. components are arranged at different heights, this
height difference must be taken into account as an
• The minimum bending radii selected during routing additional pressure difference.
must be such that no narrowing of the cross-section
occurs. • No air or dirt is allowed to enter the system via the
suction line.
• It must be ensured that the lines are secured
correctly; the distance between the fastening points
must not exceed 300 mm.

Suction line
Operating pressure: 0.5 to 1.1 bar absolute
A prefilter with mesh width of min. 100 µm is required in

the fuel tank (already integrated in the delivered
Daimler AdBlue® tank).

Pressure line
Operating pressure: 10 bar
Max. burst pressure: 60 bar
Material: EPDM, NBR

Return line
Technical cleanliness for AdBlue® lines If the pressure line is replaced, the filter of the AdBlue®
metering device must be changed.
The AdBlue® lines are subject to high requirements with
regard to cleanliness. If these requirements are ignored, Lubricants (silicone-based) are not permissible as
it is no longer possible to guarantee reliable operation assembly aids.
and functioning of the AdBlue® circuit.
If the suction line is replaced, the prefilter of the AdBlue®
pump module must be changed.

AdBlue®heating - System description

2 Pump module
3 AdBlue®tank
A4 Engine management control unit (MCM)
A60 Exhaust gas aftertreatment (ACM) control
unit
Y627 AdBlue®heater coolant solenoid valve
C1 Coolant feed from engine
C2 Coolant feed to AdBlue®tank
C3 Coolant feed to pump module
C4 Coolant return to engine
R AdBlue®return line W49.20-A102-11
AdBlue® heater – Installation specifications Heating of AdBlue® lines by means of integrated

coolant lines – Installation specifications
The AdBlue® tank (3) and the pump module (2) are
heated by means of coolant, for which approx. 140 l/h of The AdBlue® lines heated by coolant can be extended in
coolant is removed from the engine cooling system. accordance with the suggestions below.
The vehicles are supplied with coolant-heated AdBlue® It is important to make sure that the coolant line and the
lines. AdBlue® line are lying tight against each other, which
The following basic principle applies: If system can be achieved using, e.g. fabric tape. The attachment
modifications are carried out, the body manufacturer with fabric tape (e.g. A 001 989 63 85) should be carried
out at least every 100 mm or over the entire length.
must ensure the prescribed rapid condensing of AdBlue®
and the subsequent, correct circulation of AdBlue®. It must also be ensured that both lines are additionally
enclosed in a hose (corrugated hose or "zipper hose",
It is essential to ensure:
e.g. from Zipper Technik GmbH). This outer cover or
• Fulfillment of the legal requirements/certification. The hose increases the heat transfer between the two lines.
system must be ready for metering after a defrosting Alternatively, a sleeve with Velcro fastener can also be
time of max. 60 min. used. In all cases, the ends of the outer cover must be
• Cooling of the AdBlue® metering device (A67) and fixed in place using fabric tape and/or cable ties so that
prevention of thermal overloading of the injection the cover cannot move and to maximize the heat
nozzle. transfer between the coolant and the AdBlue® line at
these points.
After extending the lines, the body manufacturer must
ensure that system leak tightness is given.

V Delivery package of connection

components, Kunzer order number HAVS49
(Note: The component assignment supplied by
Willy Kunzer GmbH must also be observed.)
S1 AdBlue®hose A 967 476 05 01
S2 Coolant hose, inside diameter 12 mm, wall
thickness 3.5 mm (Note: Compatibility with the
1-ear clamps supplied with the connection
components (V) is only guaranteed with the
listed hose inside diameter and wall thickness.)
W49.20-A140-11
Extension component overview
The delivery package of connection components (V) can Willy Kunzer GmbH, Römerstrasse 17,
be ordered with the number HAVS49 from 85661 Forstinning, Tel. +49 (0) 8121 220-0.

• • Separate lines with special tool.

• Push outer corrugated pipe back.
• Secure with cable ties to prevent it slipping back.
W49.20-A138-11

W49.20-A139-11
W49.20-A141-12
Double union in special drive-in bushing
• Example: Double union in smooth tube (with an

external diameter of 6 mm), knock in with a sleeve or
similar.
W49.20-A142-10
Double union
W49.20-A143-10
Fitting
• Knock in special bushing.

This bushing also forms the raised bead for the coolant
hose, which is installed over it.
W49.20-A144-11
Fitting in special drive-in bushing
W49.20-A146-11
Push on coolant hose (internal ∅ 12 mm and wall
thickness 3.5 mm) by approx. 20 mm.

W49.20-A145-11
Attach hose clamps
W49.20-A147-10
Protective hoses (insulating hoses)
W49.20-A148-10
Join with fabric tape at least every 100 mm in order to ensure
sufficient thermal contact.
Example:
Protective hose with Velcro:
• A 000 821 06 97, ∅ 30 mm
• A 000 821 05 97, ∅ 40 mm
W49.20-A149-10
Protective hoses (insulating hoses) mounted and secured with
cable ties.
AdBlue® supply • A clearance of 130 mm in a downward direction at an

angle of ±45° from vertical (in all directions) is
AdBlue® tank - Installation specifications necessary for maintenance (detaching and attaching
The AdBlue® tank should only be used in combination filter housing).
with the intended genuine Mercedes-Benz AdBlue® fill • A guard to protect against dirt and stone chippings
level sensor/temperature sensor and the genuine may be necessary.
Mercedes-Benz heater.
General information on attaching/detaching:
If a different tank size (Mercedes-Benz genuine parts
only) is installed, the parameters valid for the new tank • Do not spill any AdBlue®.
must be transferred to the vehicle. Please contact your • Do not allow AdBlue® to come into contact with plug
Mercedes-Benz Service Partner. contacts and plugs.
The surface temperature of the tank must not exceed • Do not place the detached pump module on the
80 ℃. cover; seal the connections.
AdBlue® pump module • Escaping AdBlue® can damage the electrical plug
contacts.
AdBlue® pump module - Installation specifications
Attaching pump module
Temperatures
The standard holder of the pump module is attached to
Operating temperatures: ₋40 ℃ to +85 ℃ the vehicle frame with two M16 screws (see document
"Threaded and welded connections")
• The holder is bolted to the frame.
• The filter housing must face downward.
• The pump module is mounted to the holder with two
• ±45° in all directions is permissible. vibration dampers and secured using two screws.

Bolts: M8×25 (for 5 mm holder)
Classification: 8.8
Torque: 18 Nm ±20 %
If the standard holder has to be replaced, it must be version and fastened to the vehicle frame/body
dimensioned in the same way as the factory supplied accordingly.
---------------------------------------------------------------------------
Exhaust gas aftertreatment unit
The following basic variants are used.


Exhaust gas aftertreatment unit table
Engine Exhaust certification Exhaust gas aftertreatment unit Equipment
OM 470 Euro VI standard U2G 1 diesel oxidation catalytic converter

OM 471 1 diesel particulate filter
OM 473 2 SCR catalytic converters
2 ammonia slip catalytic converters
Function using cable ties, taking strain relief into consideration.

In the vehicle, the exhaust gas aftertreatment unit is the (120‑pin plug by means of holder bolted to the control
primary component for limiting pollutant emissions. In its unit).
function as muffler, it also ensures that noise emissions • The control unit must be installed above the fording
remain within the legally prescribed limits. line.
Exhaust gas aftertreatment control unit Electric lines and electrical connectors to the
Location exhaust gas aftertreatment unit control unit
The ACM (exhaust gas aftertreatment control unit (A60)) Depending on the vehicle model designation used, the
is rigidly attached to a holder on the exhaust gas wiring harnesses are dimensioned so that one wiring
aftertreatment unit. harness can be used for different wheelbases. For this
reason, the body manufacturer must check whether,
Installation specifications after the cable ties have been removed, the wiring
harnesses routed in the frame can possibly be used for
Temperatures
the newly selected position of the components.
Ambient temperature of control unit:
If it is necessary to change the length of the wiring
- 40 ℃ ... max. 85 ℃ (body manufacturer must ensure harnesses, however, the specifications in the Body/
that sufficient air cooling is provided) Equipment Mounting Directives (see document
"Extending electric lines"), and alternatively the
Electrical connection specifications stored in the Workshop Information
39-pin plug to exhaust gas aftertreatment control unit System (WIS) must be observed.
Installation position Variant 1

• Maximum protection against mechanical damage is CAN line (between plug of exhaust gas
necessary. aftertreatment unit control unit and cab/chassis
• Ensure stone chipping protection. interface FF)
• Ensure protection against splash water. The CAN line (four-core twisted-pair cable) may not be
subsequently extended. If a different length is required,
• Protect connector plug and wiring harness from water
the existing CAN lines must be replaced by new lines.
entry.
• Wiring harness strain relief must be ensured. The
body manufacturer must attach the wiring harness
---------------------------------------------------------------------------
Electric lines (between exhaust gas aftertreatment into account the work instructions and specifications
unit control unit plug and existing vehicle wiring (see document "Extending electric lines") or
harness) alternatively the specifications for repair and extension of
All electrical feed lines (with the exception of CAN lines) wiring harnesses stored in the Workshop Information
to the electrical connector of the exhaust gas System (WIS).
aftertreatment unit control unit may be extended, taking

W49.20-A122-79
1 Exhaust gas aftertreatment control unit electrical 4 CAN line A 000 540 83 27, four-core, twisted,
connector, 39-pin (partially assigned) number of twists/m: 30. The line lengths of all CAN
lines must be the same. The maximum
permissible length of the CAN line is 7800 mm.
2 Vehicle line electrical connector 39‑pin (partially 5 Existing lines from vehicle cable set
assigned), receptacle housing A 028 545 60 26,
cover A 002 545 31 83, contact + seal 2.5 mm²
A 014 545 79 26 + A 000 545 29 39, contact +
seal 0.75 mm² A 014 545 80 26 + A 000 545 28 39
3 FF connecting point X52‑40‑pin, 6 Corrugated hose, cable tie
contact 0.75 mm²A 005 545 76 26
Electric lines (between exhaust gas aftertreatment Variant 2

unit control unit plug and existing vehicle wiring Alternatively to the procedure described in Variant 1, it is
harness) also permissible to install an appropriate adapter cable
All electric feed lines (with the exception of CAN lines) to ("extension cable") between the control unit – exhaust
the electrical connector of the exhaust gas system electrical connector and the electrical connector
aftertreatment unit control unit may be extended, taking of the vehicle wiring harness.
into account the work instructions and specifications • This adapter cable ("extension cable") is to be
(see document "Extending electric lines") or fabricated to the required length using the
alternatively the specifications for repair and extension of components listed below and in compliance with the
wiring harnesses stored in the Workshop Information parameters described, and installed and
System (WIS). appropriately fastened by the body manufacturer.


1 Exhaust gas
aftertreatment
control unit
electrical
connector, 39-pin
(partially assigned)
2 Adapter line
electrical connector
39 pin (partially
assigned),
receptacle
housing A 028 545
60 26, cover
A 002 545 31 83,
contact + seal 2.5
mm²
A 014 545 79 26 +
A 000 545 29 39,
contact + seal 0.75
mm²
A 014 545 80 26 +
A 000 545 28 39,
dead end plug W49.20-A163-76
A 000 545 62 80 for
all remaining
unassigned contact
cavities
3 Adapter line
electrical connector
39-pin (partially
assigned), mating
connector A 058 54
5 94 28,
cover A 002 545 31
83,
contact + seal 2.5
mm² A 014 545 79
26 +
A 000 545 29 39,
contact + seal
0.75 mm² A 014 54
5 80 26 + A 000 54
5 28 39,
dead end plug A 00
0 545 62 80 for all
remaining
unassigned contact
cavities
4 Electrical
connector, existing
vehicle wiring
harness to exhaust
gas aftertreatment
unit electrical
connector, 39 pin
(partially assigned)
5 CAN line
A 000 540 83 27, 4-
core, twisted,
number of twists/m:
30. The line lengths
of all CAN lines
must be the same.
The maximum
permissible length
of the CAN line is
7800 mm.
6 Corrugated
hose "17" A 004 54
6 35 30, cable
tie A 002 997 68 90
2+3+5+6 Adapter line fully
assembled by body
manufacturer
Sensors • The mounting supports must not be fixed in the

It is not permissible to change the (installation) position center of the longitudinal member (diaphragm effect).
of the sensors on the exhaust gas aftertreatment unit. The screw connections must be positioned at the top
and bottom row of holes in the longitudinal member.
Exhaust gas aftertreatment unit operational (Make the connections using series-production
durability - Installation specifications mounting supports corresponding to the series-
production configuration!)
If the exhaust gas aftertreatment unit is moved,
Daimler Truck AG is unable to make any statement The information in the document "Installation of
regarding its operational durability. The body compressors" regarding the installation of compressors
manufacturer is therefore responsible for providing applies equally to the installation of the exhaust gas
information on service life. aftertreatment unit.
• Attachment is carried out with the approved genuine
Other notes:
Mercedes-Benz mounting support. The shims and
• Lifting the vehicle, e.g. using a vehicle jack, salvage inner reinforcement plates must also be reused.
crane, at the exhaust gas aftertreatment unit is not
• Fastening the mounting supports to the longitudinal
permissible.
frame member (see document "Threaded and
• It is not permitted to stand on the exhaust gas welded connections")
aftertreatment unit.
• The fastening must be carried out via the defined and
• If the exhaust gas aftertreatment unit is installed at secured screw-on points on the exhaust gas
exposed positions, it is important to note that these aftertreatment unit.
positions are not suitable for bearing loads which
• Make sure that the components are in perfect
occur, e.g. in the case of impacts or when obstacles
condition when attaching.
are set down on or are dragged against the unit. The
unit must therefore be provided with sufficient • Make sure that the contact surfaces of the
protection if installed at exposed positions on the components are clean.
vehicle! • Make sure that the components are attached and
• Welding and other modifications (drill holes, etc.) on secured correctly before the exhaust gas
the exhaust gas aftertreatment unit are not aftertreatment unit is mounted to the vehicle and that
permissible. the mounting points are designed for the intended
purpose.
Mounting to the vehicle longitudinal frame member
Installation position and incline angle of exhaust gas
• Attachment is only permissible at the secured
aftertreatment unit in vehicle
mounting points and using the series-production
bracket. Only the mounting supports available from It is not permitted to perform installation at a position
Mercedes-Benz are permissible. rotated about the X and Y-axis. Rotation about the Z-
axis is only permitted by 180°. In the case of installation
• To ensure that force influences, e.g. torsion from the
rotated about the Z-axis, it is important to note that the
chassis, are not transferred to the unit, the mounting
local coordinates system must also be rotated
supports must be attached to the longitudinal
accordingly.
member.


Definition of vehicle coordinates system:
x Positive in vehicle longitudinal direction
y Positive from right to left (viewed in direction of travel)
z Positive in upward direction
W49.20-A103-01
Attachment of detachable parts to exhaust gas • Exhaust pipe connections (clamp connections) must
aftertreatment unit be gas-tight.
Additional points of load application resulting from • In order to avoid possible thermal runaway,
additional detachable parts are generally not permitted. appropriate covers, seals or trim must be installed on
Exceptions are specifically approved series-production the body side.
detachable parts: Surface temperatures of exhaust gas aftertreatment
• Heat shields unit.
• Exhaust baffles The following exhaust gas temperatures and mass flows
correspond to an OM 471 engine variant in the typical
• Front fastening points for side protection device truck application.
Temperatures at the exhaust gas aftertreatment unit The information applies to, e.g.:
Owing to the high temperatures and the high heat • Free-standing unit without detachable parts, e.g. heat
retaining capacity, it is important to observe the following shield, contact guard
points: • Ambient temperature < 25 ℃
• The exhaust gas aftertreatment unit must not come The insulation must be designed such that, under the
into contact with combustible objects, fluids or gases. above-mentioned boundary conditions, a max. surface
• If combustible objects, fluids or gas are located temperature of approx. 250 ℃ is not exceeded even in
above or close to the exhaust gas aftertreatment unit, the case of full-load operation and/or correctly performed
appropriate measures must be taken to ensure that active DPF regeneration.
the temperature of these materials remains at a non- Exceptions are areas with limited insulation, e.g. at joints
critical level. and sensor positions. These areas can reach surface
• When the exhaust gas aftertreatment unit is installed, temperatures of up to 480 ℃. This also applies to the
it must be ensured that adequate free convection of area at the service flap. Additionally, in this area and in
cool ambient air is provided in order to prevent the area around the rear mounting point, air heated up to
overheating of components on the unit and in the 480 ℃ can be discharged from the inside.
surrounding area. Owing to the high heat capacity, the surface temperature
If in doubt, observance of the maximum temperatures also remains at a high level for a relatively long time
must be ensured by implementing appropriate after operation. This also applies to the exhaust outlet
measures, and this must be verified by means of temperature.
appropriate measurement. This particularly applies in It is important to note that additional detachable parts,
the case of restricted installation space and if such as heat shields, or installation in a space with
additional components are attached to the unit, limited ventilation increase the temperatures
e.g. contact guards. considerably. This can result in permissible
• Particular attention must be paid to operating ranges temperatures of the detachable parts being exceeded.
with high load and to the active regeneration of the This must be avoided by implementing appropriate
diesel particulate filter (DPF). measures.
• Maintenance operations must only be carried out
when the system is cold (including removal of service
flap).

W49.20-A124-82
Example of an exhaust gas aftertreatment unit with typical surface
temperatures at full load
Temperatures of the exhaust flow

Exhaust gas temperatures in relation to the lateral outer
surface of the exhaust gas aftertreatment unit:

Typical temperature ranges at exhaust outlet:
Range 120 ℃ Range 250 ℃
Stationary regeneration at v = 0 m/h Up to approx. 100 cm Up to approx. 40 cm
Full load at v = 30 km/h Up to approx. 110 cm Up to approx. 60 cm
Temperature limit values for electrical detachable

parts
Maximum ambient temperatures:

NOx sensor
Exhaust gas aftertreatment unit NOx sensor control –40 ℃ ... 105 ℃
unit
Exhaust gas aftertreatment unit NOx sensor cable –40 ℃ to 200 ℃

Temperature sensor
Flat plug housing –40 ℃ to 120 ℃
Electric line and corrugated pipe –40 ℃ to 260 ℃
Exhaust gas aftertreatment control unit –40 ℃ to 85 ℃
Pressure sensors –40 ℃ to 125 ℃
The actual alignment of the exhaust flow and the gases do not pose a hazard for the surrounding area.
occurring temperatures are influenced by the outlet Here, the actuated load points, the local conditions
variant, the ambient boundary conditions (wind, and the wind situation must be taken into
temperatures, etc.) as well as the vehicle model consideration. It must also be ensured that active
(e.g. ground clearance) and the vehicle speed. regeneration can take place when the vehicle is
• When the power take-off is in operation, it is stationary.
important to ensure that the discharged hot exhaust
---------------------------------------------------------------------------
Exhaust gas line between engine and exhaust gas element must be installed immediately upstream
aftertreatment unit of the exhaust gas aftertreatment unit.
The following aspects must be taken into consideration • Permissible sectional loads on exhaust gas
for the connection: aftertreatment unit
• Modifications to the factory-fitted exhaust pipe layout • Use of certified pipe extensions or, alternatively, use
are only permissible downstream of the decoupling of specified insulation and observance of permissible
element (EKE). pipe lengths
• The vehicle-side component parts must be • Work and installation instructions for processing
decoupled from the engine-side component parts. certified pipe extensions (see document "Extension
• To compensate for stress in static and dynamic of insulated exhaust gas lines")
mode, the genuine Mercedes-Benz decoupling • Compliance with exhaust gas back pressure limits
element must be installed downstream of the • Possible surface temperatures are approx. 110℃ at
transition point. It must be ensured here that the the insulated exhaust gas line, approx. 300℃ at the
decoupling element is not overloaded in its static uninsulated exhaust gas line and approx. 200℃ at
and dynamic working range. the decoupling element.
• The free inertial forces introduced at the engine • The exhaust must be routed such that the max.
must be kept as small as possible. For permissible temperatures of the adjacent
example, the exhaust pipe on the chassis components parts are not exceeded (frame wiring
downstream of the decoupling element must be harness: 100℃, compressed-air line: 120℃,
fixed to the chassis for pipe lengths of 1000mm compressed-air connector: 100℃, transmission
and longer (incl. decoupling element). control unit: 80℃ (further limit values available on
• With a pipe length of 2000mm or longer (without request).
decoupling elements), a second decoupling

Overview of transition points along exhaust gas

line
A Engine
C Vehicle frame
1 Transition point "engine/exhaust pipe"
2 Decoupling element (EKE)
3 Connection "decoupling element to exhaust pipe"
4 Transition point "exhaust pipe/exhaust gas
aftertreatment unit" W49.20-A125-10
5 Second decoupling element, if required

Overview of clamps and connections
Item Part designation Part designation OM OM 473 or OM 470/471
470/471 with C7Q and/or 4-axle
vehicle with 2 front axles
1 V-band clamp (no seal A 001 995 92 02, A 001 995 52 02,
necessary) A 629 493 02 80 A 960 492 05 80
2 Decoupling element A 960 492 40 59 ¹⁾ A 960 492 41 59 ²⁾
3 Welded connection (V-seam)
4 Parts kit (clamp, clamping LU A 003 995 62 02

disk, sealing ring)
1) The decoupling element (D100/A 960 492 40 59) is installed at the factory in combination with D100 pipes. This decoupling element
and the exhaust pipes with D100 must not be modified. An extension is only permissible after the factory-supplied conical pipe flare to
D120 with D120 pipes. If a second decoupling element is required, use decoupling element D120/A 960 492 41 59.
2) Not available as an individual replacement part (i.e. the item number cannot be obtained individually from the Mercedes Benz Service
Partner). The part can be taken from, e.g., the exhaust gas line assembly with item number ZB A 961 490 16 52.
"Engine exhaust gas/chassis" transition point Connection to exhaust nozzle

The exhaust gas is fed from the engine at the transition A decoupling element is screwed directly to the exhaust
point "engine exhaust gas/chassis" to the chassis-side nozzle.
exhaust pipe.

Assembly operations on OM 47x

On engine OM47x, a V-band clamp must be used for connection to the
exhaust nozzle.
• Place the seal (4) over the exhaust nozzle (5). Push the clamp side with
the folded edge (2) over the connector (3) in the direction of the engine.
• Position the connector (3) with clamp (1) over the exhaust nozzle (A).
1 Clamp
2 Folded edge
3 Connector (chassis-side exhaust pipe with decoupling element)
4 Seal N49.10-A004-01
5 Exhaust nozzle (engine-side exhaust pipe) Structure of connection

exceeded.
Tightening torques:
Clamp diameter 130 mm: 25 Nm
Diameter 100 mm: 14 Nm
disassembled.
Bending moment on OM 47x

If the exhaust nozzle is not supported at the engine on
the OM 47x, the body manufacturer must take measures
to limit the permissible bending moment which acts on
the flange of the exhaust gas turbocharger due to the W49.20-A126-11
exhaust pipes. Max. permissible installation angle
The permissible bending moment of the exhaust nozzle
(not supported at engine) is 2 Nm.
decoupling element)
Decoupling element (EKE)

The exhaust gas line from the transition point "engine
exhaust gas/chassis" up to the transition point "chassis/
exhaust gas aftertreatment unit" must have at least one
decoupling element.
W49.20-A127-11
Example: Pipe routing and position of decoupling element for OM
470/471
The following points must be observed when installing • The two arrow markings on the decoupling element
the decoupling element: and engine-side exhaust pipe must be in alignment
• The flexible pipe section with decoupling element (OM 473).
must not be installed until after the engine and/or • The decoupling element must be installed when
exhaust gas aftertreatment unit has been installed. straight (no bending, no S-shape deformation, no
• The decoupling element must not exhibit any torsion). The length must be measured at 3 positions
damage on the outer shell. distributed around the circumference between the
inner edges of the outer rings (installation control
• The decoupling element must be aligned coaxially dimension of decoupling element).
with the flange of the exhaust gas turbocharger.
This exhaust gas aftertreatment unit uses 2 decoupling
• The permissible angle of ±2° may not be exceeded. elements:
• D100/A 960 492 40 59: 234 mm ± 3 mm • D120/A 960 492 41 59: 234 mm ± 3 mm

W49.20-A128-03
Example: Pipe routing and position of
decoupling element for OM 473
1 Marking on exhaust manifold

2 Marking on decoupling element
W49.20-A154-11
Example: Markings

The decoupling element (D100/A 960 492 40 59) is installed at the factory
in combination with D100 pipes. This decoupling element and the exhaust
pipes with D100 must not be modified. An extension is only permissible
after the factory-supplied conical pipe flare to D120 with D120 pipes. If a
second decoupling element is required, use decoupling element D120/
A 960 492 41 59.
N49.10-A003-01
Example: Measure decoupling element
Exhaust pipes The length of the exhaust pipe from the connecting point
at the engine to the inlet of the exhaust gas
aftertreatment unit is part of the certification.
i A pipe extension with insulation will be necessary
Leaks in piping due to corrosion and possible depending on the pipe length between the engine and
consequential damage to other components of the exhaust gas aftertreatment unit. Only pipes with certified
exhaust system: insulation are permitted to be used.
Prevent the accumulation of condensation and Daimler Truck AG provides certified pipe extensions with
ingress of moisture. The body manufacturer must certification number.
ensure that the insulation on the piping is dry and
If necessary, the specified insulation can optionally be
leak-tight.
used to produce your own insulated pipes (also see the
information on insulation for pipe extensions on the
following pages).
The exhaust pipe between the engine and decoupling
element must not be changed. Transition point "chassis/exhaust gas aftertreatment
The exhaust pipe must be made of stainless steel and unit"
must be gas-tight and liquid-tight. Fuel loss during active At the transition point "chassis/exhaust gas
regeneration must be avoided. aftertreatment unit", the exhaust gas is fed from the
The exhaust pipe must not have any bends over a length chassis-side exhaust pipe to the exhaust gas
of 300 mm downstream of the HC injection point (of the aftertreatment unit.
nozzle unit for DPF regeneration). The body manufacturer must provide a clamp, clamping
To prevent the accumulation of fuel in the exhaust pipe, disk and sealing ring for this transition point.
a siphon trap in the piping must be avoided. If this is Tightening torque:
unavoidable for installation reasons, the use of a siphon
Clamp diameter 120 mm: 20 Nm
must be approved by the relevant contact person (see
To prevent excessive cooling by external influences, the
uninsulated areas of the exhaust pipe should be
protected against splash water.

Example illustrations
2 Clamp
6 Clamping disk
7 Sealing ring
C Slot in sealing ring
D Slot in clamping disk
E Opening in clamp
W49.20-A097-01
Example illustration of transition point
1 Clamp
2 Clamping disk
3 Seal
4 Exhaust gas aftertreatment unit inlet pipe
5 Exhaust pipe
A Insertion dimension for exhaust pipe (min. 17mm)
X Transition point "chassis/exhaust gas
aftertreatment unit"
W49.20-A096-10
Transition point in detail
The following points must be observed when carrying disk must be on the exhaust pipe during this
out work on the transition point: procedure.
• The sealing ring, clamp and clamping disk must be • A pipe bend ≥90° can be installed after the straight
replaced each time they are disassembled. pipe section of at least 160 mm in length.
• When the clamp is installed, the exhaust pipe must
be aligned coaxially with the inlet pipe. The clamping

A straight pipe section (A-B) must be installed over

≥160 mm upstream of the "exhaust gas inlet/exhaust
gas aftertreatment unit" interface. In this minimum
length, an angle of up to 17° in all directions is
permissible.
W49.20-A132-11

Certified pipe extensions
The approved certification number is punched on the
pipe extensions certified by Daimler Truck AG.
During installation, the work and installation instructions
for certified pipe extensions must be observed see
document "GA49.10-W-0002-01B". At least one
certification number must remain on each welded pipe.
The drawing "Specification of exhaust pipe extension"
contained in the certificate contains the specification and
the thermal resistance of the pipe insulation to be used. W49.20-A098-10
If necessary, a pipe extension with insulation can also
be manufactured individually. The body manufacturer is
obliged to provide proof that the insulation specifications
contained in the certificate have been observed.
A pipe bracket must be positioned at the weld joints.
The max. spacing between the pipe brackets is
1100mm.
W49.20-A099-11
Dimensions for pipe extension
The "calibrated" pipe extension or a comparable

calibrated pipe section must be used at the transition
point to the exhaust gas aftertreatment unit.
In order to keep the exhaust gas back pressure as low
as possible, we recommend using pipe bends with a
large radius A 960 490 14 23.
• A pipe bracket must be positioned at the weld joints.
The maximum permissible spacing between the pipe
brackets is 1100 mm.
W49.20-A133-12
Dimensions of "calibrated" pipe extension (uninsulated)

Engine Certification External Wall Insulation Piping Pipe bend Mercedes-Benz
number ∅ thickness length radius no.
c d a b
OM 47x RA 2021 120 mm 1.5 mm 15 mm 200 mm - A 960 492 73 90

1000 mm - A 960 490 87 50
2000 mm - A 960 490 88 50
- 80 mm A 960 490 15 23
- 196 mm A 960 490 14 23
1) Not insulated

Example excerpt from the certificate:
Insulation material with certification number: RA 2021
Stainless steel foil t = 0.15 mm
Silicate fiber / fiberglass mat -

Thermal resistance of insulation
℃ 50 200 300 400 500
m²K/W 0.333 0.25 0.183 0.144 0.109

Permissible pipe lengths between engine and The pipe bends must be taken into account in the
exhaust gas aftertreatment unit overall extended length.
The permissible pipe length for exhaust pipes between • The pipe length must not be shorter than the
the engine and exhaust gas aftertreatment unit is: specified minimum length and must not be longer
• dependent on the engine output than the specified maximum length.
• dependent on the pipe version (without insulation or • The max. permissible sum of angles of 450° (5x90°)
with certified insulation) must be observed.
• dependent on the pipe routing (number of bends and • Noncompliance with the specifications described
max. permissible sum of angles) here will render the certificate invalid.
• certification-relevant The required insulation must be observed but can also

be exceeded.
The following assumptions apply as the basis for the
max. pipe lengths listed in the tables: This means, e.g. that in the case of an application for
which no insulation is required, it is possible to use
• The pipe length applies between the transition point exhaust pipes with insulation in order to reduce heat
"engine exhaust/chassis" and the transition point dissipation to surrounding components.
"chassis/chassis exhaust gas aftertreatment unit".

Table of permissible pipe lengths between engine and exhaust gas aftertreatment unit Euro VI Standard d
(sales code M5C)
Engine OM 470 Euro VI-D OM 471 Euro VI-D OM 473 Minimum
Euro VI-D vehicle
curb weight
Major D470.913 D470.913 D471.926 D471.926 D471.926 D473.909

assembly D470.921 D470.921 D471.944 D471.944 D471.944 D473.919
model
designation
Exhaust box GATS 2.0 GATS 2.0 GATS 2.0 GATS 2.0 GATS 2.0 GATS 2.0
Truck Truck Truck Truck Truck Truck
Certification SC2142, SC2142, SC2143, SC2143, SC2143, SC2143,

no. SC2148 SC2148 SC2149 SC2149 SC2149 SC2149
of exhaust box
Output 240‑265 290‑335 310‑330 350 kW 375‑390 380‑460

variant kW kW kW kW kW
Exhaust pipe 0.40m -1.00 m Optional insulation No access

length restrictions
between
engine outlet 1.00m – 1.50m RA 2021²⁾ RA 2021²⁾ RA 2021²⁾ RA 2021²⁾ RA 2021²⁾ RA 2021 No access
and exhaust restrictions
box inlet ¹⁾
1.50m – 3.00m RA 2021 RA 2021 RA 2021 RA 2021 RA 2021 RA 2021 No access
restrictions
3.00m – 4.00m Not RA 2021 Not RA 2021 RA 2021 RA 2021 12 t

permissibl permissibl
e e
4.00m – 5.00m Not RA 2021 Not RA 2021 RA 2021 RA 2021 24 t

permissibl permissibl
e e
1) Between engine outlet and exhaust gas aftertreatment unit inlet. Extended length with max. 5 x 90° pipe bends.
2) Ex factory scope, D=100 mm

Table of permissible pipe lengths between engine and exhaust gas aftertreatment unit Euro VI Standard e
(sales code M4X)
Engine OM 470 Euro VI-E OM 471 Euro VI-E OM 473 Minimum
Euro VI-E vehicle
curb weight
Major D470.913, D470.915, D471.926, D471.937, D473.909,

assembly D470.921, D470.929 D471.944, D471.946 D473.919
model
designation
Exhaust box GATS 2.0 GATS 2.0 GATS 2.0 GATS 2.0 GATS 2.0
Truck Truck Truck Truck Truck
Certification SC2142 SC2142 SC2143 SC2143 SC2149

number of
exhaust box
Output 240‑265 kW 290‑335 kW 310‑330 kW 375‑390 kW 380‑460 kW

variant
Exhaust pipe 0.40m -1.00 m Optional insulation No access

length restrictions
between
engine outlet 1.00m – 1.50m RA 2021²⁾ RA 2021²⁾ RA 2021²⁾ RA 2021²⁾ RA 2021 No access
and exhaust restrictions
box inlet ¹⁾
1.50m – 3.00m RA 2021 RA 2021 RA 2021 RA 2021 RA 2021 No access
restrictions
3.00m – 4.00m Not RA 2021 Not RA 2021 RA 2021 12 t

4.00m – 5.00m Not RA 2021 Not RA 2021 RA 2021 24 t


Table of permissible pipe lengths between the engine and the exhaust gas aftertreatment unit Euro VI
Standard E (sales code M4X) without exhaust gas turbocharger with optimized fuel consumption (sales code
M6E)
Engine OM 471 Euro VI-E Minimum vehicle
curb weight
Major assembly D471.943

model
designation
Exhaust box GATS 2.0 Truck
Certification SC2154
number of
exhaust box
Output 310kW/2100Nm 330kW/2400Nm³⁾ 350kW/2500Nm³⁾

variant 310kW/2300Nm³⁾ 375kW/2500Nm 390kW/2600Nm
330kW/2200Nm
350kW/2300Nm
Exhaust pipe 0.40m -1.00 m Optional insulation No access restrictions

length between
engine outlet 1.00m – 1.50m RA2021 (RA2022)²⁾ No access restrictions
and exhaust
box inlet ¹⁾ 1.50m – 3.00m RA2021 No access restrictions
3.00m – 4.00m Not permissible RA2021 RA2021 12 t
4.00m – 5.00m Not permissible Not permissible RA2021 24 t

3) With code M0E, torque increase in 12th gear

Table of permissible pipe lengths between the engine and the exhaust gas aftertreatment unit Euro VI
Standard E (sales code M4X) with exhaust gas turbocharger with optimized fuel consumption (sales code
M6E)
Engine OM 471 Euro VI-E Minimum vehicle
curb weight
Major assembly D471.943

model
designation
Exhaust box GATS 2.0 Truck
Certification SC2154
number of
exhaust box
Output 310kW/2100Nm 310kW/2300Nm³⁾ 330kW/2400Nm³⁾

variant 330kW/2200Nm 350kW/2500Nm³⁾
350kW/2300Nm
Exhaust pipe 0.40m -1.00 m RA2021 (RA2022)²⁾ Optional insulation Optional insulation No access restrictions
length between
engine outlet 1.00m – 1.50m RA2021 (RA2022)²⁾ No access restrictions
and exhaust
box inlet ¹⁾ 1.50m – 3.00m Not permissible Not permissible RA2021 No access restrictions
3.00m – 4.00m Not permissible 12 t
4.00m – 5.00m Not permissible 24 t

3) With code M0E, torque increase in 12th gear
Permissible angle sum between engine and exhaust Modifications to the exhaust pipe layout are therefore
gas outlet from the exhaust tailpipe. only permissible within the scope of the boundary
The max. permissible sum of angles of 810° (9 x 90°) conditions described here. Modifications to the exhaust
must be observed. There must be an exhaust outlet element are not permissible. It is the responsibility
backpressure measurement if the max. angle sum is of the body manufacturer to check the eligibility for
exceeded. registration, e.g. with regard to compliance with noise
regulations.
The length and routing of the exhaust pipes also
influence the exhaust gas back pressure. The exhaust Exhaust system, tailpipe to right and outwards,
gas line between the engine and exhaust gas sales code K7D
aftertreatment unit up to the exhaust outlet must be
taken into consideration here.


Variant 1:
Not permissible in combination with live power take-off
code N4W, N4X/N4Y/N4Z and/or semitrailer trucks with
factory-fitted side trim.
As-delivered state ex factory:
1+3 M8 threaded connections (tightening
torque: 18 Nm)
2 Accessory holder (standard)
4 Connecting clamp on the connecting
flange (tightening torque: 51 Nm) W49.20-A164-10
Exhaust system, sales code K7D (standard)
For special combinations (e.g. all-wheel drive vehicles For an inclination of 30°, a extended holder (5) can be
and/or oversize tires with side protection devices), it may procured via the Mercedes-Benz Service Partner under
be necessary to increase the ex-factory tailpipe the part number A 960 490 78 71 and installed in place
inclination of 15° in order to prevent the exhaust stream of the factory-fitted holder. The ex-factory M8 threaded
from flowing directly onto other components (e.g. side connections (1+3) and the connecting clamp on the
protection devices). connecting flange (4) can be reused.

W49.20-A165-01
Accessories for extended holder,
A 960 490 78 71
After the conversion, a minimum distance "A" of

≥ 320 mm must be ensured (measured with the vehicle
stationary and loaded to the maximum permissible gross
mass).
A Distance from ground to bottom of outside edge
of shield
B Ground
W49.20-A167-11
Exhaust system, sales code K7D, dimensions with extended
holder
Version 2:
Semitrailer truck with factory-fitted side trim.
Changing the position or design of the tailpipe is not
permissible.
1 Exhaust tailpipe
2 Side trim
W49.20-A169-11
Example of exhaust system, sales code K7D (factory-fitted side
trim)
Exhaust system, tailpipe to right and outward,

horizontal sales code K8D
Changing the position or design of the tailpipe is not
permissible.
1 Exhaust tailpipe
W49.20-A300-11
Example of exhaust system, sales code K8D (standard with live
power take-off code N4W/N4X/N4Y/N4Z)
Dump truck body heating connection pre- 2 and 3-axle chassis

installation, sales code K7G 2 and 3-axle chassis version K7G with dumper chassis:
This exhaust gas aftertreatment unit is optionally The exhaust gas aftertreatment unit corresponds to the
equipped with an exhaust gas connection for a dump exhaust system variant with upward tailpipe, sales code
box heater at the top or rear. The hot exhaust gases can K7W.
be directed from there into the various cavities/firewall of
dump truck/dumper semitrailer and into the surrounding The tailpipe section serves, among other things, for the
floor ducts. transfer of the vehicle and can be used as a basis for the
subsequent pipe extension.
The exhaust outlet is behind the exhaust gas
aftertreatment unit on semitrailer trucks and above it on
dump trucks.
The outlet pipes are flange-mounted and can be
exchanged for right-pointing outlets in the summer
months or when operating in hot countries.


W49.20-A170-11
W49.20-A171-11
Version K7G for semitrailer trucks

The exhaust gas aftertreatment unit corresponds to the
exhaust system, exhaust tailpipe to outside right, sales
code K7D.

W49.20-A172-11
Example illustration with tailpipe section, heat protection cover,
wiring harness and control unit
W49.20-A173-11
Example illustration with tailpipe section and heat protection cover
removed
Mechanical connection/connection/additional
specifications
The outer pipe diameter at the exhaust gas
aftertreatment unit for connecting the subsequent pipe
extensions is 120 mm (wall thickness 1.5 mm).
The corresponding pipe extension requires an inner pipe
diameter of 121 mm and must be slotted 3 times around
the circumference to use the connecting clamp supplied
from the factory.
Material: Steel EN 10296‑2‑1.4301 W49.20-A174-10
Example: Design of connector

It is possible and permissible to shorten the tailpipe
sections supplied from the factory. The remaining
connecting flange can then be used as the basis for the
subsequent pipe extension (weld joint).
W49.20-A175-11
Example of shortening of tailpipe section of semitrailer tractor
chassis
The tightening torque for the factory-supplied connecting registration, e.g. with regard to noise regulations, is part
clamp at the connecting flange is 51 Nm. of the conversion process.
In the code K7G version for semitrailer trucks, a suitable Water and bulk cargo must be prevented from entering
additional heat shield which protects the detachable the exhaust gas aftertreatment unit.
parts, wiring harnesses and control units on the exhaust The exhaust gas temperatures at the outlet of the
gas aftertreatment unit against excessive thermal loads exhaust gas aftertreatment unit can reach 600 ℃.
and additional mechanical influences, must be fitted in
accordance with the version/pipe run of the subsequent When designing the dump truck body heating system,
pipe extension. always pay attention to the potential risk of heating
electronic components. Leaks through which the exhaust
The transition from the pipe extension (scope attached gas can escape are not permissible.
to vehicle) to the inlet of the dump box heating (on the
body) must be contact-free or decoupled on the body Minimum distances for adjacent components and lines
side even if twisted. must be taken into account.
It is important to ensure that all national registration and The dynamic sectional loads at the outlet of the exhaust
accident prevention regulations are complied with as gas aftertreatment unit must not exceed the values
part of the conversion. below:
The acoustic limits must not be exceeded, even with
dump truck body heating. The checking of eligibility for

Permissible maximum Exhaust gas Exhaust gas Exhaust gas
sectional loads aftertreatment unit, inlet aftertreatment unit, rear aftertreatment unit, left
outlet outlet
Fx 2 million LW [N] 1800 1400 1800
Fy 2 million LW [N] 1200 1200 1200
Fz 2 million LW [N] 1200 1200 1200
Mx torsion 2 million LW [Nm] 450 450 450
My bend 2 million LW [Nm] 150 150 150

LW Load change
W49.20-A176-11
Exhaust gas aftertreatment unit, inlet
W49.20-A177-11
Exhaust gas aftertreatment unit, rear outlet

W49.20-A178-11
Exhaust gas aftertreatment unit, left outlet
Decoupling elements and brackets fixed to the frame Unless only a short, straight tailpipe extension is used, a
may have to be used after the flange in order to decoupling element must always be fitted in the outlet
guarantee compliance with the strength values. pipe of the exhaust gas aftertreatment unit in order to
Any additional connection of pipe extensions of the meet the described sectional load limit values.
dumper body heating system to the exhaust gas
aftertreatment unit is not permissible.
---------------------------------------------------------------------------
Limit values for the exhaust gas back pressure
The exhaust gas back pressures and conversion
instructions described below must be observed for the
installation/assembly of the dump box heater.

Table for OM 470 Euro VI Standard d (sales code M5C)
OM 470LA.6-6 335kW/1600rpm 22.1 ¹⁾
OM 470LA.6-7 315kW/1600rpm 20.6 ¹⁾
OM 470LA.6-8 290kW/1600rpm 18.5 ¹⁾
OM 470LA.6-9 265kW/1600rpm 16.8 ¹⁾
OM 470LA.6-10 240kW/1600rpm 14.9 ¹⁾

1) +1.0 kPa

Table for OM 470 Euro VI Standard e (sales code M4X)
OM 470LA.6GE-01 335kW/1600rpm 21.1 ¹⁾
OM 470LA.6GE-02 315kW/1600rpm 19.4 ¹⁾
OM 470LA.6GE-03 290kW/1600rpm 17.2 ¹⁾
OM 470LA.6GE-04 265kW/1600rpm 15.1 ¹⁾
OM 470LA.6GE-05 240kW/1600rpm 13.6 ¹⁾

1) +1.0 kPa

OM 471LA.6-8 390kW/1600rpm 25.8 ¹⁾
OM 471LA.6-9 375kW/1800rpm 24.7 ¹⁾
OM 471LA.6-10 350kW/1800rpm 22.4 ¹⁾

OM 471LA.6-11
OM 471LA.6-12 330kW/1800rpm 20.6 ¹⁾

OM 471LA.6-13
OM 471LA.6-14 310kW/1800rpm 18.8 ¹⁾

OM 471LA.6-15
1) +1.0 kPa

Table for OM 471 Euro VI Standard E (sales code M4X)
OM 471LA.6GE-01 390kW/1600rpm 28.1 ¹⁾
OM 471LA.6GE-02 375kW/1800rpm 27.4 ¹⁾
OM 471LA.6GE-03 350kW/1800rpm 23.2 ¹⁾
OM 471LA.6GE-04
OM 471LA.6GE-05 330kW/1800rpm 21.9 ¹⁾
OM 471LA.6GE-06
OM 471LA.6GE-07 310kW/1800rpm 20.1 ¹⁾
OM 471LA.6GE-08
OM 471LA.6GE-09 390kW/1600rpm 27.5
OM 471LA.6GE-10 375kW/1600rpm 26.0
OM 471LA.6GE-11 350kW/1600rpm 24.0
OM 471LA.6GE-12
OM 471LA.6GE-13 330kW/1600rpm 21.9
OM 471LA.6GE-14
OM 471LA.6GE-15 310kW/1600rpm 20.2
OM 471LA.6GE-16
OM 471LA.6GE-25 350kW/1600rpm 26.5
OM 471LA.6GE-26
OM 471LA.6GE-27 330kW/1600rpm 25.0
OM 471LA.6GE-28
OM 471LA.6GE-29 310kW/1600rpm 21.2
OM 471LA.6GE-30
1) +1.0 kPa

OM 473LA.6-4 460kW/1600rpm 34.2 ¹⁾
OM 473LA.6-5 425kW/1600rpm 29.3 ¹⁾
OM 473LA.6-6 380kW/1600rpm 25.5 ¹⁾

1) +1.0 kPa

Table for OM 473 Euro VI Standard E (sales code M4X)
OM 473LA.6GE-01 460kW/1600rpm 36.5 ¹⁾
OM 473LA.6GE-02 425kW/1600rpm 31.0 ¹⁾
OM 473LA.6GE-03 380kW/1600rpm 26.7 ¹⁾

1) +1.0 kPa
Exhaust gas back pressure measurement • 1x winter operation (exhaust gas flows into or through
The maximum permissible exhaust gas back pressure is the dump box.)
measured at rated speed and at full load in accordance Additionally with dump box tilted:
with the work instructions. • 1x summer operation (if different from winter
Procedure for a measurement to determine the operation)
exhaust gas back pressure with a heated dump box • 1x winter operation
All measured values must be below the values stated in
the certificate.
i
Possible shortening of exhaust gas regeneration Preparation of vehicle and engine for measurement
intervals:
In vehicles with the facility to switch the dump truck
body heating system between summer and winter i
operation, the heating must be switched to winter Possible fault entry and necessary recalibration in
operation before performing the teach-in process. vehicles with camera system MPC2:
Otherwise the system could detect an inadequate Cover the camera lens before the test is started on
back pressure. The changeover between summer the chassis dynamometer. Remove the cover again
and winter operation can then be made by the after the test. If this instruction is ignored, a fault
operator without having to consider further actions. entry will occur and the camera system will be shut
down.
The steps described below must be strictly adhered to in

order to ensure that the certification of the affected A measuring point for exhaust back pressure
vehicles and their engines is not invalidated: measurement shall be fitted to the vehicle exhaust pipe.
• It is essential that the vehicle be tested on a Position and design of measuring point:
dynamometer, generally a roller dynamometer. Roller
• Position the measuring point on the vehicle exhaust
dynamometers are installed e.g. at certain Bosch
pipe coming from the engine directly behind the
service centers.
decoupling element (EKE) on the side facing the
• At least one measuring point, the rated output at exhaust gas aftertreatment unit.
rated speed, must be run up to.
• Do not install the measuring point at the outer or
• The measurement must be carried out several times: inner curvature.
Dump box in drive position: • The thermal insulation may have to be partially
• 1x summer operation (exhaust gas is discharged removed in the area of the intended measuring
separately outside the dump box, e.g. via pipes on connection area.
the dump box front wall)


Measuring point connection M14x1.5
Another measuring point, for reference, should be installed immediately
before the inlet to the heated dump box.
1 Measuring point
2 Thermal insulation
W49.20-A179-02
Example of position of measuring
connection
Parameterization of outlet variant and the engine was only started for loading and
The following points must be considered when installing unloading:
a dump box heater: • Initial startup is carried out after installation of the
Variant 1 dump box heater and reparameterization is not
required.
The vehicle is equipped ex factory with exhaust system
with connection for dump truck heating, sales code K7G, Variant 3
and was transferred to the body manufacturer under its The vehicle was not delivered with sales code K7G
own power. The procedure here is as follows: (e.g. exhaust system, upward tailpipe, sales code K7W)
• After installation, a Mercedes-Benz Service Partner and was equipped with a dump box heater by the body
must temporarily parameterize a different exhaust manufacturer:
variant and then parameterize it back to sales code • In this case, the Mercedes-Benz Service Partner
K7G. A mechanical modification is thus recognized must perform parameterization to sales code K7G
and a new teach-in process is initialized. after installation of a dump truck body heating
Variant 2 system.
The vehicle is equipped with sales code K7G and was

not transferred under its own power but on a low loader
Vertical exhaust system behind cab, Euro VI Standard
aWarning
Welding Page 130
Soundproofing Page 53
Exhaust system, upright behind cab, sales code K7J

General
The upward exhaust system behind
the cab is available for 4-axle
vehicles with two front axles. It is
equipped with a touch/heat shield on
the exhaust gas aftertreatment unit
and on the tailpipe. The arrangement
creates free space on the right side
of the vehicle frame and replaces the
exhaust system, vertical tailpipe,
sales code K7A., on these vehicles
W49.20-A195-02 W49.20-A196-02
Upward tailpipe, sales code K7J, ex factory Upward tailpipe, sales code K7J
Relocation of the exhaust system

Relocation of the entire exhaust gas aftertreatment unit
is not permissible.
---------------------------------------------------------------------------
Shortening/rotating the tailpipe It is the responsibility of the body manufacturer to ensure
Shortening/rotating the tailpipe in the straight area that the vehicle is eligible for registration, e.g. with
directly in front of the outlet is possible to a small extent. regard to noise regulations (see document
"Soundproofing") and the durability of the modified
The exact length and any protrusion of the exhaust tailpipe and/or rotated outlet.
system over the cab can be found in the chassis
drawings or 3D design data in the Mercedes-Benz Welding work is necessary to carry out the conversion.
Bodybuilder Portal. This may only be carried out by qualified personnel (see
document "Welding").
The exhaust is factory-fitted at an angle of 6°, deviating
from the direction of travel laterally to the rear.


Removing the tailpipe
• For cutting and welding, the tailpipe must be
removed. To do this, loosen the tensioning straps
directly above the exhaust gas aftertreatment unit
and on the frame (A). Observe the specified
tightening torques for reassembly.
• Loosening the tensioning strap (B) on the exhaust
allows it to be removed.
A Band clamp on exhaust gas aftertreatment unit
with hexagon head bolt M10x1.5x40
(N 910105 010011) to MBN 10105 and nut
M10x1.5 (N 913023 010002) to MBN 13023,
tightening torque MA 51 Nm
B Exhaust pipe tensioning strap screw connection
to frame with nut M8x1.25 with clamping part
(A 004 990 72 50), tightening torque MA 17.6 Nm W49.20-A197-11
• Disassemble the upper exhaust by loosening the

band clamp (C).
• Finally, remove the heat shield by loosening the
screws screwed to the four small cylinders (D).
C Band clamp with hexagon head bolt M10x1.5x35
(N 910105 01007) to MBN 10105 and nut
M10x1.5 (N 913023 010002) to MBN 13023,
tightening torque MA 51 Nm
D 4 mounting cylinders for heat shield
W49.20-A198-12
Disassembly of heat shield
Shortening the tailpipe

• In the middle, straight part of the tailpipe (3), a
section has to be taken out with two cuts. A
maximum shortening of approx. 380 mm is possible.
The upper part of the remaining tailpipe must be kept
to at least X = 40 mm to ensure the function of the
upper water separator. The lower cut must be made
above the bent pipe part.
X Length of the upper section to be retained (at
least 40 mm)
Y Length of the removable pipe section (max.
380 mm)
Z Total length of X+Y: Maximum 420 mm
S1 Position of the upper cut
S2 Position of the lower cut
W49.20-A199-12
Exhaust tailpipe, cutting area
The outlet (1), the curved part of the tailpipe (3) and the
rain/condensation water separator (2, 4) must be
retained.
1 Outlet that must not be changed/processed
2 Water separator for water entering through outlet
(e.g. rainwater)
3 Area in which tailpipe can be shortened (straight
area only)
4 Water separator for condensation
W49.20-A200-12
Exhaust tailpipe
• The upper remaining pipe section must then be must be fabricated and attached to the shortened
welded all-round to the lower pipe section. Welding part of the pipe.
procedure MAG 135 according to DIN EN ISO 4063 • The direction of rotation of the exhaust can be
with welding filler material changed when it is mounted. Make sure that no
DIN EN ISO 14343‑A‑G 18 8 Mn. exhaust gas flows onto cab parts including the air
Install shortened exhaust tailpipe intake or onto persons (e.g. on the cab step). It is the
responsibility of the body manufacturer to check the
• The installation of the shortened tailpipe is done in eligibility for registration, e.g. with regard to noise
reverse order. If necessary, separate heat insulation regulations.
Code K7W - Exhaust system, vertical tailpipe, rotating outle...

Exhaust system, vertical exhaust tailpipe, rotating gases in the area of the exhaust muffler. The upright
outlet, sales code K7W exhaust pipe is a statutory requirement for certain
General vehicle models in some countries.
The upward tailpipe reduces dust turbulence while

stationary and provides better protection from exhaust

W49.20-A180-11
Upward tailpipe, sales code K7W, ex factory
1 Attachment tailpipe
2 Additional band clamp
3 Adapter
4 Additional strut (mounted ex works, not for all
versions)
W49.20-A181-11
Upward tailpipe, modified
Relocation of the exhaust system (http://bb-portal.mercedes-benz-trucks.com)

It is permissible to relocate the exhaust gas Lengthening/rotating the exhaust tailpipe in the area
aftertreatment unit (but not the frame behind the cab directly in front of the outlet is possible to a small extent.
including the upward tailpipe) in accordance with the The exhaust is factory-fitted at an angle of 6°, deviating
specifications in the previous sub-chapters. from the direction of travel laterally to the rear.
Lengthening/rotating the tailpipe It is the responsibility of the body manufacturer to ensure
The exact length and any protrusion of the exhaust that the vehicle is eligible for registration, e.g. with
system over the cab can be found in the chassis regard to noise regulations (see the document
drawings or 3D design data in the Mercedes-Benz "Soundproofing") and the durability of the modified
Bodybuilder Portal. tailpipe and/or rotated outlet.

Required parts
For extension, a 700 mm long intermediate piece is
available from Mercedes-Benz service partners.
• Part number A 961 492 06 06, internal dia.: 120 mm
(for 2, 3 and 4-axle vehicles with one front axle and
engine OM47x)
(for 2, 3 and 4-axle vehicles with one front axle and
engine OM936)
(for 4-axle vehicles with 2 front axles)
Shorten this to the desired length if necessary. In doing
so, measured from the bottom, maintain at least
300 mm.
A Top side
W49.20-A182-11
B Bottom side Adapter (3)
3 Adapter
Additional band clamp (2),

• for adapter A 961 492 06 06: part number A 655 492
01 40, with hexagon head bolt M10x1.5x40 (N
910105 01011) and nut M10x1.5 (N 913023 010002)
00 40, with hexagon head bolt M10x1.5x35 (N
910105 010007) and nut M10x1.5 (N 913023
010002)
05 40 with hexagon head bolt M10x1.5x35 (N
910105 010007) and nut M10x1.5 (N 913023
010002)
2 Band clamp
W49.20-A183-11

Loosen band clamp (2) on attachment tailpipe (1).
2 Band clamp
W49.20-A187-11
Remove attachment tailpipe (1).

W49.20-A188-11
Put on the adapter (3).

3 Adapter
W49.20-A189-11
Fit attachment tailpipe (1) on adapter (3).

The direction of rotation of the exhaust can be changed
when it is mounted. Make sure that no exhaust gas
flows onto cab parts including the air intake or onto
persons (e.g. on the cab step). It is the responsibility of
the body manufacturer to check the eligibility for
registration, e.g. with regard to noise regulations.
3 Adapter
W49.20-A190-11
Fasten adapter (3) and attachment end pipe (1) with one
band clamp (2) each using hexagon head bolt and nut
with tightening torque 51 Nm.
2 Band clamp
3 Adapter
W49.20-A191-11
Remove/install exhaust flex pipe

The following must be observed when removing/ Installation of the flexible exhaust pipe is described
installing the flexible exhaust pipe: below, in case an installation gauge is not available.
The seals of the clamps on the engine and on the Procedure for installation of flexible exhaust pipe,
exhaust gas aftertreatment system must be changed engine 470.9 and 471.9
after each removal operation if the engine was in
operation beforehand (heating of the seal). The clamps
including seal must be changed.

N49.10-A000-71 N49.10-A001-71 N49.10-A002-71

Flexible exhaust pipe Installation situation for model 963 with Installation situation for model 963 with
engine 473.9 and model 964 engine 470.9/471.9
1 Decoupling element (EKE) 1 Decoupling element
Basic requirements
• Insert exhaust pipe into fitting of exhaust gas aftertreatment unit up to
end stop (when doing so, the decoupling element (EKE) 1 is tilted away
from the vehicle frame).
• Turn the exhaust pipe toward the ball connection on the engine side
and align, including the decoupling element (observe the marking).
• Attach the V-clamp on the engine side and tighten slightly.
N49.10-A003-01
Measure the installed length of the
decoupling element on three sides (120°
each).
• Adjust the length of the decoupling element via the • If the installation reference dimension is OK and the
slip fit on the fitting of the exhaust gas aftertreatment decoupling element is in straight alignment, tighten
unit (see the table "Installation reference the V-clamp:
dimension for decoupling element"). • Tighten to the torque specified by the manufacturer
• Tighten the connecting point on the exhaust gas (see the table "Torques").
aftertreatment system. Observe the torque specified • Important: The decoupling element must not turn
by the manufacturer (see the table "Torques"). during tightening.
• Check again that the upper V-connection is seated • Check the installation reference dimension again and
correctly (observe the marking). check the alignment of the overall system. Pay
• Check the installation reference dimension (see the attention to the distances to the adjacent
table "Installation reference dimension for components.
decoupling element").

1 Pipe clamp
2 Folded edge
3 Exhaust pipe
4 Item number of seal: A 629 493 02 80 (d ₌ 100 mm) A 960 492 05 80
(d ₌ 130 mm)
5 Casting (engine side)
N49.10-A004-01
Components for clamp connection at
engine
Installation steps

• Remove adhesive tab.

• Place seal over casting.
• Align clamp with folded edge towards engine.
• Slide clamp over exhaust pipe.
• Position exhaust pipe with clamp over casting. Max. 2° for slant
permissible. Torque tightening (see the table "Torques").
N49.10-A005-01
Components for clamp connection at
exhaust box
1 Turnbuckle
2 Tensioning ring
3 Seal
4 Exhaust pipe
5 Folded edge
6 Casting (box side)
N49.10-A006-80
Sectional view of clamp connection at exhaust box
• Remove adhesive tab. • Slide clamp over exhaust pipe.

• Place seal over casting. • Position exhaust pipe with clamp over casting.
• Align clamp with folded edge towards exhaust gas Max. 2° for slant permissible. Torque tightening (see
aftertreatment unit. the table "Torques").


1 Clamp (downstream of exhaust gas
turbocharger)
2 Clamp (upstream of exhaust gas
aftertreatment system)
3 Flexible exhaust pipe
4 Exhaust pipe (downstream of exhaust
gas turbocharger)
5 Exhaust pipe
6 Clamping disk
7 Seal
Pfeil C Opening
Pfeil D Opening
Pfeil E Opening
N49.10-A007-11
• The flexible exhaust pipe 3 is installed with a new • Adjust the installation reference dimension as per the
clamping disk 6 and a new sealing ring 7. table "Installation reference dimension for
• Position the flexible exhaust pipe 3 at the exhaust decoupling element" and tighten clamps 1 and 2.
pipe 5 and 4 with new clamps 1 and 2.

Component Item number
Pipe clamp A 002 995 07 02
Clamping disk A 000 994 37 25
Shaped gasket A 020 997 68 45
The screws of the clamps must be tightened to a certain

torque (see the table "Torques").

Installation reference dimension for decoupling element
A 960 492 14 59 None (high stiffness)
A 960 492 23 59 234 ± 3 mm
A 960 492 16 59 217 ± 3 mm
A 967 492 01 59 216 ± 3 mm (Atego)

Torques
Component Diameter d Torque
Exhaust pipe at manifold flange (engine 130 mm 25 Nm

end)
100 mm 13 to 14 Nm
Bolt, exhaust pipe clamp to exhaust gas 130 mm 16 Nm

aftertreatment unit (exhaust box end)
Exhaust pipe at manifold flange (engine 90 mm 25 Nm

end)
Bolt, exhaust pipe clamp to exhaust gas 90 mm 22 Nm

aftertreatment unit (exhaust box end)
Extension of insulated exhaust gas lines

• If insulated exhaust gas lines are to be extended, the
two separate lines must be stripped of insulation
material and stainless steel foil at the planned
connection point.
• The exposed stainless steel pipes are then welded
together gas-tight using the wolfram inert gas or
metal active gas welding procedure (WIG or MAG
welding procedure) (for precise details, see the
"WIG and MAG welding procedure" tables).
• After the stainless steel foil has been pushed down
around the circumference of the pipe, it must be
secured to the exhaust pipe on each side using a
stainless steel clamping ring (see the picture; for
presentation purposes, only one clamping ring
on the left side is shown).
W49.10-A005-11
Stainless steel clamping rings secure stainless steel foil on pipe on
both sides of weld seam.
Required connection material

The clamps to be used have the following item numbers: i
Prepare for welding using a rotating stainless steel
A 005 997 54 90 for OM 47x and
brush.
A 005 997 29 90 for OM 936.

TIG welding
Diameter of tungsten 2.4 mm

needle:
Current strength: 30 A
Welding filler material: ∅1.6 mm-W 18.8 Mn = 1.4370
Nozzle: ∅11 mm/11 l/min
Welding gas: Argon -4.8
Forming gas: Argon -4.8

MAG welding procedure
Inert gas: M 12 (97.5 Ar/2.5 CO₂) No. B 1878102520
Welding filler material: ∅1 mm/15 kg

Coil/SG‑X (15 Cr Ni Mn 18 8)
Power take-off, general information and exhaust gas aftertre...
Power take-off
aDanger
Risk of accident caused by vehicle starting off on its own Ensure that jack stands are standing firmly. An authorized
when jacked up. Risk of injury caused by rotating parts person must occupy the driver's seat. Wear closed and
when working on running engine or drive train. close-fitting work clothes. Do not touch hot or rotating
parts.
German regulation concerning the transport of dangerous Page 678

goods by road, rail and inland waterways
Vehicles for transport of hazardous goods Page 545
i i
In this chapter, representations, code scopes and Possible damage to the body or to body-mounted
pre-installations of other model designations and assemblies:
model series are listed for reasons of If the pre-parameterized ADR (working speed
standardization. The information that is applicable to control) function is modified or deactivated,
your model designation/model series must regeneration can cause unwanted increases in the
exclusively be used. engine idle speed. The driven body-mounted
assemblies or their condition of use may not be
designed for this.
i
Technical data on power take-offs are available in
the Mercedes‑Benz Bodybuilder Portal
.
i
Possible risk of fire:
When the power take-off is activated, the vehicle
changes from driving mode to the work mode. In this
state, the stationary heater must be deactivated
during working speed control (ADR). Amend the
operator's manual. For further information, see
"Vehicles for the transportation of hazardous
goods" document.
---------------------------------------------------------------------------
General • Front engine power take-off (not disengageable)
Power take-off versions currently available ex factory: • Rear engine power take-off (not disengageable)
• Transmission power take-off (engageable)
• Transmission-independent power take-off (only for
model 963, 964) (engageable)
---------------------------------------------------------------------------
Power take-off and regeneration of Euro VI Standard System description
exhaust gas aftertreatment system During regeneration of the exhaust gas aftertreatment
To enable regeneration to occur, deactivate working system, the engine noise and the idle speed can change
speed control (ADR) (e.g. by pressing the "constant-rpm (see "Vehicle operator's manual").
control" switch).
Power take-off
The regeneration processes which occur when On engines of model series OM 93x, this parameter is
stationary or while driving are "active" regeneration, factory-set to "Do not allow" as standard in the exhaust
"manual" regeneration and "HC burn off" regeneration. gas aftertreatment control unit.
• "Active" regeneration: The system does not actively It is not possible/not permissible to change the
increase the engine rpm when the vehicle is moving. parameter to "Allow".
It prevents the idle speed from dropping below 800 Disabling active regeneration during power take-off
rpm. operation prevents any increase due to regeneration of
• "Manual" regeneration ("high idle" regeneration): The the exhaust gas temperature at the exhaust outlet and at
idle speed is increased to 1400 rpm when stationary the components of the exhaust system. However, this
only. The regeneration is displayed on the instrument may cause faster loading of the diesel particulate filter
cluster and must be actively confirmed by the driver. depending on the conditions of use. The corresponding
Manual regeneration is aborted when you switch on warning stages (see "Vehicle operator's manual") are
the transmission power take-off. If the power take-off reached and passed through more quickly.
is on, you cannot start manual regeneration (see "HC burn off" regeneration still takes place irrespective
also the vehicle operator's manual). of this function lockout. Observe the relevant
• "HC burn off" regeneration: The idle speed is requirements regarding "HC burn off" regeneration and
increased to 1400 rpm when stationary only. the requirement for working speed control (ADR).
Regeneration starts automatically with no prior
indication, e.g. via a CAN signal or instrument cluster. Installation instructions for rpm-sensitive
Therefore, when a power take-off is being used applications
(engine-driven or transmission-driven), the "HC burn If an rpm-sensitive application is to be used or an rpm-
off" regeneration with its idle speed increase to sensitive component (e.g. a pump) is to be operated, the
1400 rpm must be taken into account. ADR requirement must be met via the ASAM. With ADR,
On engines of model series OM 47x, it is possible to "HC burn off" regeneration (and manual regeneration) is
disable "active regeneration" during power take-off disabled. Adjusting the idle speed with the basic idle
operation. speed control function (via the steering wheel buttons) is
not sufficient because this setting is overridden by the
This can be achieved through a parameter change in the "HC burn off" regeneration.
exhaust gas aftertreatment control unit.
• For this reason, the ADR is pre-parameterized at the
On engines of model series OM 47x, this parameter is factory for all transmission power take-offs.
set to "Allow" as standard ex factory.
• With the engine-driven power take-offs or the
In order to improve the regeneration behavior (cooling transmission-independent power take-offs, rpm-
down of the exhaust gas aftertreatment unit is avoided), sensitive applications must also be operated with
we recommend in PTO operation to set an engine working speed control. In the case of engine-driven
speed > 800 rpm with a power consumption at the PTO power take-offs, this is pre-parameterized ex factory
of < 20 kW (example: operation of milk collection to occur when the "constant-rpm control" switch is
vehicles). pressed.
On engines of model series OM 93x, "active With live power take-offs, working speed control is
regeneration" during power take-off operation is not also pre-parameterized on activation of the live power
permissible due to system constraints. take-off switch.
---------------------------------------------------------------------------
Power take-off and Euro V Standard exhaust gas The exhaust gas outlet variant to the left (code K7I) is
aftertreatment system (only model 963, 964) not permissible in combination with the transmission-
The Euro V Standard exhaust gas aftertreatment system independent power take-off (N4W, N4X, N4Y, N4Z).
works solely according to the principle of selective Depending on the overall situation of the body, the heat
catalytic reduction (SCR). trapped under the vehicle can cause degradation or
An additional particulate filter is not installed. accelerated aging of components (e.g. tires, lines and
hoses).
The regeneration procedures of "active" regeneration,
"manual" regeneration and "HC burn off" regeneration If necessary, the exhaust outlet should be routed to the
for the particulate filter of the Euro VI Standard exhaust left side, as with code K7N, or a vertical exhaust pipe,
gas aftertreatment system are therefore not available for code K7A, should be used.
the Euro V Standard exhaust gas aftertreatment system.
---------------------------------------------------------------------------
Power take-off and Predictive Powertrain Control combination with Predictive Powertrain Control (PPC),
(PPC), sales code G0T (only model 963, 964) sales code G0T.
Affects vehicles with rear engine power take-off (N7I,
N7O, N7M) and/or a live power take-off (N4W, N4X) in
Power take-off
Tapping torque via live power take-offs while driving can Predictive Powertrain Control is not available for cement
have adverse effects on the functioning of the Predictive mixer vehicle chassis.
Powertrain Control (sales code G0T).
It is possible to deactivate this comfort function
temporarily at any time when power is drawn while
driving.
---------------------------------------------------------------------------
Vehicles with electronic ignition lock (EIS) (ignition) is switched off after 1 h. This is for rundown
Vehicles with code F8B, 2 transmitter keys, are protection of the vehicle battery. The engine can only be
equipped with an electronic ignition lock (EIS control started by pressing the start/stop button again in the cab.
unit). If this function is not wanted when in work mode, the
If the engine is switched off externally (through ASAM/ value can be changed from 1 h up to a value of 42.5 h
PSM2) or the start/stop button when in work mode, the (in the EIS control unit A156, designated as a "No
EIS is parameterized at the factory so that terminal 15 shutdown" parameter) using XENTRY Diagnosis.
Tilt pump
Power take-off
aWarning
Meiller axial piston pump ex factory

The Meiller axial dumper pump installed as standard on dump trucks with
ex-factory dumper body can also optionally be delivered for all other
chassis.
Power take-offs for dumper pumps are available in two versions:
• "b" version: with flange for drive via the propeller shaft.
• "c" version: with splined profile for direct connection (for pumps as per
ISO 7653 D).
W55.20-A004-03
Meiller axial dumper pump on power take-
off
The operating energy input (torque required at the power take-off) can be
calculated using the opposite formula:
M Torque (Nm)
P Output (kW)
n Speed (rpm)
η Efficiency (approx. 0.85)
W55.20-A001-01
Tilt pump
Power take-off
Use the opposite formula if the pump volume is known:

M Torque (Nm)
Q Pump volume (l/min)
P Output (kW)
n Speed (rpm)
W55.20-A002-01
Installation of hydraulic pumps (http://bb-portal.mercedes-benz-trucks.com)

Observe the following if other hydraulic pumps are for viewing.
installed: Vibration characteristics of the engine suspension,
Safe distance to the major assemblies and chassis parts provide a separate mount on the vehicle frame if
(propeller shafts, crossmembers) necessary.
Static and dynamic load on the pump
For the permissible blocking bending moments, refer to
the arrangement drawings for the respective power take-
offs in the Mercedes-Benz Bodybuilder Portal

W55.20-A000-11
Dumper pump power take-off
The pump output can be calculated using the following formula:

P Output (kW)
Q Pump volume (l/min)
p Pressure (bar)
W55.20-A003-01
Rear engine power take-off for direct flange-mounting of pum...
Power take-off
aDanger
parts.
aWarning
Risk of accident from vehicle starting off by itself when Secure vehicle to prevent it moving off. Wear closed and
engine running. Risk of injury (bruises and burns) close-fitting work clothes. Do not touch hot or rotating
resulting from working on the engine while it is being parts.
started or when it is running.
aWarning
Risk of injury from engine start by remote start function Prior to starting work, deactivate the remote start function,
do not reach into the rotation area or danger zone of
freely rotating parts, wear closed and snug-fitting work
clothes
Steering-related modifications
Vehicle frame material
Vehicle frame material Page 150
i i
In this chapter, representations, code scopes and Notes on the installation position in the vehicle can
pre-installations of other model designations and be found in the arrangement drawings in the
model series are listed for reasons of Mercedes-Benz Bodybuilder Portal.
standardization. The information that is applicable to (http://bb-portal.mercedes-benz-trucks.com)
your model designation/model series must
.
exclusively be used.
i
Possible damage to the engine and power take-off:
Radial power draw, e.g. a belt or chain drive system,
at the power take-offs is not permissible.
---------------------------------------------------------------------------
Rear engine power take-off for direct flange- toothed receptacles (drivers) for the corresponding
mounting of pumps in combination with OM 93x hydraulic pump variants.
engines • Sales code N7K
Engines OM 93x can be optionally ordered with a gear- Direct flange-mounting of pumps SAEA/225Nm
driven power take-off as special equipment. Connections
for direct flange-mounting of pumps are available with
Power take-off
• Sales code N7N (model series 967)/N7L (model • Sales code N7M
series 963, 964) Direct flange-mounting of pumps ISO7653‑D/550Nm
Direct flange-mounting of pumps SAEB/250Nm Gear ratios:

nM nEngine
nN nPTO
W26.45-A076-01

OM 93x:
(PTO output speed = 1.07 x engine speed)
Right-hand rotation, i.e. clockwise (viewed in direction of travel/toward
engine/engine power take-off).
The power at the flywheel of the engine is reduced by the power
consumption of the major assemblies driven by the engine power take-off.
All power take-offs are supplied without hydraulic pumps and without driven
major assemblies. These are to be attached by the body manufacturer.
A rear engine power take-off can only be retrofitted at great effort and cost. W26.45-A077-01
Possible arrangement of applications
Variant 1
1 Engine
2 Power take-off
3 Driven major assembly
W26.45-A060-01
Power take-offs for direct flange-mounting
of pumps, sales code N7K, N7N, N7M, N7L
The maximum permissible moment of inertia must be In order to prevent the maximum permissible torque from
observed. being exceeded, suitable overload protection should be
• 0.017kgm² at 4-cylinder engine OM934 provided, e.g.by means of pressure limitation or anti-lock
protection.
• 0.020kgm² at 6-cylinder engine OM936
To reduce stress on the power take-off and major
Maximum permissible torques at power take-off assemblies, the engine should always be started with no
load on the power take-off whenever possible.
The table below lists the maximum possible power take-
off torques by PTO code. Operation must be free of shocks and vibrations. If
necessary, the torques listed below should be reduced
by the corresponding shock factor.
Power take-off
Tapping torque via live power take-offs while driving can It is possible to deactivate this comfort function
have adverse effects on the functioning of the Predictive temporarily at any time when power is drawn while
Powertrain Control (sales code G0T, only available for driving.
model series 963, 964). Predictive Powertrain Control is not available for cement
mixer vehicle chassis.

Power take-off Rpm range [rpm] Maximum rated torque, Maximum peak torque,
continuous operation temporary operation
[Nm] (start-off/shifting) [Nm]
Sales code N7K(SAEA) > 600 225 270
Sales code N7M(ISO-7653- > 600¹⁾ 550¹⁾ 660¹⁾

D)
Sales code N7L, N7N > 600 250 300

(SAE B)
1) Check that the required engine torque is available at the engine at the desired engine speed.
The factory-fitted cover on the PTO flange (cap, seal and • compensate for relative movements between the
screws) acts only as a temporary seal until such time as engine and the vehicle (body),
the major assembly is installed by the body • be in order with regard to vibrations and
manufacturer. The parts must not be reused.
• have sufficient clearance to vehicle components.
The new bolts which are therefore required, as well as
an appropriate seal for the power take-off/major If necessary, additional shielding from the hot,
assembly interface must be supplied and installed by the e.g.exhaust gas-carrying, components may be required.
body manufacturer.
Permissible combinations of gross mass and total
It is possible to reuse the nuts with collar (M12/class 10/ lever arm of implement applications in combination
overall height 12mm - part number A0059900050) with the sales codes N7K (SAEA), N7N (SAEB,
supplied in conjunction with sales code N7M (ISO7653- 250Nm), N7M (ISO7653‑D), N7L (SAE B)
D) for fastening the cover. The teeth on the driver must
It is not permissible to exceed the permissible gross
be greased when the major assembly is attached. The
masses (F) and total lever arms (g + a) in relation to the
following lubricating paste is recommended: Optimol
White T, part number A0009898051 (DBL6880.10). timing case that are listed in the tables below.
Alternatively, engine oils approved by Mercedes-Benz Installation of an additional pump support/assembly
can be used. The lines connected to the major assembly support is not permissible.
must:

Power take-off
a Distance of overall CoG (major assembly and

accessories ¹⁾) from power take-off
connecting flange in mm
g Distance between timing case and connecting
flange of power take-off in mm
Sales code N7K(SAEA)=25.8mm
Sales code N7N(SAEB)=25.8mm,
Sales code N7M(ISO7653‑D)=84.3mm
Sales code N7L (SAE B) = 25.8 mm
g+a Distance of overall CoG (major assembly and
accessories ¹⁾) from timing case connecting
flange in mm
F Gross mass in kg (major assembly and
accessories ¹⁾)
W26.45-A061-12
Connection of major assembly to timing case
¹⁾ In addition to the major assembly, the connected lines vehicle frame or body at a maximum distance of 600mm,
(fully assembled and filled) must also be taken into relative to the connecting point on the major assembly.
account in the overall considerations for determining the This attachment must be designed so that the
actual blocking bending moment. The connected lines proportionate inertia forces of the lines can be absorbed.
do not need to be considered if they are attached to the

Sales code N7K (SAE A)

g+a Distance of center of
gravity of pump from
transmission flange [mm]
F Weight of pump (kg)
+ Mounting permissible
x Mounting not permissible
W26.45-A078-06
Power take-off
Sales code N7N, N7L (SAE B)
g+a Distance of overall CoG
(major assembly and
accessories) from timing
case connecting flange
[mm]
F Gross mass (major
assembly and
accessories) (kg)
+ Combination of gross
mass and total lever arm
permissible
x Combination of gross
not permissible
W26.45-A079-06
Sales code N7M (ISO7653‑D)

(major assembly and
accessories) from timing
case connecting flange
[mm]
F Gross mass (major
assembly and
accessories) (kg)
permissible
not permissible
W26.45-A080-06
Power take-off
1 Flange for transmission (rear

edge of flywheel housing)
W Shaft connection A
W26.45-A064-05
Connection geometry SAEA and SAEB and connection dimensions of shafts
1 Flange for transmission (rear

edge of flywheel housing)
W Shaft connection A (power
take-off connection axis)
W26.45-A062-05
Connection geometry ISO7653‑D and connection dimensions of shafts (power take-off
connection axis)

Connecting flange Shaft connection A b [mm] C [°] d [mm] e [mm] f [mm] g [mm]
Sales code ANSI B 92.1, 9T. 106.4 3 82.55 H7 11.8 33.7 25.8
N7KSAE A 16/32 DP
Sales code N7N, ANSI B 92.1, 13T. 146.0 19 101.6 H7 11.8 33.7 25.8
N7LSAE B 16/32 DP
Sales code Splined hub 8x32x36 80x80 0 80.00 H7 12.7 41.7 84.3
N7MISO 7653‑D ISO 7653‑D
Power take-off

Connecting flange Shaft connection A H in/from flange [mm] Tightening Driver assembly
torque ¹⁾
Sales code ANSI B 92.1, 9T. Blind hole 2xM10x1.5 depth 57 Nm A 906 230 01 26
N7KSAE A 16/32 DP 22 mm
Sales code N7N, ANSI B 92.1, 13T. Blind hole 2xM12x1.5 depth 104 Nm A 906 230 00 26 ³⁾
N7LSAE B 16/32 DP 22 mm
Sales code Splined hub 8x32x36 Stud bolt²⁾ 4xM12x1.75 70 Nm²⁾ A 936 230 01 26
N7MISO 7653‑D ISO 7653‑D length 28.5 mm
1) According to MBN10130 Class II and in combination with a mounting bolt to MBN10105 Class 10.9, or hexagon nut with flange, part
number A0059900050, total friction coefficient µtot =0.08...0.14. This may be reduced as a result of specifications from the pump
manufacturer.
2) Stud bolt, class 8.8
3) Alternative part (not standard): Driver assembly A9062300226 for pumps with 41mm shaft projection. Please contact your nearest
Mercedes-Benz ServicePartner if necessary.
W26.45-A083-11
Connecting flange, sales code N7K/N7N
Power take-off
W26.45-A176-81
Connecting flange, sales code N7M
Rear engine power take-off with propeller shaft flange in co...
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
i i
In this chapter, representations, code scopes and Possible damage to the engine and power take-off:
pre-installations of other model designations and Radial power draw, e.g. a belt or chain drive system,
model series are listed for reasons of at the power take-offs is not permissible.
standardization. The information that is applicable to
i
Notes on the installation position in the vehicle can
be found in the arrangement drawings in the
Mercedes-Benz Bodybuilder Portal.
http://bb-portal.mercedes-benz-trucks.com
---------------------------------------------------------------------------
Rear engine power take-off with propeller shaft • Sales code N7P:
flange in combination with OM93x engines Rear engine power take-off, b, flange 100mm,
The engines of model series OM934 and OM936 can be 600Nm
optionally ordered with a gear-driven power take-off as • Sales code N6E:
special equipment. This power take-off has a flange for
connection of a propeller shaft. Flexible coupling for engine power take-off (loose)
(different versions for OM934 and OM936)
The available variants of the rear engine-driven power
take-off with propeller shaft flange are:

Power take-off
Ratio
nM nEngine
nN nPTO
W26.45-A076-01
OM 934 and OM 936:
W26.45-A077-01
(PTO output speed = 1.07 x engine speed)
Right-hand rotation, i.e. clockwise (viewed in direction of All power take-offs are supplied without propeller shaft
travel/toward engine/engine power take-off). and without driven assemblies. These are to be attached
The power at the flywheel of the engine is reduced by by the body manufacturer.
the power consumption of the major assemblies driven A rear engine power take-off can only be retrofitted at
by the engine power take-off. great effort and cost.

Variant 2
1 Engine
2 Power take-off
3 Complete propeller shaft
W26.45-A047-10
Power take-offs for propeller shaft connection, without flexible
coupling
Power take-off
Variant 3
1 Engine
2 Power take-off
4 Flexible coupling
W26.45-A066-10
Power take-offs for propeller shaft connection, with flexible
coupling
Maximum permissible torques at PTO flange • Operation must be free of shocks and vibrations.
The table lists the maximum permissible torques at the • If necessary, the permissible torques should be
power take-off flange. reduced by the corresponding shock factor.
However, these can only be used in conjunction with an Tapping torque via live power take-offs while driving can
engine variant which can actually deliver the required have adverse effects on the functioning of the Predictive
torque at the corresponding engine speed. Powertrain Control (sales code G0T, only available for
There are no mandatory code combinations or model series 963, 964).
mandatory assignments of suitable engine variants. It is possible to deactivate this comfort function
• In order to prevent the maximum permissible torques temporarily at any time when power is drawn while
from being exceeded, suitable overload protection driving.
should be provided, e.g.,by means of a pressure Predictive Powertrain Control is not available for cement
limiter or anti-lock protection. mixer chassis.
• To reduce wear, only start the engine when the
power take-off is not under load.

Engine power take- Working speed range Maximum rated Maximum peak Comment
off [rpm] torque, continuous torque, temporary
operation [Nm] operation (start-off/
shifting) [Nm]
V2 propeller shaft ≥600 rpm 600Nm 720Nm Without flexible

connection, sales coupling, sales
code N7P code N6E
V3 propeller shaft ≥600 rpm 150Nm - With flexible

connection with coupling, sales
flexible coupling, ≤750 rpm code N6E
sales code N7P +
N6E ≥750 rpm 400Nm -

≤900 rpm
≥900 rpm 600Nm 720Nm
Maximum permissible moments of inertia/torsional

rigidity for V2 and V3

Power take-off
Variant 2 without flexible coupling

1 Engine
2 Power take-off
W26.45-A047-10
Power take-offs for propeller shaft connection, without flexible
coupling
Complete propeller shaft Complete propeller shaft

+driven major assembly
J C J
Minimum kgm² Maximum kNm/rad Maximum kgm²
OM 934 (4-cylinder) 0.003 20 0.018 ¹⁾
30 0.016 ¹⁾
OM 936 (6-cylinder) 0.003 30 0.018 ¹⁾

J Moment of inertia (kgm²)
C Rigidity of propeller shaft (kNm/rad)
1) If the maximum permissible moments of inertia are exceeded, a flexible coupling is required.
Variant 3 with flexible coupling

1 Engine
2 Power take-off
4 Flexible coupling (Daimler)
W26.45-A066-10
Power take-offs for propeller shaft connection, with flexible
coupling
Power take-off

Complete propeller shaft B Driven major Complete

assembly propeller shaft
+driven major
assembly
J max. kgm² C max. Flexible coupling J kgm² J max. kgm²

kNm/rad
OM934 (4-cylinder) 0.006 20 Type 1 0.013 ... 0.038 0.044 ¹⁾

A 934 230 03 28
30 0.011 ... 0.038 0.044 ²⁾
OM936 (6-cylinder) 0.012 30 Type 2 0.013 ... 0.038 0.05 ¹⁾

A 936 230 02 28
C Rigidity of propeller shaft (kNm/rad)
J Moment of inertia (kgm²)
1) Special case 1: If the sum of the actually existing moments of inertia is ≤0.018 kgm², the flexible coupling may nevertheless not be
installed.
2) Special case 2: If the sum of the actually existing moments of inertia is ≤0.016kgm², the flexible coupling may nevertheless not be
installed.
Attachment according to variant 3

For attachment according to variant 3 the following
flexible couplings must be installed:
For power take-off, sales code N7P+engine
OM934(4‑cylinder):
• Type I - Flexible coupling A9342300328 (sales code
N6E)
Outside dimensions:
• ∅ 250mm
• Width = 74.4±0.5mm
• Weight = 10.5kg
• CoG distance relative to pump-side flange: 35.8mm
For power take-off, sales code N7P+engine OM936
(6‑cylinder): W26.45-A089-11
• Type II - Flexible coupling A9362300228 (sales code
N6E)
Outside dimensions:
• ∅ 238mm
• Width = 74.4±0.5mm
• Weight = 7kg
• CoG distance relative to pump-side flange: 45.5mm
If other couplings (flexible, switchable) are to be used, a The flexible couplings must be installed at the major
non-objection check is required for this installation assembly end.
situation. The relevant tests are extremely complex. The Pay attention to the direction of installation of the flexible
costs for this must be borne by the client. coupling (see figure).

Power take-off
Direction of installation
Refer to the information label for the direction of
installation.
The flexible coupling must not be cleaned with
aggressive media, e.g.,pure benzine, cold cleaning
solvent.
The flexible coupling is maintenance free.
A visual check is to be performed as part of the general
maintenance and inspection routines.
W26.45-A068-10
If there is damage to the elastomer or to the metallic
Direction of installation of flexible coupling
components, the flexible coupling must be replaced
complete.
When propeller shafts are used for power output, the
data described in the "Installation of propeller shafts"
document must be complied with.
W23.20-A001-08
Propeller shaft flange 100x6x8mm
Connection geometry
A ∅ 8.1 mm (6x) D ∅ 57 mm h7 G 7 mm
B ∅ 84 mm E ∅ 100 mm H 9.8 mm
C ∅ 43 mm max. F 2 mm
Upper right rear engine power take-off in combination with H...
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
i i
Possible damage to the engine and power take-off: Further information regarding the installation position
Radial power draw, e.g. a belt or chain drive system, in the vehicle can be found in the arrangement
at the power take-offs is not permissible. drawings in the Mercedes-Benz Bodybuilder Portal:
---------------------------------------------------------------------------
Right upper rear engine power take-off in • Sales code N7K Direct flange-mounting of pumps
combination with engines OM 470, OM 471 and • SAE A/250 Nm
OM 473
• Sales code N7L Direct flange-mounting of pumps
The engines OM 470, OM 471 and OM 473 can be
optionally ordered with a gear-driven right upper rear • SAE B/250 Nm
power take-off as special equipment. Propeller shaft • Sales code N7M Direct flange-mounting of pumps
connections as well as connections for direct flange-
• ISO 7653‑D/550 Nm
mounting of pumps are available with toothed
receptacles (drivers) for the corresponding hydraulic • Sales code N6E Flexible coupling for rear engine
pump variants. power take-off
The available variants of the rear engine power take-off • Different versions for N7I/N7O
are: ¹⁾ In combination with active Hydrostatic Auxiliary Drive
• Sales code N7I Propeller shaft connection (HAD), sales code A1H and sales code N7I, the
maximum permissible torque is reduced. Further
• ∅ 100 mm/650 Nm¹⁾
information can be found in document "Hydraulic
• Sales code N7O Propeller shaft connection Auxiliary Drive (HAD)".
• ∅ 120 mm/900 Nm

Power take-off
nM nEngine
nN nPTO
W26.45-A076-01
Gear ratios
OM 470
Power take-off speed = 1.30 x engine
speed
OM 471, OM 473
Power take-off speed = 1.22 x engine
speed
Left-hand rotation,
i.e. counterclockwise (viewed in
direction of travel/toward engine/
engine power take-off). W26.45-A092-01 W26.45-A093-01
OM 470 OM 471, OM 473
The power at the flywheel of the engine is reduced by • In order to prevent the maximum permissible torques
the power consumption of the auxiliary assemblies from being exceeded, suitable overload protection
driven by the rear engine power take-off. should be provided, for example by means of a
All power take-offs are supplied without hydraulic pumps pressure limiter or anti-lock protection.
or driven assembly. These are to be attached by the • Only start the engine when the power take-off is load-
body manufacturer. free in order to protect the power take-off and major
A rear engine power take-off can only be retrofitted at assemblies.
great effort and cost. The listed engine power take-offs are designed and
guaranteed for the following service life:
Maximum permissible output torques: Engine
OM 470/471/473 + sales code N7I/N7K/N7L/N7M/N7O The minimum service life with output of the maximum
permissible continuous torque is 4000 hours.
The table lists the maximum possible power take-off
torques at the rear engine power take-off by code. Operation must be free of shocks and vibrations.
These can only be used in conjunction with an engine • If necessary, the permissible torques should be
variant which can actually deliver the required torque at reduced by the corresponding shock factor.
the corresponding engine speed. There are no
mandatory code combinations or mandatory
assignments of corresponding engine variants.

Power take-off

Upper right rear engine Working speed range Maximum continuous Maximum peak torque in
power take-off rated torque short-term operation
(e.g. when starting off/
shifting)
Power take-off for propeller ≥ 600 rpm ≤ 800 rpm 400 Nm¹⁾ -
shaft connection, sales code
N7I+ N7O (100/120)
Power take-off for propeller ≥ 800 rpm 650 Nm²⁾ 780 Nm

N7I (100)
Power take-off for propeller ≥ 800 rpm 900 Nm 1080 Nm³⁾

N7O (120)
Power take-off for flange ≥ 600 rpm 250 Nm 300 Nm

connection, sales code N7K
(SAE A)

connection, sales code N7L
(SAE B)

connection, sales code N7M
(ISO 7653‑D)
1 With flexible coupling, not permissible in combination with continuous full load engine operation at engine speeds up to 800 rpm.
2 In combination with active Hydrostatic Auxiliary Drive (HAD), sales code A1H and sales code N7I, the maximum permissible torque is
reduced. Further information can be found in document "Hydraulic Auxiliary Drive (HAD)".
3 Only permissible in stationary operation, not in driving operation. Stationary operation also includes engaging a start-off gear from
"neutral" and moving off and driving in this gear, but not any subsequent shifting.
Tapping torque via live power take-offs while driving can Predictive Powertrain Control is not available for cement
have adverse effects on the functioning of the Predictive mixer vehicle chassis.
Powertrain Control (sales code G0T).
It is possible to deactivate this comfort function
driving.

Variant 1
Sales code N7K, N7L, N7M
1 Engine
2 Power take-off
A Moment of inertia of driven assembly
W26.45-A094-10
Power take-offs for direct flange-mounting of pumps
Power take-off
Variant 2
Sales code N7I/N7O, without flexible coupling, sales
code N6E
1 Engine
2 Power take-off
4 Propeller shaft
B Moment of inertia of driven assembly plus
propeller shaft
W26.45-A095-10
Power take-offs for propeller shaft connection
Variant 3
Sales code N7I/N7O, with flexible coupling, sales code
N6E
1 Engine
2 Power take-off
4 Propeller shaft
5 Flexible coupling
C Moment of inertia of propeller shaft
D1 Moment of inertia of propeller shaft-end W26.45-A096-10
component of flexible coupling Power take-offs for propeller shaft connection
D2 Moment of inertia of assembly-end component

of flexible coupling
E Moment of inertia of driven assembly

Maximum permissible moments of inertia for engine OM 470
OM 470 Variant 1 Variant 2 Variant 3
Maximum A [kgm²] B [kgm²] C [kgm²] D [kgm²] E min. E max. Variant 3 in

rated [kgm²] [kgm²] combination
torque with flexible
[Nm] coupling
- - Total of Propeller D1 D2 Driven Driven

propeller shaft only assembly assembly
shaft + only only
driven
assembly
0 to 200 (L) 0.020 0.0405 (M) 0.0070 0.011 0.036 0.0355 0.0460 Type II
0 to 400 (L) 0.020 0.0335 (M) 0.0070 0.011 0.036 0.0285 0.0460 Type II
0 to 650 0.020 0.0260 (M) 0.0070 0.011 0.036 0.0210 0.0460 Type II
0 to 900 - 0.0160 (N) 0.0065 (N) 0.0092 0.0682 0.0095 0.0460 Type III
Power take-off


[Nm] coupling

shaft + only only
driven
assembly
0 to 200 (L) 0.020 0.0405 (M) 0.0070 0.011 0.036 0.0355 0.0460 Type II
0 to 400 (L) 0.020 0.0335 (M) 0.0070 0.011 0.036 0.0285 0.0460 Type II
0 to 650 0.020 0.0260 (M) 0.0070 0.011 0.036 0.0210 0.0460 Type II
0 to 900 - 0.0115 (N) 0.0065 (O) 0.0092 0.0682 0.0050 0.0460 Type III


[Nm] coupling

shaft + only only
driven
assembly
0 to 200 (L) 0.020 0.0376 (M) 0.0070 0.011 0.036 0.0185 0.0460 Type II
0 to 400 (L) 0.020 0.0317 (M) 0.0070 0.011 0.036 0.0185 0.0460 Type II
0 to 650 0.020 0.0235 (M) 0.0070 0.011 0.036 0.0185 0.0460 Type II
0 to 900 - 0.0110 (N) 0.0065 (P) 0.0092 0.0682 0.0045 0.0460 Type III
(L) Not permissible in combination with continuous full Moment of inertia ≥ 0.0035 kgm² to ≤ 0.0065 kgm² and
load engine operation at engine speeds ≤ 800 rpm rigidity ≥ 0.030 to ≤ 0.060*106 Nm/rad
(M) The propeller shaft used must have the following The values in the table are only valid with the respective
moment of inertia: ≥ 0.0035 kgm² approved flexible coupling, sales code N6E:
(N) The propeller shaft used must have the following • Type II: A 471 237 01 38
moment of inertia: ≥ 0.0035 kgm² to ≤ 0.0065 kgm²
(For power take-off, sales code N7I)
(O) The propeller shaft used must have the following
• Type III: A 471 237 07 38
properties:
(For power take-off, sales code N7O)
Moment of inertia ≥ 0.0035 kgm² to ≤ 0.0065 kgm² and
rigidity ≥ 0.025 to ≤ 0.060*106 Nm/rad The values in the table are valid for the corresponding
engines in combination with manual or automated
(P) The propeller shaft used must have the following manual transmission.
properties:
Power take-off
If the moments of inertia (B) listed under variant 2 are • The new bolts/nuts which are therefore required, as
exceeded, it is imperative to switch to variant 3 in well as an appropriate new seal for the power take-
combination with a flexible coupling. off/major assembly interface, must be supplied and
If variant 2 is operated with a flexible coupling contrary to installed by the body manufacturer.
the specifications, this can lead to premature • It is absolutely essential that, when mounting the
degradation of the flexible coupling and failure of the major assembly, the teeth of the driver are greased.
power take-off. The following lubricating paste is recommended: Optimol
The specified moments of inertia of the driven assembly White T - part number A 000 989 80 51 (DBL 6880.10)
(Emin or Emax) under variant 3 may be neither undershot Alternatively: Approved engine oils
nor exceeded.
The lines connected to the assembly must compensate
Power take-offs for direct flange-mounting of for the relative movements between the engine and the
pumps, variant 1 (sales codes N7L, N7K, N7M) vehicle (body), must be in order with regard to vibrations
and must have sufficient clearance to vehicle
The factory-fitted cover on the PTO flange (cap + seal +
components.
bolts/nuts) acts only as a temporary seal until such time
as the assembly is installed by the body manufacturer. If necessary, additional shielding from the hot,
e.g. exhaust gas-carrying, components may be required.
The parts must not be reused.

Permissible combinations of gross mass and total

lever arm of implement applications
It is not permissible to exceed the permissible gross
masses and total lever arms in relation to the connecting
flange of the power take-off as listed in the tables.
Installation of an additional pump support/assembly
support is not permissible.
The connected lines do not need to be considered if
they are attached to the vehicle frame or body at a
maximum distance of 600 mm, relative to the connecting
point on the assembly. This attachment must be
designed so that the proportionate inertia forces of the
lines can be absorbed.
accessories ¹⁾) from power take-off connecting
flange in mm
F Gross mass in kg (major assembly and
accessories ¹⁾)
W26.45-A097-12
Implement: Weight and lever arm
¹⁾ In addition to the complete assembly, the connected account in the overall considerations for determining the
lines (fully assembled and filled) must also be taken into actual gross mass and total lever arm.

Power take-off
Engine OM 470/471/473 with PTO,
sales code N7K (SAE A) and N7L
(SAE B)
(assembly and
accessories) from power
take-off connecting flange
[mm]
F Gross mass of assembly
(pump and accessories)
[kg]
permissible
not permissible
W26.45-A098-06
Engine OM 470/471/473 with PTO,

sales code N7M (ISO 7653‑D)
(assembly and
accessories) from power
take-off connecting flange
[mm]
F Gross mass of assembly
(pump and accessories)
[kg]
permissible
not permissible
W26.45-A099-06
Power take-off
Power take-offs for propeller shaft connection (sales

code N7I, N7O), variant 2 and 3
For attachment according to variant 3 the following
flexible couplings must be installed:
For power take-off, sales code N7I:
• Type II - Flexible coupling A 471 237 01 38
Outside dimensions:
• ∅ 213 mm
• Width = 85 mm W26.45-A068-10
• Weight = 8.5 kg Installation position and installation direction
For power take-off, sales code N7O:

• Type III - Flexible coupling A 471 237 07 38
Outside dimensions:
• ∅ 250 mm
• Width = 114 mm
• Weight = 12.3 kg
If other couplings (flexible, switchable) have to be used, a non-objection

check is essential for this installation situation. The relevant tests are
extremely complex. The costs for this must be borne by the client.
The flexible couplings must be installed at the major assembly end.
Pay attention to the direction of installation of the flexible coupling (see
figure).
W26.45-A100-01
Information label: Direction of installation
The engine speed must not fall below 800 rpm when the Propeller shafts can be operated in Z and W layouts in
power take-off is operating at full load (maximum rated two and three dimensions.
torque).

The total propeller shaft angle (GW) including all measurement tolerances must not exceed the following
angles
Variant 2 Without flexible coupling GW ≤ 6°; GW ≠ 0°
Variant 3 In combination with flexible coupling GW ≤ 6°; GW ≠ 0°

Type II/A 471 237 01 38
In combination with flexible coupling GW ≤ 10°; GW ≠ 0°

Type III/A 471 237 07 38
Power take-off
The absolute differential angle between the working • 9T
angles of a shaft (including all measurement tolerances) • 16/32 DP
must be < 1°. A value of 0° should be aimed for.
• Delivery package ex factory (collapsible cardboard
The flexible coupling must not be cleaned with box in cab):
aggressive media, e.g. pure benzine, cold cleaning
solvent. • Driver: A 471 230 06 26
The flexible coupling is maintenance free. • Shaft coupling: A 471 236 03 66
A visual check is to be performed, however, as part of Fastening thread for connecting the pump (implement)
the general maintenance and inspection routines. M10, length 22 mm (blind hole thread¹⁾)
If there is damage to the elastomer or to the metallic Max. tightening torque = 57 Nm²⁾
components, the flexible coupling must be replaced Minimum screw-in depth 1.5 x screw diameter
complete.
¹⁾ Note: Use the correct screw length.
Connection geometry OM 470/471/473 + sales code ²⁾ According to MBN 10130 Class II and in combination
N7K (SAE A) with a bolt to MBN 10105, class 10.9, μtot = 0.08 - 0.14,
Driver for: tightening torque may be reduced by specifications of
the pump (implement).
• SAE A gearing
• ANSI B 92.1

W26.45-A102-09
Screw diameter, connection geometry OM 470/471/473 + sales code N7K (SAE A)
1 Rear edge of timing case 4 Package contents of driver SAE A
A 471 230 06 26
2 Shaft coupling/short A 471 236 03 66 5 Hydraulic pump SAE A shaft protrusion
3 Custom connection (observe installation-specific
guidelines.)
Connection geometry OM 470/471/473 + sales code • Delivery package ex factory (collapsible cardboard
N7L (SAE B) box in cab):
Driver for: • Driver: A 471 230 07 26
• SAE B gearing • Shaft coupling: A 471 236 03 66
• ANSI B 92.1 Fastening thread for connecting the pump (implement)
• 13T M12x1.5, length 20 mm (full-length thread)
• 16/32 DP Max. tightening torque = 104 Nm¹⁾
Power take-off
¹⁾ According to MBN 10130 Class II and in combination Minimum screw-in depth 1.5 x screw diameter
with a screw to MBN 10105, class 10.9, μtot = 0.08 -
0.14, tightening torque may be reduced by
specifications of the pump (implement).

W26.45-A102-09
Screw diameter, connection geometry OM 470/471/473 + sales code N7L (SAE B)
1 Rear edge of timing case 4 Package contents of driver SAE B
A 471 230 07 26
2 Shaft coupling/short A 471 236 03 66 5 Hydraulic pump SAE B shaft protrusion
3 Custom connection (observe installation-specific
guidelines.)
Connection geometry OM 470/471/473 + sales code • 4 x nut:

N7M (ISO 7653-D) A 385 990 05 51 M12, size 16
Driver for: Tightening torque of stud bolt:
• ISO 7653‑D N 000000 002944 = 40 Nm
• Gearing: Splined hub A 8x32x36 (similar to Observe installation direction of stud bolt (protrusion
DIN 5462) dimension 30 mm).
• Delivery package ex factory (collapsible cardboard Max. tightening torque of nut:
box in cab): A 385 990 05 51 = 104 Nm¹⁾
• Driver: A 471 230 04 26 ¹⁾ According to MBN 10130 Class II and in combination
• Shaft coupling: A 471 236 02 66 with a nut of class 10, μtot = 0.08 - 0.14, tightening
torque may be reduced by specifications of the pump
• 4 x stud bolt: (implement).
N 000000 002944 DIN 835‑M12x30 DBL9440.40

Power take-off
W26.45-A103-09
Connection geometry OM 470/471/473 + sales code N7M (ISO 7653-D)
1 Rear edge of timing case Tightening torque: 40 Nm
2 Shaft coupling A 471 236 02 66 5 Nut M12 SW16 A 386 990 05 51 (4x)
3 Custom connection (observe installation-specific 6 Package contents of driver/ISO A 471 230 04 26
guidelines)
4 Stud bolt N 000000 002944 7 Hydraulic pump ISO 7653‑D shaft protrusion
DIN 835 - M12x30 - 10.9 DBL9440.40 (4x)
Connection geometry OM 470/471/473 + sales code

N7I (propeller shaft flange diameter 100 mm,
ISO 7646 - 100x6x8)

Power take-off
W26.45-A104-09
Connection geometry OM 470/471/473 + sales code N7I
1 Rear edge of timing case 2 Custom connection (observe installation-specific
guidelines.)
Connection geometry OM 470/471/473 + sales code

N7O (propeller shaft flange diameter 120 mm,
ISO 7646 - 120x8x10)

W26.45-A105-09
Connection geometry OM 470/471/473 + sales code N7O
1 Rear edge of timing case 2 Custom connection (observe installation-specific
guidelines.)
Center upper rear engine power take-off with propeller shaft...
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
i i
Possible damage to the engine and power take-off: Notes on the installation position in the vehicle can
Radial power draw, e.g. a belt or chain drive system, be found in the arrangement drawings in the
at the power take-offs is not permissible. Mercedes-Benz Bodybuilder Portal.
---------------------------------------------------------------------------
Center upper rear engine power take-off with Available variant
propeller shaft flange in combination with OM 460 • Sales code N7P
engines
Rear engine power take-off, b, flange 100 mm,
Engines of model series OM 460 can be optionally 600 Nm
ordered with a gear-driven power take-off in the "center
upper rear" position as special equipment. This power • Additionally sales code N6E
take-off has a flange for connection of a propeller shaft. Flexible coupling, for engine power take-off (loose)

Power take-off
Gear ratios/rotation direction

PTO output speed = 1.07 x engine
speed
Left-hand rotation,
engine power take-off).
The power at the flywheel of the
engine is reduced by the power
consumption of the auxiliary
assemblies driven by the engine W26.45-A076-01 W26.45-A077-01
power take-off.
A rear engine power take-off can
only be retrofitted at great effort and
cost.
nM nEngine
nN nPTO
Maximum permissible output torques should be provided, for example by means of a

• Continuous operation: ≤ 600 Nm pressure limiter or anti-lock protection.
• Short-term operation (e.g. start-off and shifting): • Only start the engine when the power take-off is load-
≤ 720 Nm free in order to protect the power take-off and major
assemblies. Operation must be free of shocks and
Permissible working speed vibrations.
When the power take-off is operating at full capacity, an • If necessary, the permissible torques should be
engine speed ≥ 1200 rpm is required. reduced by the corresponding shock factor.
These can only be used in conjunction with an engine Tapping torque via live power take-offs while driving can
variant which can actually deliver the required torque at have adverse effects on the functioning of the Predictive
the corresponding engine speed. There are no Powertrain Control (sales code G0T). It is possible to
mandatory code combinations or mandatory deactivate this comfort function temporarily at any time
assignments of corresponding engine variants. when power is drawn while driving. Predictive Powertrain
Control is not available for cement mixer chassis.
• In order to prevent the maximum permissible torques
from being exceeded, suitable overload protection

Possible arrangement of applications, variant 2

Power take-off for propeller shaft connection without
flexible coupling
W26.45-A047-10
Power take-off without flexible coupling
Power take-off
Possible arrangement of applications, variant 3
Power take-off for propeller shaft connection with
flexible coupling (N6E)
1 Engine
2 Power take-off
4 Propeller shaft
5 Flexible coupling
B Moment of inertia of driven assembly (including
flange) plus propeller shaft W26.45-A096-10
C Moment of inertia of propeller shaft plus Power take-off with flexible coupling
propeller shaft-end component of flexible
coupling
D1 Moment of inertia of propeller shaft-end
component of flexible coupling
D2 Moment of inertia of assembly-end component
of flexible coupling
E Moment of inertia of driven assembly (including
flange) plus assembly-end component of
flexible coupling

Maximum permissible moments of inertia
Variant 2 Variant 3
B (kgm²) C (kgm²) D (kgm²) E (kgm²)
- - D1 D2 -
0.01 ¹⁾ 0.026 0.014 0.034 0.11

1) If the permissible moment of inertia of variant 2 (B) of 0.01 kgm² is exceeded, the flexible coupling (code N6E) must be installed. The
permissible moments of inertia of variant 3 must be complied with.
The additional length of the flexible coupling must be Width = 85 mm

taken into account when defining the propeller shaft Weight = 8.6 kg
length.
The flexible coupling must be installed on the assembly
Flexible coupling side (see figure).
Item number A 444 250 00 01 (sales code N6E) Refer to the information label for the direction of
Outside dimensions/weight: installation ("Engine").
∅ 212 mm

Power take-off
The flexible coupling must not be cleaned with

aggressive media, e.g. pure benzine, cold cleaning
solvent.
The flexible coupling is maintenance free.
A visual check is to be performed as part of the general
maintenance and inspection routines.
If there is damage to the elastomer or to the metallic
components, the flexible coupling must be replaced
complete.
If other couplings (flexible, engageable) provided by the W26.45-A068-10
body manufacturer are to be used, a non-objection Direction of installation of flexible coupling
check is required for this installation situation. The
relevant tests are extremely complex. The costs for this
must be borne by the client.
Connection geometry of power output flange
W26.45-A107-11
View from side
Power take-off
W26.45-A108-12
View from rear in direction of travel/toward engine/engine power
take-off
Center upper rear engine power take-off for direct flange-mo...
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
i i
Possible damage to the engine and power take-off: Further information regarding the installation position
Radial power draw, e.g. a belt or chain drive system, in the vehicle can be found in the arrangement
at the power take-offs is not permissible. drawings in the Mercedes-Benz Bodybuilder Portal:
---------------------------------------------------------------------------
Center upper rear engine power take-off for direct Available variant
flange-mounting of pumps in combination with • Sales code N7K
OM 460 engines
Direct flange-mounting of pumps, SAE A, 250 Nm
The OM 460 engines can be optionally ordered with a
gear-driven power take-off as special equipment. • Sales code N7L
Connections for direct flange-mounting of pumps are Direct flange-mounting of pumps, SAE A, 250 Nm
available with toothed receptacles (drivers) for the
corresponding hydraulic pump variants.

Power take-off
Gear ratios/rotation direction
PTO output speed = 1.07 x engine
speed
Left-hand rotation,
engine power take-off)
The power at the flywheel of the
engine is reduced by the power
consumption of the auxiliary
assemblies driven by the rear engine W26.45-A076-01 W26.45-A077-01
power take-off.
All power take-offs are supplied
without hydraulic pumps or driven
assembly. These are to be attached
by the body manufacturer.
A rear engine power take-off can
only be retrofitted at great effort and
cost.
nM nEngine
nN nPTO
Permissible working speed

When the power take-off is operating at full capacity, an engine speed
≥ 1200 rpm is required.
Permissible moment of inertia

The maximum permissible moment of inertia of the driven major assembly
is 0.01 kgm².
Sales code N7K, N7L
1 Engine
2 Power take-off
W26.45-A060-01
Power take-offs for direct flange-mounting
of pumps
Maximum permissible output torques • Only start the engine when the power take-off is load-
The table below lists the maximum possible power take- free in order to protect the power take-off and major
off torques by PTO code. assemblies. Operation must be free of shocks and
vibrations.
These can only be used in conjunction with an engine
variant which can actually deliver the required torque at • If necessary, the permissible torques should be
the corresponding engine speed. There are no reduced by the corresponding shock factor.
mandatory code combinations or mandatory Tapping torque via live power take-offs while driving can
assignments of corresponding engine variants. have adverse effects on the functioning of the Predictive
• In order to prevent the maximum permissible torques Powertrain Control (sales code G0T). It is possible to
from being exceeded, suitable overload protection deactivate this comfort function temporarily at any time
should be provided, for example by means of a when power is drawn while driving. Predictive Powertrain
pressure limiter or anti-lock protection Control is not available for cement mixer chassis.

Power take-off

Power take-off Maximum rated torque, continuous Maximum peak torque, temporary
operation [Nm] operation (start-off/shifting) [Nm]
Sales code N7K (SAE A) 250 300
Sales code N7L (SAE B) 250 300
Cap/pump assembly/lines The following lubricating paste is preferred and

The factory-fitted cover on the PTO flange (cap + seal + recommended for this:
bolts/nuts) acts only as a temporary seal until such time Optimol White T – part number A 000 989 80 51
as the assembly is installed by the body manufacturer. (DBL 6880.10)
The parts must not be reused. Alternatively: Approved engine oils
• The new bolts/nuts which are therefore required, as The lines connected to the assembly must compensate
well as an appropriate new seal for the power take- for the relative movements between the engine and the
off/major assembly interface, must be supplied and vehicle (body), must be in order with regard to vibrations
installed by the body manufacturer. and must have sufficient clearance to vehicle
It is absolutely essential that, when mounting the major components.
assembly, the teeth of the driver and shaft coupling are If necessary, additional shielding from the hot,
greased. e.g. exhaust gas-carrying, components may be required.

Permissible blocking bending moment of implement

applications
The maximum permissible static blocking bending
moment, with respect to the timing case connecting
flange, is 60 Nm.
Installation of an additional pump support/assembly
support is not permissible.
1 Power take-off connecting flange
2 Timing case connecting flange
accessories ¹⁾) from power take-off
connecting flange in mm
g Distance between timing case connecting
flange and power take-off connecting flange
in mm
Sales code N7K (SAE A) = 36.5 mm
Sales code N7L (SAE B) = 57.0 mm
g+a Distance of overall CoG (major assembly and
accessories ¹⁾) from timing case connecting
flange in mm
W26.45-A112-12
F Gross mass in kg (major assembly and Dimensions and weight of power take-off
accessories ¹⁾)
¹⁾ In addition to the assembly, the connected lines (fully Connection geometry of OM 460, sales code N7K
assembled and filled) must also be taken into account in (SAE A)
the overall considerations for determining the actual Driver for:
blocking bending moment.
• SAE A gearing
Exception:
• ANSI B 92.1
The connected lines do not need to be considered if they
are attached to the vehicle frame or body at a maximum • 9T
distance of 600 mm, relative to the connecting point on • 16/32 DP
the assembly. This attachment must be designed so that
the proportionate inertia forces of the lines can be
absorbed.
Power take-off
• Delivery package supplied ex-factory: • Shaft coupling: A 424 230 00 28
• Driver: A 471 230 06 26

W26.45-A109-09
Connection geometry of OM 460, sales code N7K (SAE A)
1 Driver assembly A 424 230 02 26 5 Connecting flange for pump
2 Shaft coupling assembly A 424 230 00 28 6 Hydraulic pump SAE A shaft protrusion
3 Timing case connecting flange G Distance between timing case connecting flange
and power take-off connecting flange
4 Fastening thread for connecting the pump
(implement) M10, length 24.5 mm (blind hole
thread ¹⁾), tightening torque = 50 Nm²⁾, minimum
screw-in depth 1.5 x screw diameter
¹⁾ Note: Use the correct screw length. • SAE B gearing

²⁾ According to MBN 10130 Class II and in combination • ANSI B 92.1
with a bolt to MBN 10105, class 10.9, μtot = 0.08 - 0.14, • 13T
tightening torque may be reduced by specifications of
the pump (implement). • 16/32 DP
• Delivery package supplied ex-factory:
Connection geometry of OM 460, sales code N7L
(SAE B) • Driver: A 444 230 01 26
Driver for: • Shaft coupling: A 424 230 00 28

Power take-off
W26.45-A110-09
Connection geometry of OM 460, sales code N7L (SAE B)
1 Driver assembly A 424 230 02 26 5 Connecting flange for pump
2 Shaft coupling assembly A 424 230 00 28 6 Hydraulic pump SAE B shaft protrusion
3 Timing case connecting flange x 43.7 mm
4 Fastening thread for connecting the pump G Distance between timing case connecting flange
(implement) M12, length 12 mm (full-length and power take-off connecting flange
thread¹⁾)
Tightening torque = 80 Nm²⁾
¹⁾ Note: Use the correct screw length. tightening torque may be reduced by specifications of
²⁾ According to MBN 10130 Class II and in combination the pump (implement).
with a bolt to MBN 10105, class 10.9, μtot = 0.08 - 0.14,
Transmission power take-off
Power take-off
aDanger
parts.
i i
In this chapter, representations, code scopes and Technical data on the transmission power take-offs
pre-installations of other model designations and are available in the Mercedes‑Benz Bodybuilder
model series are listed for reasons of Portal.
standardization. The information that is applicable to (http://bb-portal.mercedes-benz-trucks.com)
i
Possible transmission damage:
i
Observe the specifications given in this document.
In vehicles with the combination of a turbo retarder
clutch (TRK) with a transmission power take-off, the
transmission power take-off is not adequately
powered during a driving-off procedure or when
maneuvering. The reason for this is the low engine i
speed and the power loss in the TRK until the dry Observe the operator's manual of the vehicle:
clutch closes. Read "Details of operation" before parameterizing
This combination is therefore unsuitable for the use the power take-off.
case described.
Depending on the vehicle model, the engine power
take-offs N7I and N7Q are available as alternatives
for combining with the TRK.
Observe the following when

retrofitting transmission power take-
offs:
• After installation, fill the
transmission with oil up to the
lower edge of the filler opening.
Refer to the notes in the
"Operation" chapter of the
operator's manual!
• Allow the engine to run for
approx. two minutes and engage W26.45-A085-01 W26.45-A086-01
the power take-off. Dual power take-off Pump power take-off, under top edge of
• Check the oil level again and frame
correct if necessary.
Power take-off
Installation of a non-MB power take-

off requires consultation with the
relevant contact person (see
document "Advice for body
manufacturers").
The operational safety and reliability
of the transmission cannot be
guaranteed if unsuitable power take-
offs are used.
The power take-off version and ratio
selection both depend on the power W26.45-A087-01 W26.45-A088-01
output and rotational speed of the Propeller shaft power take-off, under top Power take-off with 4 shafts
major assembly to be driven. edge of frame
Transmission power take-offs may
only be engaged and disengaged
with the vehicle stationary. Engaging
and disengaging (see operator's
manual).
The power take-off is connected to
the oil circuit of the manual
transmission.
They are designed for continuous
operation in combination with an oil
cooling system, code N6Z.
With the transmission power take-off engaged it is additional inertia forces of the major assemblies to be
possible to start off and drive the vehicle in one of the driven are not taken into account.
start-off gears. However, subsequent shifting and gear Select the power take-off ratio such that a minimum
changes are not permitted. To engage a start-off gear, engine speed of 650 to 800 rpm is maintained with the
the mounted application on the transmission power take- power take-off under load. The power output should be
off must be switched load-free (drag torque ≤ 50 Nm). within the range of the maximum engine torque.
If the vehicle is equipped with an automated manual Exposed propeller shafts or belt pulleys must be
transmission and a transmission power take-off, it is covered.
possible by means of parameter modifications in the
SSAM, PSM (model 967) and ASAM (model 963/964) No belts or chain drives may be fitted to the drive shaft
control units to shift the desired "splitter box" (low/high) or drive flange of a power take-off.
in the transmission automatically when the power take- The power take-off is driven by the transmission
off is engaged. Please note that this function is active countershaft in the following versions:
only when the vehicle is stationary and the transmission
• One or two drives
is in the neutral position. When a start-off gear is
engaged, the transmission changes to the appropriate • Shift lock for transmission
"splitter box" of the selected start-off gear regardless of • Different directions of rotation
the settings in the SSAM, PSM or ASAM. This
functionality must be taken into account in your design. • With or without coupling flange
The maximum transferable torques (Nm) for each of the
power take-offs are guideline values for shock-free and
vibration-free operation.
For the permissible torques, refer to the overview tables
for the respective power take-offs in the Mercedes-Benz
Bodybuilder Portal.
Maximum permissible jolting moment (during activation):
≤ 1.3 x MMax PTO (maximum permissible torque of
power take-off).
The data were based on a highly durable gearing design
and a calculated service life of at least 500 h (BR 967)
and 600 h (BR 963/964) at maximum power output. The
Power take-off
• "b" version: Drive with flange for propeller shaft exceeded. For the permissible blocking bending
• Flange 100x6x8 as per ISO 7646 Type A moments, refer to the arrangement drawings for the
Standard for: respective power take-offs in the Mercedes‑Benz
Bodybuilder Portal (http://bb-portal.mercedes-
PTO 60-2b, PTO 61-10b, benz-trucks.com). Installation of an additional pump
Dual PTO 60-11b/x, dual PTO 61-11b/x, support/assembly support is not permissible.
PTO 121-1b • The factory-fitted cover on the PTO flange (cap and
PTO 131‑2b (code N2D), PTO 121‑1b (code N2F) seal) acts only as a temporary seal until such time as
and for PTO with special equipment (code N9Y) the major assembly is installed by the body
manufacturer.
• Flange 120x8x8 as per ISO 7646 Type A for:
The parts must not be reused.
PTO 125-10b in model 967, dual PTO 125-11b/x
in model 967, in model 963, 964 Standard The factory-supplied flange head nuts A 005 990 00
(exception: not for PTO 131-2b (code N2D), 50 or hexagon nuts A 385 990 05 51, both M12, size
NA121-1b (code N2F)) 16, can be reused.
• Flange 120x8x10 similar to ISO 7646 TYPE A Recommended tightening torque: 65 Nm
However, bore diameter different to ISO: 10 mm Power take-offs without an oil cooler are only approved
instead of 8 mm (for PTO with special equipment for brief operation at full power.
code N9X) Brief operation:
• "c" version: Direct mounting of a hydraulic pump (as • Maximum duty cycle approx. 30 min
per ISO 7653 D)
• Subsequent cooling-off period at least 30 min
• When a hydraulic pump is installed directly, the
maximum permissible weight moments may not be

Continuous operation:
• Full power output with transmission oil cooling, sales
code N6Z
W23.00-A001-11
Transmission cooler, sales code N6Z (model 967)
Transmission-independent power take-off
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
i i
Notes on the installation position in the vehicle can Possible risk of accident for the user:
be found in the arrangement drawings in the The function of automatic activation of the live power
Mercedes-Benz Bodybuilder Portal: take-off after engine start can produce safety-critical
http://bb-portal.mercedes-benz-trucks.com states in the driven implements. Take suitable
measures to ensure that no safety-critical states of
the driven implement arise in conjunction with the
parameterized function of automatic activation of the
live power take-off after engine start.
The functional behavior of the vehicle must be taken
into consideration in the safety concept of the
implement driven by the live power take-off.
---------------------------------------------------------------------------
Abbreviations specifications. For questions regarding the boundary
NMV Live power take-off conditions if implements are located within the critical
limits or if it is unclear whether an implement is
NA3 Power take-off 3 switch compatible, please get in touch with the relevant contact
XMC Parameterizable special module, 2nd generation person (see "Advice for body manufacturers" document).
When doing so, please also send the necessary
ASAM Advanced Signal Actuator Module
technical information, function descriptions, power
ADR Working speed control draws, torque draws, moments of inertia, etc. Where
AKL Dependence claw necessary, coordination can take place in advance to
define measures that will ensure safe commissioning
UAKL Independence claw/sliding sleeve and safe operation of the body implement.
The body implements and drive concepts must be
checked for compatibility and compliance with these
---------------------------------------------------------------------------
Transmission-independent power take-off in
combination with vehicles of model generation 5/
code V2B, V2F, V2J, V3L

Power take-off
Live power take-off (NMV)
A transmission-independent, live power take-off (NMV)
can be ordered as special equipment.
The live power take-off is designed for high power draws
and continuous operation. It is driven directly by the
engine via pairs of gears. The vehicle's clutch is used to
start up the live power take-off.
Only variants with propeller shaft connections are
available. See the vehicle operator's manual
regarding engaging and disengaging the power take-off
and emergency operation mode. The live power take-off
is connected to the oil circuit of the manual transmission
and to a corresponding oil cooler.
Two variants are available (A and B), each with two
different gear ratios.
W26.45-A111-11
Example for live power take-off, sales code N4Y/N4Z
Technical limit values of the live power take-off Sales code N4W (i = 1/1.19), speed = 1.19 x engine
speed
Variant A
Sales code N4X (i = 1/1.65), speed = 1.65 x engine
For use while stationary – clutch-dependent speed
Sales code N4Y (i = 1/1.19), speed = 1.19 x engine Variant B is designed for use while stationary and
speed optionally while driving. Due to the additional demands
Sales code N4Z (i = 1/1.65), speed = 1.65 x engine of operation while driving, variant B does not exhibit the
speed same product characteristics as variant A during
stationary operation. The live power take-off in variant B
Variant A is designed exclusively for use while
can only be activated when the transmission is in the
stationary. It can start up with high moments of inertia
neutral position.
and deliver high output torques.
Variant B
For use while stationary and while driving – partially
clutch-dependent
---------------------------------------------------------------------------
Left-hand rotation, i.e. counter-clockwise (viewed toward of the engine is reduced by the amount of power drawn
engine/live power take-off flange in direction of travel). by the live power take-off.
A live power take-off can only be retrofitted at great effort Radial power draw (e.g. a belt or chain drive system) at
and cost, if at all. the live power take-off is not permissible.
In connection with variant B, it should be noted that,
while driving, the available power output at the flywheel
---------------------------------------------------------------------------
Power output flange tilt compensator The installation angle of the drivetrain in all-wheel drive
The live power take-off is equipped with an integrated tilt vehicles is only 2°. As the live power take-off is used in a
compensator for the position of the power output flange. structurally identical manner with its tilt compensator
This fully compensates for the 3.5° installation angle of designed for non-all-wheel drive vehicles, the difference
the drivetrain in non-all-wheel drive vehicles. The of 3.5° to 2° means that the angle compensation is not
extension of the longitudinal axis of the power output complete. The extension of the longitudinal axis of the
flange is thus parallel with the top edge of the drive flange (relative to the top edge of the longitudinal
longitudinal frame member. frame member) is consequently angled 1.5° upward.

Power take-off
W26.45-A115-10
Tilt compensator in non-all-wheel drive vehicles
Maximum permissible output torques and moments Variant B

of inertia at the power output flange of the live power For operation of the live power take-off variant B, the
take-off when switching on/off following diagrams apply for the maximum permissible
Variant A output torque as a function of the moment of inertia of
the body implement at the live power take-off power
Sales code N4Y (i = 1/1.19) = maximum recommended output flange.
output torque 410 Nm
Operating points that lie below the limit line G in the
Sales code N4Z (i = 1/1.65) = maximum recommended range Z must always be selected.
output torque 300 Nm
The ideal case is to select operating points in the range
Maximum permissible moment of inertia: no limit Z that are as far as possible from the limit line G.
The start-off torque is limited by the service life of the
clutch (wear). If the service life of the clutch is not taken
into account, the live power take-off can be started with
the full available engine torque.

Sales code N4W (i = 1/1.19)

G Limit line
kgm² Permissible moment of inertia at live power
take-off power output flange
Nm Permissible output torque at live power take-
off power output flange
Z Permissible range below limit line
W26.45-A116-11
Power take-off
Sales code N4X (i = 1/1.65)
G Limit line
kgm² Permissible moment of inertia at live power
Nm Permissible output torque at live power take-
off power output flange
Z Permissible range below limit line
W26.45-A117-11
If your particular application results in an impermissible Variant B

ratio between moment of inertia and output torque Stationary operation ¹⁾:
(outside range Z, above limit line G), then additional
rotating masses must be installed (to increase the Sales code N4W (i = 1/1.19) = 2250 Nm
moment of inertia) and/or the torque draw must be Sales code N4X (i = 1/1.65) = 1650 Nm
reduced in order to ensure that ratios within the
¹⁾ Stationary operation with variant B also includes
permissible range Z and below the limit line G are
engaging a start-off gear from "neutral" and moving off
achieved.
and driving in this gear, but not any subsequent shifting.
In this respect, please also observe the specifications in
the section on the maximum permissible weight pressure Driving mode
at the propeller shaft flange of the live power take-off. Sales code N4W (i = 1/1.19) = 1000 Nm
With variant B, it is only possible to switch to driving Sales code N4X (i = 1/1.65) = 720 Nm
operation (by means of the "sliding sleeve") if the limit
values are observed. Otherwise, the live power take-off Operation must be free of shocks and vibrations.
cannot be engaged/disengaged. If this cannot be guaranteed, the permissible output
Torque is not the moment that is required to accelerate torques should be reduced by the corresponding shock
mass inertia, but refers exclusively to the pure load factor.
torque at constant engine speed. In order to prevent the maximum permissible output
torque from being exceeded, suitable overload
Maximum permissible output torques at power protection must be provided (e.g. by means of pressure
output flange of live power take-off during operation limitation, anti-lock protection).
These are the maximum permissible output torques at Drawing torque via live power take-offs while driving can
the propeller shaft flange of the live power take-off. have adverse effects on the Predictive Powertrain
These can only be used in conjunction with an Control function (sales code G0T).
appropriate engine variant that can actually deliver the
required torque. It is possible to deactivate this comfort function
The power output at the flywheel of the vehicle's engine driving.
is reduced by the power consumption of the live power
take-off. Predictive Powertrain Control is not available for cement
mixer vehicle chassis.
There are no mandatory code combinations or
mandatory assignments of corresponding engine Maximum permissible torque changes per second
variants to live power take-offs. (triggered by the body implement) at the live power
Variant A
Stationary operation: Variant A
Sales code N4Y (i = 1/1.19) = 2500 Nm Stationary operation:
Sales code N4Z (i = 1/1.65) = 1800 Nm Sales code N4Y (i = 1/1.19)
= maximum increase: +840 Nm/s
Power take-off
Maximum reduction: -2500 Nm/s Maximum reduction: -420 Nm/s

Sales code N4Z (i = 1/1.65) Sales code N4X (i = 1/1.65)
= maximum increase: +600 Nm/s = maximum increase: +300 Nm/s
Maximum reduction: -1800 Nm/s Maximum reduction: -300 Nm/s
Variant B Maximum permissible propeller shaft angular offsets

Stationary operation: When propeller shafts are used for power output, the
Sales code N4W (i = 1/1.19) data described in the "Installation of propeller shafts"
= maximum increase: +840 Nm/s
Propeller shafts can be operated in Z and W layouts in
Maximum reduction: -2500 Nm/s two and three dimensions.
Sales code N4X (i = 1/1.65) Contrary to the "Installation of propeller shafts"
= maximum increase: +600 Nm/s document, the maximum propeller shaft angular offset
of 10° (including all measurement tolerances) must not
Maximum reduction: -1800 Nm/s
be exceeded (limit value ≤ 10°; limit value ≠ 0°).
Driving mode The absolute differential angle between the angular
Sales code N4W (i = 1/1.19) offsets of the propeller shaft (including all measurement
tolerances) must be < 1°. A value of 0° should be aimed
= maximum increase: +420 Nm/s for.

1 Live power take-off
2 Max. 250 N
3 Propeller shaft (GW)
4 Body
W26.45-A118-10
Maximum permissible weight pressure at propeller limit values for resonance-free operation of the live
shaft flange of live power take-off power take-off/transmission components.
The maximum permissible proportional weight pressure If these limits are complied with, it is not necessary to
at the propeller shaft flange of the live power take-off use a torsionally elastic coupling in the propeller shaft
must not exceed 250 N. drive.
Maximum permissible imbalance of propeller shaft Variant A

used The diagrams below apply for operation of the live power
The maximum permissible imbalance of the propeller take-off variant A.
shaft used is: Uperm = 160.0000 m/n Operating points that are above the resonance range R
Uperm = Permissible residual imbalance in gmm must always be selected for resonance-free operation.
m = Mass of propeller shaft in kg The ideal case is to select operating points that are as
far as possible from the limit line.
n = Maximum output speed of NMV in rpm
It is not permissible to operate the live power take-off
Calculation must be carried out in line with while stationary below an engine speed of 848 rpm.
DIN ISO 21940‑11 accuracy class G16.
Resonance-free operation must also be ensured during
Minimum rotating masses/moments of inertia at activation (drop in engine speed due to load on the live
power output flange of live power take-off during power take-off).
operation If the required minimum rotating masses are not present,
The minimum total rotating masses (at the power output the engine speed must be increased accordingly (the
flange of the live power take-off) plotted in the diagrams necessary working speed control must be parameterized
below against the available engine speed represent the accordingly).
Power take-off
The body manufacturer must ensure that the major
assemblies to be connected are resonance-free.

The dark gray area in the diagram merely serves to

indicate the theoretical continuation of the curves below
the idle speed.
Sales code N4Y (i = 1/1.19)
1/min Engine speed
kgm² Cpl. rotating mass of major assembly
R Resonance range below limit line
W26.45-A119-11

the idle speed.
Sales code N4Z (i = 1/1.65)
1/min Engine speed
W26.45-A120-11
Variant B It is not permissible to operate the live power take-off

The diagrams below apply for operation of the live power while stationary below an engine speed of 848 rpm.
take-off variant B. Resonance-free operation must also be ensured during
Operating points that are above the resonance range R activation (drop in engine speed due to load on the live
must always be selected for resonance-free operation. power take-off).
The ideal case is to select operating points that are as The body manufacturer must ensure that the major
far as possible from the limit line. assemblies to be connected are resonance-free.

Power take-off

the idle speed.
Sales code N4W (i = 1/1.19)
1/min Engine speed
W26.45-A121-11

the idle speed.
Sales code N4X (i = 1/1.65)
1/min Engine speed
W26.45-A122-11
Maximum permissible rotating masses/moments of Maximum permissible engine speed when activating
inertia during operation the live power take-off
The permissible moments of inertia are: Recommended maximum engine speed when activating
Variant A: no limit (clutch wear):
Variant B: driving operation: maximum 10 kgm², Variants A and B: 1000 rpm

stationary operation ¹⁾: no limit
¹⁾ Stationary operation with variant B also includes
engaging a start-off gear from "neutral" and moving off
and driving in this gear, but not any subsequent shifting.

Power take-off
Service life
The live power take-off is designed
and protected for the following
service life:
Maximum continuous torque (Nm) at
power output flange of live power
take-off/service life in hours (h), see
diagram.
W26.45-A123-05
Power output flanges

The following power output flanges are available:
Smooth flange as per ISO 7646

• Flange diameter: 150 mm
• Hole diameter: 12 mm
• Number of holes: 8
W26.45-A124-01
Sales code N9S: 150x8x12
Cross-serrated flanges as per ISO 8667

• Stud bolts M10x1, quality 10.9
Delivery package supplied ex factory
• Tightening torque for nuts M10x1, quality 10: 52 Nm
Not supplied ex factory. In combination with µtot = 0.08 - 0.14
W26.45-A125-01
Sales code N9U: T120 (120 KV)
Power take-off
Sales code N9W: T150 (150 KV)

Sales code N9V: T180 (180 KV)
W26.45-A126-01 W26.45-A127-01
Sales code N9W: T150 (150 KV) Sales code N9V: T180 (180 KV)
Function description of live power take-off CAN or via the XMC switching input X1 40/37 during the
live power take-off engagement process.
Rpm behavior and specifications for engagement/
disengagement If you want to use a transmission-driven and
transmission-independent/live power take-off (NMV) at
Only valid in combination with vehicles of the model the same time, observe the sequence in the table when
generation 5 (code V2B, V2F, V2J, V3L)! switching on/off.
It must be ensured that no working speed control enable Further details on operation can be found in the vehicle
or request signals are sent by the body over the body operator's manual.

Switch-on/off sequence for simultaneous use of transmission power take-off and live power take-off
Switching on/off Sequence
1. 2.
Live power take-off A: ON Transmission power take-off Live power take-off

(N4Y/N4Z)
OFF Transmission power take-off Live power take-off
Live power take-off B: ON Live power take-off Transmission power take-off

(N4W/N4X)
OFF Transmission power take-off Live power take-off
Variant A If a body implement (e.g. a fan) is still spinning (down)

If an engine stop is requested during a live power take- during an engagement process, the engine speed is
off activation or deactivation process, this can prevent synchronized accordingly in order to enable the
the system from automatically disengaging the live engagement to take place.
power take-off. The drive clutch is opened.
Activation (engagement process): • The live power take-off changes from its neutral
• Manual transmission in neutral position position to the AKL position.
• Any working speed controls (ADR) must be • The drive clutch closes and the live power take-off
deactivated. output is accelerated.
• Live power take-off request via switch NA3 • The indicator lamp of the NA3 switch is continuously
(alternatively via body CAN/XMC) lit.
• When the indicator lamp of the NA3 switch stops • The live power take-off is fully activated (engaged).
flashing, the engagement process starts. Working speed control with working speed limits from
• The engine speed is increased to the value stored in equation 050.530 for minimum rpm limitation for power
the ASAM in equation 030.550 for minimum rpm take-off 3 and equation 050.590 for maximum rpm
limitation for power take-off 3. limitation for power take-off 3 is active and the engine
speed is increased to the stored value.
Engine speed ≥ 848 rpm. A maximum of 1000 rpm is
recommended to avoid premature clutch wear. Engine speed (equation 050.530) ≥ 848 rpm.
Deactivation (disengagement process):
Power take-off
• Manual transmission in neutral position synchronized accordingly in order to enable the
• All transmission power take-offs are deactivated or engagement to take place.
unloaded (drag torque ≤ 50 Nm). • The drive clutch is opened.
• Live power take-off deactivation via switch NA3 • The live power take-off changes from its neutral
(alternatively via body CAN/XMC) position to the AKL position.
• The working speed control is deactivated • The drive clutch closes and the live power take-off
(equation 050). power output flange is accelerated. In the process,
• The drive clutch is opened. the load and the moment of inertia of the driven
implement are measured by the appropriate vehicle
• The live power take-off power output flange is no systems. The engine speed is regulated by the
longer driven and spins down; at the same time, the vehicle systems so that the live power take-off
engine speed drops to the set idle speed. reaches an operating status in which it can be
During a disengagement process, the live power take-off switched from the AKL position to the UAKL position.
power output is not accelerated by the engine. The engine speed may decrease during this
• In parallel, the live power take-off is switched from synchronization process down to, but not below, the set
the AKL position to the neutral position. idle speed.
• Indicator lamp of NA3 switch goes out. The live power take-off changes from the AKL position to
the UAKL position.
• The live power take-off is fully deactivated
(disengaged). • The indicator lamp of the NA3 switch is continuously
lit.
• The drive clutch is closed.
• The live power take-off is fully activated (engaged).
State after engine stop
• Working speed control with working speed limits from
In the event of an engine stop, the live power take-off is
equation 050.530 for minimum rpm limitation for
automatically deactivated (disengaged) and remains
power take-off 3 and equation 050.590 for maximum
deactivated when the engine restarts. In order to be able
rpm limitation for power take-off 3 is active and the
to use the live power take-off again, the activation
engine speed is increased to the stored value.
(engagement) process must be repeated.
Engine speed (equation 050.530) ≥ 848 rpm.
An exception to this is the option of automatic activation
(engagement) of the live power take-off in combination Driving operation: As soon as the vehicle is set in motion
with an engine start. With appropriate parameterization via the accelerator pedal with live power take-off B
in the ASAM, the live power take-off is automatically engaged, the working speed control is no longer active.
reactivated (engaged) by the system when the engine is The power output at the flywheel of the vehicle's engine
restarted. is reduced by the power consumption of the live power
take-off. This can result in limitations while driving,
Variant B maneuvering and changing gear.
If an engine stop is requested during a live power take- Deactivation (disengagement process):
off activation or deactivation process, this can prevent
• Manual transmission in neutral position
the system from automatically disengaging the live
power take-off. • All transmission power take-offs are deactivated or
unloaded (drag torque ≤ 50 Nm).
Activation (engagement process):
• Live power take-off deactivation via switch NA3
• Manual transmission in neutral position
(alternatively via body CAN/XMC)
• Any working speed controls (ADR) must be
• The working speed control is deactivated
deactivated.
(equation 50).
• All transmission power take-offs are deactivated or
• The drive clutch is opened.
unloaded (drag torque ≤ 50 Nm).
• The engine speed drops to the set idle speed.
• Live power take-off request via switch NA3
(alternatively via body CAN/XMC) During a disengagement process, the live power take-off
power output is not accelerated by the engine.
• When the indicator lamp of the NA3 switch stops
flashing, the engagement process starts. In parallel, the live power take-off is switched from the
UAKL position to the neutral position.
• The engine speed is increased to the value stored in
the ASAM in equation 030.550 for minimum rpm • Indicator lamp of NA3 switch goes out.
limitation for power take-off 3. • The live power take-off is fully deactivated
Engine speed ≥ 848 rpm. A maximum of 1000 rpm is (disengaged).
recommended to avoid premature clutch wear. • The drive clutch is closed.
If a body implement (e.g. a fan) is still spinning (down)
during an engagement process, the engine speed is
Power take-off
State after engine stop An exception to this is the option of automatic activation
In the event of an engine stop, the live power take-off is (engagement) of the live power take-off in combination
automatically deactivated (disengaged) and remains with an engine start. With appropriate parameterization
deactivated when the engine restarts. In order to be able in the ASAM, the live power take-off is automatically
to use the live power take-off again, the activation reactivated (engaged) by the system when the engine is
(engagement) process must be repeated. restarted.
Front engine power take-off
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
An engine power take-off at the front is not currently • Front engine power take-off, pre-installation of Frigo
available for model series 963. Any modifications in the generator AW22.5, sales code N7G
area of the engine and additional power take-offs are not The alternator itself is not included in the scope of
permissible. supply.
For some 963.xxx vehicle model designations (not low The alternator may only be installed by personnel
frame chassis), two versions are available for the pre-
authorized and trained by FRIGOBLOCK®.
installation of the Frigo generator. The pre-installations
are not available for vehicle model designations 964.xxx. If you have any questions, please contact the
FRIGOBLOCK® customer service department at:
• Front engine power take-off, pre-installation of Frigo
generator AW30, sales code N7H Tel.: +49 201 61301‑0
Power take-off via externally installed transfer case
Power take-off
aDanger
parts.
aWarning
aWarning
clothes
i i
Possible risk of fire and overheating of the vehicle: Possible failure of proper functioning:
The body manufacturer must provide separate Loss of control by the driver possible. Do not modify
thermal protection if high power (> 100 kW) is any screw connections that are relevant to safety,
tapped while the vehicle is stationary in combination e.g. that are required for wheel control, steering or
with the equipment "Exhaust system, on right of braking functions.
frame, tailpipe inward", sales code K7I or K7D
(Outlet directed 15° downward at side).
If necessary, the exhaust outlet should be routed to
the left side, as with sales code K7N, or by using an i
upward exhaust pipe, sales code K7A, or an upward Danger for the user from the vehicle starting off by
exhaust system behind the cab, sales code K7J, or a itself during operation:
horizontal exhaust system with the tailpipe routed to To reliably prevent uncontrolled forward motion of
the right and outward, sales code K8D. the vehicle, the factory default activation conditions
in ASAM equation 020 must not be changed.
i
Possible risk of fire and damage to the vehicle:
When the vehicle is operating in stationary work
mode with high power draws, high exhaust gas
temperatures and flow volumes occur. Depending on
the overall situation of the body, the heat trapped
under the vehicle can cause degradation or
accelerated aging of component parts (e.g. tires,
lines and hoses), or can cause the ground to get
very hot. The exhaust flow must not be aimed
directly at the ground or onto adjacent component
parts!
Power take-off
i
Possible automatic engine shutoff during vehicle
operation and associated loss of control of vehicle:
When the vehicle's engine is started by means of an
external request via the ASAM or XMC, it switches
itself off automatically according to the time value of
30 minutes stored in the electronic ignition lock (EIS)
at the factory. This value can be increased to up to
14 hours by means of parameterization via the
XENTRY diagnostic system. The setting must be
adjusted to suit the relevant requirements of the
body implement. Unnecessarily long switch-off
intervals combined with the engine idling can have a
negative effect on the charge balance of the vehicle
batteries. General driving operation with the
externally started engine is not permissible due to
the stored switch-off function. Formulate the
operator's manual accordingly and attach
information labels.
---------------------------------------------------------------------------
General generation 5 (code V2B, V2F, V2J, V3L) as of
The sales code N6P, Pre-installation for power take-off production date 10/2019.
via externally installed transfer case, is available for For vehicles of model generation 4, use the edition
installing a transfer case with power take-off, e.g. in AeJ2019-1a of the Body/Equipment Mounting Directives
order to switch between the axle drive and the hydraulic from the archive in the Bodybuilder Portal.
pump drive for a concrete pump, for vehicles of model

W28.10-A002-02
Example of an external transfer case in the
drivetrain
In addition to special software functions, the pre- • NA2 switch (therefore a dual power take-off is not
installation code includes: offered with N6P)
• Rotational speed sensor for vehicle transmission The SAM with additional functions, XMC, sales code
(supplied) E3W, is absolutely essential additional equipment and,
• Transmission wiring harness with branch-off line for in combination with sales code N6P, contains specific
sensor basic parameterization ex factory.
The intermediate transmission itself is installed by the
body manufacturer.
Power take-off
---------------------------------------------------------------------------
Electronic parking brake to suppress the automatic disengagement of the parking
The electronic parking brake has an integrated comfort brake.
function that disengages it automatically under the A mode provided for this purpose is activated by holding
following conditions: down the P button in the parking brake control element
• Engine is running. while switching off the ignition. The mode is
automatically deactivated when the vehicle reaches a
• Gear is engaged or shifted. speed > 30 km/h.
• Accelerator pedal is operated. The operator's manual for the body must be
When an intermediate transmission is installed, it may supplemented accordingly as and when required.
be necessary – depending on the planned application –
---------------------------------------------------------------------------
Operation steps Installation of intermediate transmission and
The operation steps necessary for the conversion are as propeller shaft drive
follows: The installation of the intermediate transmission is the
• Install intermediate transmission. responsibility of the modification manufacturer (pay
attention to screw connections, weld joints and riveted
• Adapt propeller shaft drive. joints (see "Screw connections and weld joints"
• Relocate KITAS sensor to output of intermediate document)).
transmission. When unfastening screw connections at the chassis,
• Install rotational speed sensor at output of ensure that, when work is complete, a screw connection
transmission. corresponding to the original condition is made.
• Adapt parameterization of central gateway (CGW) • Refer to the Mercedes-Benz Workshop Information
control unit. System (WIS) and/or this Body/Equipment Mounting
Directive for tightening specifications.
• Adapt parameterization of drive control (CPC5)
control unit. • The screw connections at the propeller shafts must
be documented (DS feature).
• Calibrate and inspect tachograph.
• Welding at the chassis/body may only be carried out
The installation of an intermediate transmission using
by specialist personnel.
the pre-installation code N6P involves an intervention in
the drivetrain control system. In particular, an • Adapted propeller shafts (from vehicle transmission
intervention is made into the automated clutch and to intermediate transmission, as well as from
transmission control system. Therefore, the body intermediate transmission to rear axle) with length
manufacturer must exercise extreme caution with regard adjustment are to be installed (observe propeller
to the electrical integration of the intermediate shaft installation (see "Installation of propeller
transmission's connection/disconnection system. shafts" document))
---------------------------------------------------------------------------
Relocating the KITAS sensor and installing the • A KITAS 4.0 sensor (KITAS 2185) is to be used for
rotational speed sensor the intermediate transmission.
• Removal of the KITAS sensor at the vehicle 5, 6, 8 or 12 teeth at the rotor of the transfer case/
transmission output and extension of the electric line intermediate transmission are permissible and can be
(cf. illustration showing twisting of the line to the parameterized in the CPC for the KITAS sensor.
KITAS sensor) to the installation location of the Otherwise, the intermediate transmission is not suitable
KITAS sensor is at the intermediate transmission for integration purposes!
output. The tachograph must always be calibrated
and approved again for this!

Power take-off
1 KITAS sensor at intermediate transmission
2 Rotational speed sensor at manual transmission
W28.19-A002-11
Installation and routing of KITAS sensor at transmission/
intermediate transmission
A Data signal
B Real time signal
W28.19-A003-10
KITAS sensor plug as per ISO 15170 – B1 – 4.1 – Ag/K3
Twisting of line to KITAS sensor

1 Star quad
2 Pair 1 - twisted in pairs 12x21 (data signal)
3 Pair 2 - twisted in pairs 12x21 (real time signal)
W28.19-A006-01
Lay length
Max. 66 mm Max. 40 mm
(Min. 15 rev/m) (Min. 25 rev/m)
Power take-off
• Assembly of the included rotational speed sensor (B500) at the vehicle

transmission output with surface sealant (e.g. Loctite 5203), and
connection to a free branch-off line fastened to the vehicle transmission
and sealed with a blind plug. Tightening torque for rotational speed
sensor: 38 Nm.
• The body manufacturer must use two independent, potential-free
electrical NO contacts at the XMC control unit in order to ensure reliable
identification of the shift state of the intermediate transmission.
The independent input signals from the two NO contacts confirm to the
electronic drivetrain monitoring system that the intermediate transmission is
in the operating position (drivetrain externally open) and that there is no
axle through drive to the drive axles.
Connection of NO contacts at X82 plug of cab/chassis interface (behind
front-end flap):
• Pin 8
• Pin 9
Pulsed power supply +24 V via plug X82 of cab/chassis interface:
• Pin 7
X82 Cab/chassis connector, 40-pin
20 Body external, act. 1 W28.19-A004-03
19 Body external, act. 2 Connection of NO contacts to XMC
Parameterization and electrical circuit
i
Possible damage to the intermediate transmission
due to inertial spinning masses on the body: The
intermediate transmission function may only be
deactivated via the NA2 switch after performing an
external engine stop – via pin X1-40/29 at the XMC
or by a switching connection between pins X2-52/33
and X2-52/21 at the ASAM.
---------------------------------------------------------------------------
When the installation of the intermediate transmission The intermediate transmission may only switch over
and electrical components is complete, when the vehicle transmission is in the neutral position
parameterizations of vehicle control units including and the input propeller shaft is not rotating.
redocumentation using XENTRY must be carried out by When the intermediate transmission is activated using
an MB authorized workshop. the NA2 switch, this is ensured by the ex-factory ASAM
A special parameterization routine for parameterizing the parameterization of equation 020.
CPC is available in the XENTRY diagnostic system. Before plug X2 pin 40 is energized by the XMC, the
(Special measure SMCPC180423) neutral position of the vehicle transmission and the
• The CGW must also be adapted. The parameter activation of the parking brake are queried.
CF00.31.6, source of the "Vehicle speed" signal, is to The energization of plug X3 pin 2 by the XMC with the
be set to the value "Control unit‚ TCM". vehicle transmission in neutral position is parameterized
The basic parameterization provided in the ASAM and in the ASAM ex factory.
XMC ex factory can be adapted according to the In combination with a downstream relay circuit, this
requirements of the body, taking into account the ensures that the vehicle transmission neutral position
restrictions described below. can be established.
The intermediate transmission function is switched using For this, refer to the example design of a relay circuit
the NA2 switch installed in the cab ex factory. Activation with solenoid valve below.
is linked to compliance with further engagement
conditions.
Power take-off
When the intermediate transmission is in "Work mode", of the XMC to ensure that the vehicle detects an open
a feedback switch must supply ground at plug X1 pin 30 drivetrain and permits an external engine start.

1 Intermediate
transmission
2 Pumps
3 Drive
X1-40/30 Feedback
X3-21/2 Neutral
X2-52/40 NA2/PTO2
W28.19-A005-05
Example of relay circuit with solenoid valve
An external engine start/engine stop with subsequent After installation and parameterization, the following
automatic engagement of the selected working gear steps are to be carried out in the specified sequence in
(preset in the ASAM: direct gear 11 or 14) is possible order to switch from driving operation to work mode:
immediately after activation of the NA2 switch if the • Engage parking brake and neutral position. Then
engagement conditions (in particular, transmission in activate switch NA2. Intermediate transmission
neutral, parking brake engaged, signal for drivetrain switches to operating position.
externally open) are satisfied.
• Request external engine start. The stored working
The required working gear can be adapted in the ASAM gear is engaged. Working speed control and
equation (A100.570). accelerator interlock are activated. Work mode is
However, the direct gear in the vehicle transmission is active.
recommended for reasons of service lifespan! To switch the vehicle from work mode back to driving
The pin to be activated at the XMC for the external operation, perform the following steps in the specified
starting procedure (X1-40/27) (or alternatively the sequence:
switching connection between pins X2-52/32 and • Request external engine stop and then deactivate
X2-52/21 at the ASAM) must be supplied with current NA2 switch. Intermediate transmission switches to
until the gear has been engaged. Otherwise, the drive position.
engagement sequence will be aborted.
• Request external engine start. Engine starts. Engage
The operator's manual and the control system of the desired gear and drive.
body are to be adapted accordingly by the body
manufacturer. • Alternatively, press ignition start/stop button. Ignition
switches to position 0 (ignition off). Operate brake
When the parameterized working gear has been pedal. Press start/stop button again. Engine starts.
engaged, the status of the parking brake is not queried Engage desired gear and drive.
again. This allows it to be released manually by the
vehicle operator and allows the vehicle to be moved via
the external drive.
Front sensors
Driver assistance systems
i i
Possible impairment of the functioning of safety and See the vehicle operator's manual for more
driver assistance systems; risk of accident and injury information on switching the systems on and off.
for drivers or persons standing outside:
Do not install any detachable parts within the
detection ranges of sensors and camera systems.
Do not paint the sensor covers.
i
Possible loss of registration eligibility and potential
malfunctioning of other systems:
The decommissioning or automatic deactivation of
any or all of the safety and driver assistance
systems is not permissible.
---------------------------------------------------------------------------
General • Active Brake Assist (ABA), sales code S1P
To fulfill the legal requirements for a Lane Departure or
Warning System (LDWS) and Advanced Emergency • AEBS: Active Brake Assist 5 (ABA5), sales code
Braking System (AEBS), the vehicles are equipped with S1W
the Lane Keeping Assist and Active Brake Assist (ABA)
systems where necessary. These vehicles can also be equipped with a proximity
control system (Proximity Control Assist, sales
• LDWS: Lane Keeping Assist, sales code S1H code S1I).
---------------------------------------------------------------------------
A camera sensor is installed behind the windshield ex the systems by the operator is no longer possible.
factory in combination with the Lane Keeping Assist Further information on this is available in the operator's
system and a radar sensor is installed at the front end of manual for your vehicle.
the vehicle for the ABA system.
If detachable parts are mounted in the detection range The following sales codes are available for countries of
of the camera sensor or radar sensor (e.g. brush guard use (e.g. export) without legal requirements for LDWS
grilles), these can impair the function of the systems. and AEBS or for special applications:
• AEBS: Sales code S9X (Omission of Active Brake
A temporary manual deactivation of the systems by the Assist)
operator is possible via the corresponding switches in • LDWS: Sales code S9W (Omission of Lane Keeping
the instrument panel or via the on-board computer. Assist)
However, the systems are reactivated every time the
engine is restarted and/or the ignition is switched on/off! Compliance with legal requirements/eligibility for
registration must be checked and established in
In combination with the code S2J Active Brake Assist, advance.
permanently active or S2K Lane Keeping Assist,
permanently active, a temporary manual deactivation of
---------------------------------------------------------------------------
Lane Keeping Assist Relocating the camera sensor is not permissible.
Variant A (camera system MPC1) The use of a windshield that is not approved at the
factory is not permissible.
Variant A with the camera system MPC1 is installed if
the vehicle is equipped with at least one of the following Modifications to the factory wiper and washer system are
codes: not permissible.
• S1H, Lane Keeping Assist (LDWS) The use of main headlamps not approved by the factory
is not permissible.
and/or
• S1L, Attention Assist

Front sensors

Recalibration • Change in width - distance between outer edges of
Recalibration of the camera sensor/system after vehicle tires on front axle by ≥ 200 mm compared to the
modifications is necessary in the following cases: original condition(1)
(1) e.g. by permissible suspension modifications + tire
• The height of the camera sensor is changed (center
of lens is reference point) by ≥ 100 mm compared to changes.
the original condition(1)

MPC 1 detection ranges

1 Sensor
2 Sensor lens
3 Housing (open)
4 Rain sensor
W30.16-A002-10
1 Center of sensor lens

2 Horizontal reference line
3 Detection range
W30.16-A015-10

2 Vehicle longitudinal axis
3 Detection range
W30.16-A016-10
Lane Keeping Assist and additionally at least one of these codes is installed in
the vehicle.
Variant B (camera system MPC2)
• S1J, Active Drive Assist, S2A, Active Drive Assist 2
Variant B with the camera system MPC2 is installed if (ADA)
the vehicle is equipped with at least one of the following
codes: • S1W, Active Brake Assist 5 (ABA5)
• S1H, Lane Keeping Assist (LDWS) • L1D, Intelligent Headlight Control (IHC)
and/or • S1O, Traffic Sign Assist (TSA)
• S1L, Attention Assist The camera system MPC2 is functionally linked to other
systems, including the ABA 5 system. Deactivating Lane
Keeping Assist merely deactivates the warning signal
Front sensors
output, not the system itself or the functional link with the • Changing the distance between the camera lens and
other systems. front axle
Relocating the camera sensor is not permissible. • Changing the width - distance between outer edges
The use of a windshield that is not approved at the of tires on front axle by ≥ 200 mm compared to
factory is not permissible. original condition
Modifications to the factory wiper and washer system are Light bars and/or flashing lights and additional high
not permissible. beam headlamps on the cab roof and/or headlamps
mounted below the windshield and complying with legal
The use of main headlamps not approved by the factory requirements for lighting do not affect the system.
is not permissible. Parameter adjustment is not required in this case.
Recalibration/parameter adjustment Additional calibration drive:
Recalibration of the camera sensor (including calibration After any conversion or body installation on a vehicle
of a changed height) as well as parameter adjustment of equipped with the MPC2 camera system, and if at least
the system after vehicle conversion or body installation one of the following codes
is necessary when:
• S1J, Active Drive Assist, S2A, Active Drive Assist 2
• The height of the camera sensor is changed (center
of lens is reference point) by ≥ 10 mm compared to and/or
original condition. • S1W, Active Brake Assist 5
• Replacing the windshield (only factory-approved • S1I, Proximity Control Assist
windshields may be used.) is installed in the vehicle, a "teach-in drive" of the
• Replacing the main headlamps (only factory- camera system must be carried out in addition to
approved main headlamps may be used.) recalibration and parameter adjustment.

MPC 2 detection ranges

1 Sensor
2 Sensor lens
3 Housing (open)
4 Rain sensor
W30.16-A002-10

2 Horizontal reference line
3 Detection range
W30.16-A011-10
Front sensors

2 Vehicle longitudinal axis
3 Detection range
W30.16-A012-10
---------------------------------------------------------------------------
Active Brake Assist It is not permissible to reposition the sensor or change
the installation situation of the sensor.
The permissible distance range of the radar sensor
i (reference point is center point of sensor) above the
Risk of injury for persons riding on step plates (e.g. roadway is 300 - 1000 mm(2).
waste collection vehicles): (2) Factory specification according to vehicle model.
If the vehicle performs an emergency braking
procedure, the driver will receive a warning message Recalibration of the system is required if there is a
in the instrument cluster just before this occurs. This permanent change in the inclination in the vehicle
warning is also available via the body CAN longitudinal direction of ≥ 1° (e.g. fixed bodies with non-
(message 14EF82EB hex, byte 6, bit 7 to 8, value changing load conditions). Temporary changes in
01) and corresponds to the state "Warning message inclination in the vehicle longitudinal direction, e.g.
active", and enables the body manufacturer to caused by changing load conditions, do not necessitate
ensure safety by implementing appropriate recalibration of the system.
measures (e.g. the actuation of a warning buzzer in
the rear area).
---------------------------------------------------------------------------
Sensor detection ranges of variant I: Model front underride guard, with ABA/ABA5, Lane
designation 963/964, 983, vehicle category N3, with Keeping Assist.
(Combination with code C5O (Pre-installation, for special
attachments at the front) not possible)

Front sensors
W30.10-A000-09
ABA/code S1P
A Top view 1 Sensor cover 3 Radar sensor, code S1P
B Direction of travel 2 Reference point on sensor
cover
W30.16-A017-79
ABA 5/code S1W
Front sensors

A/C Reference points for upper radar cones (origin F Top view
of radar cones)
B/D Reference points for lower radar cones (origin R Reference point on left side of vehicle in
of radar cones) direction of travel (ring surface on end face and
center axle)
E Direction of travel X Distance 1440 mm to center of front axle on
model designation 964.xxx, distance 1340 mm
to center of front axle on model designation
963.xxx (distance to CAD X0, 1340 mm)
A/C Reference points for upper radar cones

(origin of radar cones)
B/D Reference points for lower radar cones (origin
of radar cones)
E Direction of travel
R Reference point on left side of vehicle in
direction of travel (ring surface on end face
and center axle)
S ABA5 radar sensor, code S1W
V Detail view of reference point R
X Distance 1440 mm to center of front axle on
model designation 964.xxx, distance
1340 mm to center of front axle on model
designation 963.xxx (distance to CAD X0,
1340 mm)
W30.16-A018-82
ABA 5/code S1W
Sensor detection ranges of variant II: Model

designation 964, vehicle category N3G, without front
underride guard, with ABA5, Lane Keeping Assist
(Combination with code C5O (Pre-installation, for special
attachments at the front) possible)

Front sensors
W30.16-A019-79
ABA 5/code S1W
A/C Reference points for upper E Direction of travel R Reference point on left
radar cones (origin of side of vehicle in direction
radar cones) of travel/upper attachment
point for code C5O (Ring
surface on end face and
center axle)
B/D Reference points for lower F Top view X Distance 1440 mm to
radar cones (origin of center of front axle on
radar cones) model designation 964.xxx
(CAD X0 1340 mm)
Front sensors

A/C Reference points for upper radar cones
(origin of radar cones)
B/D Reference points for lower radar cones (origin
of radar cones)
E Direction of travel
R Reference point on left side of vehicle in
direction of travel/upper attachment point for
code C5O (Ring surface on end face and
center axle)
V Detail view of reference point R
X Distance 1440 mm to center of front axle on
model designation 964.xxx (CAD X0
1340 mm)
1 ABA5 radar sensor, code S1W
W30.16-A020-82
ABA 5/code S1W
ABA 5 with pre-installation for attachments at the • Driver assistance systems (ABA 5 and Lane
front, code C5O Keeping Assist) deactivated by the operator
In combination with code C5O (Pre-installation, for • Subsequent driving operation/working mode is
special attachments at the front), it is possible that the possible
detection range of the driver assistance systems can be The body manufacturer must ensure that this behavior
partially or completely obstructed e.g. by a temporarily and the necessity of the operator deactivating the driver
installed front mounting plate for working implements at assistance systems (ABA 5 and Lane Keeping Assist)
the front. are covered in his safety concept and in the operator's
In this case, it is absolutely essential for the operator to manual.
deactivate the driver assistance systems (ABA 5 and If the sensor detection ranges of the driver assistance
Lane Keeping Assist) after every engine start by using systems are partially or totally obstructed, this is
the appropriate switches on the instrument panel or indicated by an appropriate notification/message in the
using the on-board computer. instrument cluster.
The systems are automatically reactivated every time When the driver assistance systems (ABA 5 and Lane
the engine is restarted or the ignition is switched on/off! Keeping Assist) are deactivated by the operator, this is
Front mounting plates for working implements, for likewise indicated in the instrument cluster.
example, may only be installed when the vehicle is • Removal
stationary and the engine/ignition is off.
• Vehicle standstill and parking brake engaged
The following procedure is to be followed:
• Engine and ignition off
• Installation
• Remove the front mounting plate from the vehicle
• Vehicle standstill and parking brake engaged
• Sensor detection ranges of the driver assistance
• Engine and ignition off systems are no longer obstructed
• Install e.g. a front mounting plate on the vehicle • Start engine
• Sensor detection ranges of the driver assistance • Driver assistance systems (ABA 5 and Lane
systems are obstructed Keeping Assist) reactivated automatically
• Start engine • Subsequent driving operation is possible
---------------------------------------------------------------------------
Front sensors
Proximity Control Assist, code S1I detection ranges of the driver assistance system –
The Proximity Control Assist system uses the same Proximity Control Assist – can be partially or completely
radar sensor and the same cover as the Active Brake obstructed, e.g. by a temporarily installed front mounting
Assist system. plate for working implements at the front.
Proximity Control Assist does not replace the legally In this case, the driver assistance system – Proximity
required Advanced Emergency Braking System (AEBS) Control Assist – must not be activated.
here. If the specifications in the "Front sensors" chapter are
It is not permissible to reposition the sensor or change ignored, the implement could be misidentified as a
the installation situation of the sensor. preceding vehicle and a warning can be issued and a
comfort braking action (perhaps to a stop) can be
Further information regarding initiated.
• the permissible distance range of the radar sensor The body manufacturer must ensure that this behavior is
• recalibration of the system covered in its safety concept and in the operator's
manual.
• and the detection range of the radar sensor
can be found in the Active Brake Assist section.
Proximity Control Assist in combination with code

C5O (Pre-installation, for special attachments at the
front)
In combination with code C5O (Pre-installation, for
special attachments at the front), it is possible that the
Side sensors

Side impact protection/side guard
Side underride guard Page 191
i i
More detailed information on the switching on and Possible functional impairment of safety and driver
off of the systems and on operating them is available assistance systems; risk of accident and injury for
in the vehicle operator's manual. drivers or bystanders:
Do not mount detachable parts in sensor detection
range. Do not paint the sensor covers.
i
Possible damage to sensors:
Ensure there is sufficient distance between folded-
down dropside and radar sensor. If necessary,
additional side board end stops must be fitted by the
body manufacturer. Possible bolting points for side
board ends stops on vehicle, see document "Side
underride guard" or "Side impact protection/side
underride guard".
---------------------------------------------------------------------------
General Depending on the selected vehicle model designation,
Side sensors are installed in the following special code equipment and whether the vehicle version is for
equipment: right-hand or left-hand traffic, one of the basic variants
listed below with the corresponding sensor arrangement,
• Cornering Assist, sales code S1R is shipped from the factory.
• Cornering Assist, permanently active, sales code S6F V1: Sensor location on models 963, 964 without side
(S6F only in combination with S1R) trim
• Active Sideguard Assist, sales code S1X V2: Sensor location on model 963, semitrailer trucks with
In conjunction with code S1R Cornering Assist, integrated side trim
permanently active or S1X Active Sideguard Assist V3: Sensor arrangement on model 983, platform
code, temporary manual deactivation of the systems by vehicles with side underride guard ex works (crash
the operator is not possible. Further information on this element) and, if applicable, code B5G Trailer brake,
can be found in the vehicle operating instructions. battery electric vehicle
---------------------------------------------------------------------------
Examples of V1 for right-hand traffic sensor
detection range (E) in side view (S) and direction of
travel (F):

Side sensors
4x2 with rear axle fender, code

C8B or C8C
W54.71-A115-74
6x4 (6x2) with rear axle fender,

code C8B or C8C
W54.71-A116-74
6x4 (6x2) with fender, for chassis

transfer, code C8F
W54.71-A117-74
6x2/2 vehicle model designation

963.427 semitrailer truck with 17.5
inch leading axle
W54.71-A118-74
Example of V2 for right-hand traffic of sensor

travel (F):

Side sensors

4x2 semitrailer truck with
integrated side trim
W54.71-A119-74
Examples of V3 for right-hand traffic sensor

travel (F):

4x2 platform vehicle with side

underride guard from factory
(crash element) and with rear axle
fender, code C8B or C8C
W54.00-A100-75
W54.00-A101-78
6x2 platform vehicle with side underride guard from factory (crash element) and with rear axle fender, code
C8B oder C8C
Side sensors
W54.00-A102-78
6x2 platform vehicle with trailer brake, battery electric vehicle code B5G and with rear axle fenders code C8B
or C8C
Sensor detection range • reporting a system malfunction/soiled sensors,

There must be no vehicle parts or other detachable parts • warning/braking without reason,
in the sensor detection range (E) (see figures). This area • not warning/not braking.
must always be free of obstruction.
As a consequence of the many combination options and
Where sensors were subsequently moved forward in the the complicated causal systematics involved, these
direction of travel, the stamped-in front wheel (both circumstances cannot be precisely defined in advance.
directions), in particular, must also be taken into
consideration. After each change in the vehicle, area surrounding the
sensors or position of the radar sensors through:
The properties of radar beams means that they do not
have a clearly defined spatial limit. The specified sensor • modification to wheelbase, chassis frame overhang,
detection range (E) is surrounded by "spread areas" with fifth-wheel lead.
more or less pronounced radar fields. • retrofitting of vehicle parts or detachable parts.
This is why detachable parts that were retrofitted under • subsequent displacement of the sensors.
unfavorable circumstances (e.g. vibrations from
it may be necessary to parameterize the control units,
retrofitted vehicle parts or detachable parts, and
and perform a service calibration and a function check.
reflections through detachable parts) result in the
Cornering Assist system:

Side sensors

Overview of measures:
Variant Parameterization Service calibration (1) Function check
Modification to wheelbase, chassis X - -

frame overhang, fifth-wheel lead
Retrofitting of vehicle parts or - - X

detachable parts
Radar sensor offset X (2) X X

in direction of travel (dimension A)
Radar sensor offset - X X

in width (dimension C) and/or height
direction (dimension B)
X = Perform measure
1 A service calibration includes calibration of the system together with a teach-in run. These scopes are carried out by our service
organization on our behalf. Contact the Mercedes-Benz Service Partner for this.
2 With code S1X: Deactivation of the active intervention by the brake system function is also required. Code/code replacement to S1R or
S1R+S6F required.
Reference dimensions for sensor

positioning for right-hand traffic
A Distance from center of
sensor (= center RSH) to
center of first rear axle
B Distance of marking on sensor
cover (cover) to roadway (only
relevant for V1)
E Sensor detection range
G Distance from end of chassis
overhang to center of last axle
H Distance from center of
sensor (= center RSH) to
center of front axle
M Height marking on sensor
cover (cover) W54.71-A120-75
S Side view
Side sensors
Reference dimensions for sensor

positioning, sensor detection
range (E) and reference points in
side view (S)
CO Sensor cover (cover)
GH Base holder
L Tolerance range of
installation position
R Reference point on cover
or sensor holder
RS Radar sensor
RSH Radar sensor holder
W54.71-A121-76
W54.00-A104-78
Reference dimensions for sensor positioning, sensor detection range (E) and reference points in top view (D)
A Distance from center of sensor (= center RSH) GH Base holder
to center of first rear axle
C Distance of sensor holder (RSH) to vehicle L Tolerance range of installation position
center
CC Distance of sensor holder (RSH) to outer edge R Reference point on cover or sensor holder
of sensor cover (cover)
CO Sensor cover (cover) RS Radar sensor
F Direction of travel RSH Radar sensor holder
Side sensors

Reference dimensions for sensor positioning,
sensor detection range (E) and reference points in
rear view (RA)
CO Sensor cover (cover)
GH Base holder
L Tolerance range of installation position
R Reference point on cover or sensor holder
RS Radar sensor
RSH Radar sensor holder
W54.71-A123-82

Overview of dimensions A, C and CC for V1
V1 Dimension A Dimension C Dimension CC Dimension C+CC
with code C8C Rear 783 mm (1) 1197 mm 59 mm 1256 mm

axle fender, 2500 mm
vehicle width
with code C8B Rear 783 mm (1) 1222 mm 59 mm 1281 mm

vehicle width
with code C8F 783 mm (1) 1197 mm 59 mm 1256 mm

Fender, for chassis
transfer
Model designation 228 mm (2) 1197 mm 59 mm 1256 mm

963.427 with code
C8C Rear axle fender,
2500 mm vehicle
width
Model designation 228 mm (2) 1222 mm 59 mm 1281 mm

963.427 with code
C8B Rear axle fender,
2550 mm vehicle
width
(1) The radar sensors are located in the direction of travel in front of the first rear axle.
(2) The radar sensors are located in the direction of travel after the first rear axle. (Adjusting the sensor in the direction of travel on model
963.427 is not permissible).
Side sensors

Overview of dimensions A, C and CC for V3
V3 Dimension A(3) Dimension C(3) Dimension CC(3) Dimension C+CC(3)
with code C8C Rear 880 mm (1) 1197 mm 65 mm 1262 mm

vehicle width
with code C8B Rear 880 mm (1) 1222 mm 65 mm 1287 mm

vehicle width
with code C8C rear 880 mm (1) 1191 mm 69 mm 1260 mm

axle fenders,
2500 mm vehicle
width and code B5G
Trailer brake, battery
electric vehicle
with code C8B rear 880 mm (1) 1216 mm 69 mm 1285 mm

axle fenders,
2550 mm vehicle
width and code B5G
Trailer brake, battery
electric vehicle
(1) The radar sensors are located in the direction of travel in front of the first rear axle.
(3) For information only. On model designation 983 it is not permissible to move the sensor.
Moving of sensors Trailer brake, battery electric vehicle, the following

Moving the sensors or changing their installation combinations are available ex factory: S1R + (S6F) +
situation in combination with variant V2 is not (B5G) + C8B Rear axle fenders, 2550 mm vehicle width
permissible. or S1R + (S6F) + (B5G) + C8C Rear axle fenders,
2500 mm vehicle width
Moving the sensors or changing their installation (**) At the factory for models 963/964, the following
situation in combination with variant V3(*) is not
permissible. combinations are available: S1R + (S6F) + C8B Rear
axle fender, 2550 mm vehicle width or S1R + (S6F) +
The sensor positions set at the factory can be changed C8C Rear axle fender, 2500 mm vehicle width
in compliance with the following boundary conditions for
Retrofitted conversions with a code/code exchange are
variants V1(**) only:
possible within the model designation. If necessary,
(*)
For model 983 in combination with an adapted please contact your local Mercedes-Benz Service
position and version of the side underride guard (crash Partner.
element) ex factory, and, where applicable, code B5G
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Moving in direction of travel - distance from center Here, it is not permissible to move in the direction of
of sensor to center of first rear axle (dimension A) travel (dimension A) on model 963.427, and
Max. 500 mm in direction of travel (50 mm opposite parameterization of the control unit is not possible.
direction of travel). Relative to position set at factory.
---------------------------------------------------------------------------
Moving in width direction - distance of sensor holder German vehicle licensing regulations (§ 32 StVZO),
(RSH) to vehicle center (dimension C) radar sensors installed at the side, that are part of a
Relative to position set at factory, inwards or outwards. device for indirect visibility, may protrude by a maximum
The distance (dimension C) may lie here between of 50 mm beyond the legally permissible vehicle width.
1172 mm - 1247 mm. Compliance with the legal requirements/eligibility for
In the scope of application of the European type registration in each country of registration must be
approval ((EU) 1230/2012) as well as in the individual checked and established in advance.
general operating permit procedure in Germany as per
Side sensors

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Offset in height direction - distance marking on
sensor cover to roadway (dimension B)
The permissible distance for dimension B is 400 mm to
720 mm. This must be assured in all load conditions.
---------------------------------------------------------------------------
weight specifications" document in the section
The radar sensor holders (RSH), radar sensors (BB) and "Chassis coordinate system") and not, e.g, to the
sensor cover (CO) must not be separated from the basic vehicle's (floor) contact surface. The maximum
holders (GH). Always reposition the unit as a whole. permissible tolerance range for installation position "L" is
± 1°. A value of 0° should be aimed for.
If the mountings/supporting tubes to which the
respective "GH" basic holders were fastened at the The maximum permissible horizontal distance (G) from
factory are to be replaced, these must be dimensioned the center of the last axle to the end of the chassis-frame
as for the factory-shipped versions and mounted onto overhang is 3900 mm (sensor detection range approx.
the vehicle frame accordingly. 2000 mm longer).
The radar sensors holders (RSH) and the respective The maximum permissible distance from the center of
basic holder (GH) are aligned relative to the theoretical the radar sensor to the center of the 1st front axle is
vehicle reference axles X, Y, Z (see "Dimensions and 6100 mm and it must not be exceeded.
---------------------------------------------------------------------------
Parameterization of control units There are various so-called "support points" in a 100 mm
The parameter setting must be adapted if the following grid. These are permanently stored distance dimensions
changes have been made to the vehicle: ("A item numbers") for the horizontal distance (A)
between the center sensor and the center of the first rear
• Fifth-wheel lead: Input range 300 mm to 1350 mm axle.
• Chassis-frame overhang: Input range 750 mm to The support point next to the actual distance dimension
3900 mm. The distance from the trailer coupling point must be selected.
to the center of the rear axle does not have to be
separately parameterized. At the factory, the distance (A) always refers to the first
rear axle (as with wheelbase specification in CGW).
Make the corresponding parameter adaptations in the Irrespective of whether this is a drive axle or e.g. a
VRDU 2 control unit. leading steering axle.
• Wheelbase: Input range dependent on vehicle model
designation. Variants V1 in widths (dimension C) - and/or height
(dimension B):
Perform corresponding parameter adaptation in the
CGW control unit. Parameterization not required. Perform a service
calibration and function check.
• Subsequent movement of radar sensors:
See also the Measures overview table in the sensor
Variants V1 in direction of travel (dimension A): detection ranges section.
Adapt parameter accordingly in SRR-R master and
SRR-R slave short-range radar control unit.
---------------------------------------------------------------------------
Vehicles with Active Sideguard Assist code S1X: code replacement (code scope S1X becomes S1R or +
If the radar sensors are subsequently moved in the S1RS6F). The required parameter changes are carried
direction of travel (dimension A) and/or the mountings/ out in the corresponding control units, and the vehicle
supporting tubes fitted at the factory are replaced, then documentation is adapted accordingly. Contact the
the active brake application function must always be Mercedes-Benz Service Partner for this.
deactivated. For this, perform a complete so-called code/
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Function check after modification

Side sensors
Requirements:
• Body and vehicle fully assembled
• All detachable parts and radar sensors at side in final
position
• Parameterization performed, if required
• Code for code replacement S1X to S1R or S1R+S6F
made, if required
• Service calibration was performed, if required:
• no Sideguard Assist system fault messages
present in instrument cluster
• no fault memory entry present in control units
VRDU2 and SRR01T
Sideguard Assist system active.
Sensor detection ranges (E) (dimension
specifications in "m")
CÜ End of chassis-frame overhang
PSG Person at walking pace
VF Vehicle front edge
W54.71-A124-82
WG "Yellow" warning display
"Vehicle standstill" function test • No warning display or a sporadic warning display

• Vehicle stationary and parking brake engaged only, means that the function test failed.
• Ignition switched on • The reason for this lies in the modified vehicle or the
detachable parts and it must be corrected
• Detection range (E) entered by a person (PSG) at accordingly.
walking pace
The yellow warning display (WG) must light up as
long as the person continues to move around the
detection range (E)
---------------------------------------------------------------------------
"Driving" function test

Side sensors

Sensor measuring ranges (E)
SB Side area
WG "Yellow" warning display
WR "Red" warning display
WS Distance (test track)
W54.71-A125-82
• Vehicle in solo operation (without trailer) several times in succession to generate relative
• Additional front passenger required to observe movement in the vehicle parts or detachable parts, if
function display and surrounding area necessary.
• Requirements on distance (test track): • The front passenger must continuously observe the
readiness display while driving the given distance.
The 3 km long distance should be selected so that, from
the outside edge of the sensor, a side area (SB) is a The specified distance must be completed without
distance of 5 m, ideally 40 m away from any stationary unwarranted system warning displays (yellow/red
and/or moving objects (where possible, no traffic and a warnings).
level open space) • If a warning message is issued when driving the
Example: Country road without built-up roadsides, and specified distance, even if a stationary and/or moving
sufficient distance to traffic following behind. object was clearly not located in the detection range
(check by front passenger and comparison with
We advise you to travel the scheduled or locally results from reference drive), then the function test
available distance with a vehicle first (ideally with the has failed.
vehicle on which the retrofit modification is to be made)
in unchanged ex-factory delivery condition as a • The reason for the warning messages lies in the
reference. modified vehicle or the detachable parts and it must
be corrected accordingly.
• Taking road safety into consideration, vary your
speed between 0-50 km/h, braking and accelerating
---------------------------------------------------------------------------
Electrical connections The vehicle wiring harness itself and the newly routed
Pre-installation at the factory: lines to the radar sensors are to then be attached again
in a professional and proper manner.
On platform, dumper and cement mixer vehicles (model
963.0, 964.0, 964.2 and 964.3), the line lengths are This pre-installation is not available for semitrailer trucks
designed such that the sensors can be moved within the (model 963.4 and 964.4 and model 983).
permissible scope. Line adaptations are not necessary. Furthermore, for semitrailer trucks without side trim or
For this purpose, the lines routed parallel to the vehicle special cases, a subsequent adaptation of the electric
wiring harness to the radar sensors must be unfastened supply lines can be made as follows.
from the vehicle wiring harness up to the branch-off line,
if necessary.
---------------------------------------------------------------------------
Side sensors
Modification of electrical supply lines Variant I

Extension by means of an adapter cable is possible.
This adapter cable must be manufactured as per the
i following specifications.
Possible system malfunctions in Cornering Assist The required line cross sections and color codings for
system through disturbances caused by EMC the electric lines are available in the "Adapter cables and
interference: component parts" drawing.
Make sure that the adapter cables and plugs
The adapter cable must be properly attached.
described here comply with the specifications in
accordance with UNR10 Electromagnetic
compatibility (EMC). If necessary, perform test.
A Scope of adapter cable

B Ex-factory lines and plugs
C Radar sensor (A 148/Master) with control unit 1
D Radar sensor (A 149/Slave) with control unit 2
W30.16-A009-11
Adapter cable and components

Item number Designation Quantity
1 A 000 153 45 24 Plug 2
2 A 000 153 21 22 Plug 2
3 A 047 545 99 28 Clamp 17
4 A 003 982 64 26 Clamp 17
5 A 004 546 39 30 Corrugated hose NW13 1 ¹⁾
6 A 004 546 37 30 Corrugated hose NW8.5 1 ¹⁾
7 A 001 545 59 80 Conductor blind plug 30
8 A 001 545 50 80 Conductor seal 34
9 A 000 540 83 27 CAN line (4-strand, 40 twists/m) 1 ¹⁾
10 A 000 540 59 27 CAN line (2-strand, 30 twists/m) 1 ¹⁾
11 A 001 982 10 07 Protective cap 4

1) The length must be determined based on the new position of the radar sensors. The specifications in the Moving radar sensors section
must be complied with.
Side sensors

Variant II The CAN line that is no longer required in the wiring
As an alternative to variant I, the adaptation of the harness must be removed entirely from the existing
electrical supply lines can also be carried out as follows: wiring harness to prevent any electromagnetic
interference.
• Complete replacement of CAN line 9
• Extension of power supply lines (E)

C Radar sensor (A 148/Master) with control unit

1
E Power supply lines
X43 Cab/chassis interface electrical connector
(40-pin)
X53 Cab/chassis interface electrical connector
(21-pin)
W30.16-A010-12
Extract of circuit diagram and components

Item number Designation Quantity
4 A 003 982 64 26 Clamp 4
8 A 001 545 50 80 Conductor seal 5
9 A 000 540 83 27 CAN line (4-strand, 40 1 ¹⁾

twists/m)
12 A 014 545 11 26 Clamp 4

1) The length must be determined based on the new position of the radar sensors. The specifications in the Moving radar sensors section
must be complied with.
Power supply lines (E) The new CAN lines "9" and the power supply line
The power supply lines (E) can be adapted to the extension (E) must be protected against mechanical
required length in accordance with the specifications damage (e.g. corrugated hose), they must also be
(see "Extending electric lines" document). See the sealed and attached properly.
diagram "Wiring diagram and components" for the
required line cross-sections and color markings of the
power supply lines.
---------------------------------------------------------------------------
Permanent deactivation of the system must be removed, the control unit VRDU 2 replaced and
It is not possible to permanently deactivate the system other conversion scopes are also required. Contact the
through a parameter change. If the existing system is to Mercedes-Benz Service Partner for this.
be permanently deactivated, then the radar sensors
Side sensors
---------------------------------------------------------------------------
Mount side underride guard (for V1) The proportional weight pressure applied to the "GH"
Along with the usual frame connections, the attachment holder must not exceed a maximum of 15 kg.
points on the "GH" holder fitted at the factory can also be
used for installing a side underride guard.
Electronic Stability Program ESP(R), center of gravity heigh...

Connecting devices
i i
In this chapter, representations, code scopes and Possible malfunction of Stability Control Assistant,
pre-installations of other model designations and code S1D:
model series are listed for reasons of Parameter changes may only be carried out by an
standardization. The information that is applicable to authorized specialist operation. Trained and certified
your model designation/model series must diagnostic technicians are available for this purpose,
exclusively be used. with the appropriate user permissions to make these
changes. Furthermore, the changes to Stability
Control Assist must be stored accordingly in the
Mercedes-Benz vehicle documentation system. For
i this reason, contact your Mercedes-Benz Service
Possible risk of skidding and accidents for the Partner.
vehicle user:
Mechanical changes to the vehicle geometry not
described here or interventions in the steering
kinematics with active Stability Control Assistant are i
not permissible. There is a risk of safety-critical Possible loss of vehicle approval requirements:
incorrect interventions of the system. Bodies or The national eligibility for registration with omission
modifications relevant to the stability of the vehicle of Stability Control Assist, sales code S9Z, is to be
must be tested using a Mercedes-Benz diagnostic checked by the orderer.
system, and the vehicle parameters must be
adjusted if necessary.
i
Possible risk of skidding and accidents for the
vehicle user:
With ESP®, a tractor/trailer combination may be
operated with a maximum of two trailers (semitrailer
or typical long tractor/trailer combination). In this
regard, also observe national legislation regarding
tractor/trailer combinations.
---------------------------------------------------------------------------
General Sometimes this is also offered for vehicles that do not
As of November 2014, trucks newly registered in the EU legally require it. Even in this case, the system must be
with a permissible gross mass > 3.5 t must be equipped correctly parameterized and all of the measures and
with a vehicle stabilization function. Exceptions to this conditions described here must be implemented and
are off-road vehicles and vehicles with more than 3 axles observed.
as per the directive (EU) 2018/858. On This Stability Control Assist is a complex safety system
Mercedes‑Benz trucks, the tried-and-tested "Electronic provided by Mercedes-Benz. As a result, one or more
Stability Program (ESP®)" system, sales code S1D, is vehicle parameters will have to be modified using a
used for this purpose. Mercedes-Benz diagnostic system on vehicles which are
modified through conversion or body mounting. This is

the only way to ensure that the ESP® system continues
to operate optimally.
---------------------------------------------------------------------------
Function description If you adopt an inappropriate driving style or if you are
The ESP® monitors the driving stability and traction i.e. inattentive, the ESP® can neither reduce the risk of an
power transmission between the tires and roadway. If accident nor override the laws of physics. Stability
the system detects that the vehicle is deviating from the Control Assist is merely an aid.
driver's intended direction, the engine output is If the indicator lamp on the instrument cluster lights up
automatically adjusted. To keep the vehicle on its continuously when the engine is running, the ESP® is
intended course within the physical limits, one or more defective. Have the ESP® system checked by a
wheels can be selectively braked for further stabilization. Mercedes-Benz Service Partner.
The ESP® can also stabilize the vehicle during braking
Irrespective of the load condition or roadway condition,
or in critical driving situations, e.g. during sudden
ESP® reduces the risk of the vehicle
evasive maneuvers or at high cornering speeds.
• skidding,
ESP® is active as of a vehicle speed of approx. 20 km/h,
irrespective of the operating status of the service brake • jackknifing,
or continuous brake. The indicator lamp on the • tipping over.
instrument cluster flashes when the ESP® intervenes.
---------------------------------------------------------------------------
Parameter changes in general modification, the vehicle conversion company or body
If the modifications listed below are made on vehicles manufacturer must first submit a non-objection query.
with Stability Control Assist, sales code S1D, vehicle After a certificate of non-objection is issued, a vehicle-
parameters have to be adjusted using a diagnostic specific parameter data record can be ordered on a data
system. There are two different procedures for this: storage medium and then transferred to the vehicle on
an automated basis using the diagnostic system. The
Manually change parameters for ESP® control after supplementary sheet for ordering the data storage
vehicle modification medium is an attachment to the certificate of non-
objection.
A manual change of vehicle parameters is made if the
vehicle modification is already present in the diagnostic Liability exclusion
system and the permissible parameter ranges for the
The vehicle conversion company or body manufacturer
respective vehicle are not exceeded. The existing
is responsible for both parameter change procedures.
parameter ranges are described in this section of the
Only they are able to determine the parameters to be
Body/Equipment Mounting Directives. In individual
changed based on the vehicle modifications they have
cases, a manual parameter change may also form part
carried out. The parameter change through manual
of a certificate of non-objection (CNO), or take the form
parameterization or a data storage medium must then be
of a written agreement (email) with the relevant contact
ordered from a Mercedes-Benz Service Partner.
person. This CNO or email entitles the diagnostic
technician to also modify parameter data ranges which Neither the Mercedes-Benz Service Partner nor Daimler
are not described here, as per the specifications therein. Truck AG can technically verify the technical
modifications carried out by the vehicle conversion
Change parameters for ESP® control after vehicle company or body manufacturer, including the associated
modification using data storage medium documentation, and they therefore provide no warranty
A change of vehicle parameters with a data storage and accept no liability for any vehicle parameter changes
medium is made if the vehicle modification exceeds the or for storing the relevant documents. Your Mercedes-
permissible parameter ranges for the respective vehicle Benz Service Partner will have a liability waiver form to
as listed in the diagnostic system or in these Body/ be signed by you.
Equipment Mounting Directives. For this type of
---------------------------------------------------------------------------
Manual parameter change or change of approved The specifications (see document "Modifications to
parameter ranges the wheelbase") must be observed.
Wheelbase modifications The list of the corresponding approved standard

wheelbase limit can also be found there.
Wheelbase modifications within the standard wheelbase
limits with sales code S1D: If your intended change is within these limits and if all
other boundary conditions relating to "wheelbase
Changes are permissible only within the standard modification" are fulfilled, the aforementioned "manual
wheelbases.

parameter change" process using a diagnostic system regularly occurring or permanent load type to ensure that
should be followed and no CNO is required. the ESP® system continues to function optimally.
If, in addition to a modified wheelbase, the vehicle is High-load parameters can also be ordered ex factory via
fitted with a body whose overall center of gravity is sales code. Please see the following table "Overall
regularly or permanently higher than the thresholds, then center of gravity height (A) above roadway" for the
the following notes under "Center of gravity height" must assignment of sales codes E0V and E0W.
be observed and complied with.
Center of gravity height (high-load parameter)

On vehicles with Stability Control Assist, sales code
S1D, the high-load parameter must be adapted to the

Types of load for overall CoG height (A) above

roadway
W42.45-A009-10
Position of the center of gravity
The following tables refer to model series 967.

Overall CoG height (A) above roadway with permissible gross mass up to 9.5 t
(A) < 1.30 m Parameter Standard (As-delivered state)
(A)> 1.30 m ... 1.40 m Parameter High (High load) sales code E0V
(A) > 1.40 m Parameter Very high (High load) sales code E0W

Overall CoG height (A) above roadway with permissible gross mass greater than 9.5 t
(A) > 1.40 m ... 1.48 m Parameter High (High load) sales code E0V

Overall CoG height (A) above roadway with permissible gross mass greater than 12.5 t
(A) > 1.50 m ... 1.60 m Parameter High (High load) sales code E0V
The following tables refer to model series 963 and 964.


Overall center of gravity position platform vehicle/dump truck/cement mixer vehicle (A) above roadway
(A) > 1.50 m ... 1.70 m Parameter High (High load) High-load parameter level 1,
sales code E0V
(A) > 1.70 m ... 1.90 m Parameter Very high (High load) High-load parameter level 2,
sales code E0W
(A) > 1.90 m Parameter Extremely high (Extremely high load)

Overall CoG height of semitrailer truck (A) above roadway
(A) > 1.65 m ... 2.00 m Parameter High (High load)
(A) > 2.00 m Parameter Very high (High load)
Depending on the control unit, not all high-load under the heading "Vehicle overview". Please note that
parameters are available. the maximum permissible height of the center of gravity
For most vehicles, the height of the chassis center of specified there for the vehicle with body attached applies
gravity is specified in the tilt threshold calculation tool, only to vehicles which are operated within the scope of
taking into account a number of items of standard and UN-R 111, e.g. tank vehicles for hazardous goods.
special equipment, in accordance with UN-R 111 in the Vehicles for other applications may exceed the
Mercedes‑Benz Bodybuilder Portal maximum permissible height of the center of gravity
specified there, subject to all the provisions listed here.
---------------------------------------------------------------------------
Stabilizer bars/Roll Control Assist It is recommended that one of these equipment items be
used for vehicles with high loads. The required
equipment is based on the type of load with which the
overall vehicle is regularly or continuously operated.
i
Possible negative influence on driving, braking and Stabilizing equipment is essential if the vehicle is used
steering behavior: In the case of attachments, for extremely high loads. Mercedes-Benz offers
installations or conversions for loads with an appropriate stabilizers (e.g. sales code C6Y/C6U) and a
unfavorable center of gravity, e.g. rear, high and side roll control assistant, sales code S1F (only available for
loads, the vehicle conversion or body manufacturer model series 963, 964) for the different vehicle model
is responsible for the driving safety of the vehicle. If designations.
necessary, carry out your own tests.

W42.45-A013-10
Auxiliary stabilizer
Changing "Vehicle type" parameter If a trailer coupling is to be retrofitted on a semitrailer

Vehicles are delivered from the factory with the "Vehicle truck, e.g. to allow it to be operated with conventional
type" parameter matching the vehicle as ordered. trailers, this is only possible with sales code S1E (ESP®
Examples: Dump truck model designation parameter set: for trailer operation on semitrailer trucks) installed or
"Dump truck", or platform model designation parameter retrofitted.
set: "Platform vehicle". The sales code is available for vehicle model
If a vehicle is to be used for a different purpose to that designations 963.402; 963.403; 963.424; 963.426;
specified for the vehicle model designation, the vehicle 964.402; 964.403; 964.414; 964.416; 964.424 and
conversion company or body manufacturer must request 964.426.
a manual change of this parameter from their Mercedes- Availability/retrofitting is not possible in all cases
Benz Service Partner. (example: sales code S1E is not possible in combination
with hydraulic auxiliary drive on the front axle, sales
Approved modifications to "Vehicle model" code A1H). For this reason, please check availability and
• Dumper model designation with platform vehicle body ensure that your order is appropriate for the vehicle use.
• Parameter to be set "Platform vehicle" Please note that subsequent parameterization is also
only possible for those vehicle model designations for
• Platform model designation with dump truck body
which S1E ESP® for trailer operation on semitrailer
• Parameter to be set "Dump truck" trucks is available.
• Dumper model designation with cement mixer vehicle Please observe (see document "Platform and swap
body body") with regard to ballasting a semitrailer truck with a
• Parameter to be set "Cement mixer vehicle" trailer load.
• Cement mixer model designation with dump truck A non-objection query should always be submitted for
body platform, dump truck or cement mixer vehicle chassis
with sales code S1D, which are intended to be used as
• Parameter to be set "Dump truck"
semitrailer trucks.
For all modifications of the vehicle model not mentioned
here, it must first be checked whether a corresponding Series production packages/series production
ESP® parameter data record is available. Only then can conversions
a release for a new vehicle type be issued on the basis Series production conversions, conversions from one
of a CNO. Furthermore, when the vehicle type is approved series production configuration to another,
changed, all the other specifications in these Body/ e.g. code swapping, must be processed according to the
Equipment Mounting Directives must be complied with. specifications of the service department. In this case, a
certificate of non-objection is not required and nor will
Retrofitting of trailer couplings on semitrailer truck one be issued. Please contact your Mercedes-Benz
model designations 963.4xx and 964.4xx Service Partner about this.
i
For further information on trailer couplings, see
document "Trailer coupling and end
crossmember".
---------------------------------------------------------------------------
Changes to parameters for ESP® control after the supplemental sheet "Information for Mercedes-Benz
vehicle conversion with a data storage medium or workshops on execution of ESP®-relevant modifications"
unapproved parameter ranges or only via the supplemental sheet "Information for
For wheelbase modifications outside the standard Mercedes-Benz workshops on execution of ESP®-
wheelbase limits or for changes to the axle configuration, relevant modifications". This is contingent, however, on
ESP® parameters for a manual change can be specified parameters that are to be changed being present in the
in individual cases via a certificate of non-objection and diagnostic system and them being alterable.
---------------------------------------------------------------------------
Car transporter vehicle model designation 963.405 If a semitrailer truck model designation (e.g. 963.403) is
On the aforementioned vehicle model designations, the to be used as a car transporter, it is essential to adapt
corresponding parameters for a car transporter body the corresponding parameters. The use of an anti-
(with body-mounted coupling device for trailer) are set ex swerve brake is also permissible here following
factory. Modifications are not required here. The use of adaptation.
an anti-swerve brake is possible.
---------------------------------------------------------------------------
Disabling Stability Control Assist Depending on the application and eligibility for
The disabling of an existing Stability Control Assist registration, vehicles can be ordered without Stability
system, sales code S1D, is not possible due to the Control Assist, sales code S9Z.
overall networking with other driver assistance systems. For countries of use without legal requirements, check
the availability of sales code S9Z.
Electronic Stability Program (ESP) shutoff

i
Automatic reactivation of the ESP® when the speed
exceeds 30 km/h.
This is legally prescribed and must be taken into
account in the design of the body and the overall
vehicle.
---------------------------------------------------------------------------
ESP shutoff, request via body conditions are also checked by EBS and this request
A body system can send a request to the vehicle via the can be blocked.
XMC for the ESP® to be shut off in certain conditions. The relevant parameterization of the function is
This ESP shutoff is possible via two methods: implemented in equation 377 of the XMC using
XENTRY.
• Via digital input
Depending on the vehicle equipment, it may be
• Via body CAN, GPM 2 B, byte 7, bits 0...1
necessary to check which usable pins are available. The
As of production month 06.2021, the option is available updated pin assignment for the XMC can be found in the
to shut off the ESP® via an automatic request from the "Equations and parameters for Actros/Arocs, model
body. In this situation, XMC receives a signal from the 963/964, model generation 5" brochure.
body system (via CAN or digital input) and sends this
Further information on the messages of the body CAN is
request via CAN to EBS.
provided in the document "Body manufacturer CAN,
This shutoff is taken into account in work mode and not description for model 963, 964", available in the
in the driving operation. The relevant boundary Bodybuilder Portal.
Position and relocation of ESP(R) module
In this case, the ESP® module must be unplugged,

i removed along with its holder and stored in an area
For reasons of standardization, representations, which is free of vibrations. After the modification work is
code scopes and pre-installations of other model completed, the ESP® module must be screwed back on
designations and model series are listed in this and plugged in at its original position and in the correct
chapter. Only the information valid for your model location.
designation/model series is to be used. In the case of wheelbase modifications, it is also
essential to observe/restore the original dimension from
the center of the front axle to the ESP® module.
It is not possible to relocate the ESP® module because
this can seriously impair the functioning of the system. After all of the work is complete, the ESP® teach-in
routine must be started using the diagnostic system to
If frame modifications or other modifications are carried ensure that the ESP® continues to function properly.
out in the vicinity of the ESP® module (<1000 mm), the
ESP® module must be temporarily removed before this
work, especially in the case of rivet removal or assembly
operations which cause strong vibrations.

W42.45-A012-11
The ESP® module was installed on the left side of the vehicle in
the direction of travel; the electrical connection points towards the
rear axle (the picture shows the Atego; the installation location can
vary depending on the model designation).
Position and relocation of ESP(R) module

Model series 967
1 Positions of ESP®module
W42.45-A010-12
Existing installation positions
W42.45-A014-09
Existing installation locations and positions of ESP® module
Model series 963, 964 and 983
1 Direction of travel
Driver assistance system
Sales code E6Z - Reverse warning device

The reverse warning device with two-stage warning device is integrated
into the tail lamp. It can be switched on and off using a switch in the cockpit
and its volume can be controlled. The warning tone is activated when
reverse gear is engaged.
Technical data
• Sound level in stage 1: 78 dB (A)
• Sound level in stage 2: 55 dB (A)
W54.00-A020-01
i Reverse warning system switch
Mercedes-Benz recommends using the reverse warning device
installed ex factory.
Repair and extension of plastic compressed-air lines of the ...
Compressed-air system
aWarning
Risk of injury from cutting pressurized compressed air Wear protective gloves and safety glasses
lines
Brake hoses or cables and lines Page 127
i i
Possible failure of brake systems and risk of Possible invalidation of operating permit:
accident for vehicle user and persons standing After any modifications, the brake system must be
outside: tested for proper operation and approved by a
The following notes and conditions must be technical inspection station. For further information,
observed to ensure continued compliance with all see document "Checks after work on the brake
requirements of UN-R 13. All modifications are only system".
possible in combination with an "electronic brake
system", sales code B1B. Extensions to the
compressed-air lines are not permissible on vehicles
which are not equipped with an electronic brake
i
system. Take particular care when working on the Malfunctions or failure of the brake or air suspension
brake system. If necessary, commission a system:
Mercedes-Benz service partner or specialist
workshop. Incorrect tightening of the cable ties used for line
fastening can result in loose or pinched lines. Take
particular care when tightening the cable ties.
Bending radii that are too small can lead to kinking
of the compressed-air line. Do not undershoot the
i bending radii specified here.
For additional information see document "Brake
hoses or cables and lines".
---------------------------------------------------------------------------
Any work carried out on the vehicle must comply with Comply with all national directives and laws.
accident prevention regulations.
---------------------------------------------------------------------------
Repair and extension of plastic lines of the brake Repair or extension of working lines or control lines
and air suspension system of brake system
• These notes must be observed for all plastic Compressed-air lines leading from axle modulators,
compressed-air lines on the brake and air suspension pressure regulating modules, from the proportional
system of the vehicle with a nominal size of 6 x 1 mm valve, ALB controller or from relay valves to the brake
(NG 6), 8 x 1 mm (NG 8), 12 x 1.5 mm (NG 12) and cylinders (possibly via ABS valves) must be kept as
16 x 2 mm (NG 16): short as possible.
• Repair or extension is only permissible using the • The compressed-air lines may only be repaired or
plastic lines and connectors approved in the extended using one connecting part.
Mercedes-Benz Workshop Information System • The line lengths installed at the factory may be
(WIS). exceeded by a maximum of 20 %.
• Repair or extension is not permissible within a
bend in a line. Repair or extension of supply lines of circuits 1 to 3
• Repair or extension is not permissible in Only new supply lines may be installed in the event of a
externally visible areas. repair or length change. Connecting parts are not
permissible here:
Circuit 1 to rear axle modulator/rear axle valve package:
• Max. 3000 mm when using 2 separate lines 12x1.5 • All lines with an overall length > 10000 mm may only
from reservoir be repaired or extended with one connecting part.
• Max. 6000 mm when using 2 separate lines 16x2 • An overall line length of 15000 mm must not be
from reservoir exceeded.
Circuit 2 to front axle modulator/relay valve: First check whether there are already connecting parts/
• Max. 4000 mm when using one line 12x1.5 connection points in the line or if extensions have been
made.
• Max. 6000 mm when using one line 16x2
Line lengths > 10000 mm are manufactured with one
Circuit 3 to trailer control valve: connecting part at the factory for production-related
• Max. 3000 mm when using one line 12x1.5 reasons.
• Max. 6000 mm when using one line 16x2 The approved systems for connection fittings are:
• VOSS 232 for all diameters
Repair or extension of all other lines
• Schäfer SDF for 6 mm lines
All other compressed-air lines may be repaired or
extended under the following conditions if replacement The following are also approved by Mercedes-Benz:
of the entire line is too complicated/costly:
• All lines with an overall length < 10000 mm may be
repaired or extended with two connecting parts.

Cross-section ∅ Punch-in drift (standard) Punch-in drift (mounting groove)
6x1 A 000 990 45 78 A 002 997 58 71
8x1 A 000 990 46 78 A 002 997 48 71
12x1.5 A 000 990 73 78 A 001 990 65 78
16x2 A 000 990 76 78 A 002 997 47 71
Cutting of compressed-air lines Routing and fastening

Compressed-air lines must be cut off at a right angle. If compressed-air lines are improperly routed, the lines
The Mercedes-Benz-approved knife with number can kink or chafing can occur. These can lead to
A 000 589 12 28 00 or another suitable tool may be used malfunctions or failure of the brake or air suspension
for this. system. The following points are to be observed when
Make sure that no particles are left in the lines. routing and fastening compressed-air lines:
• Lines may not be routed directly over sharp edges.
Use of connecting parts with drift profile
• Lines that cross over are to be fixed in place at the
The drift profile for the connecting part must be pounded intersection point using a cable tie.
in or pressed in up to the end stop in the compressed-air
line. The Mercedes-Benz-approved locking pliers with • Lines that run parallel to an elbow fitting are to be
number W 950 589 00 37 00 or another suitable tool supported at the elbow fitting.
may be used for this. • Lines on parts which move relative to each other
To avoid any damage to the connecting parts, a plastic must be free of tension and routed with enough
mallet should be used for pounding in. clearance to allow for the relative movement.
Make sure that no particles are left in the lines. • Lines may not touch or be attached to pneumatic,
diaphragm or spring-loaded brake cylinders.
Modified routing of compressed-air lines • Appropriate feed-through grommets must be used
If the routing of the compressed-air lines changes after a where lines pass through the frame.
repair or extension work, the following points must be • Plastic shims must be used, if necessary, during line
observed: routing where the lines pass over protruding bolts,
• Routing and fastening gusset plates, inserts or other protrusions.
• Permissible bending radii • Corresponding cable ties are to be used to fasten
individual compressed-air lines or a compressed-air
• Protection against battery acid
line set. Make sure that the cable ties are correctly
• Protection against excessive battery heat tensioned.
• The distance between the attachment points may not Permissible bending radii
exceed 500 mm. The following bending radii may not be dropped below
(based on 180° bend at room temperature 23 ℃ ±5 ℃):

Example per DIN 74324
For nominal size 8 (8x1 mm) 40 mm
For nominal size 12 (12x1.5 mm) 60 mm
For nominal size 15 (15x1.5 mm) 90 mm
Protection against battery acid • 100 ℃ in the vicinity of electrical connectors,

Compressed-air lines must be routed in the vicinity of the • 120 ℃ in the vicinity of a compressed-air line,
batteries so that they are protected against the effects of is not exceeded.
battery acid. If routing has to be through the area of the
batteries, then the compressed-air lines have to be
protected by suitable protective hoses.
Protection against excessive operating temperature

Route compressed-air lines such that a permissible
ambient temperature of:
Relocating compressed-air reservoirs
aWarning
lines
i i
Possible failure of brake systems and risk of Additional information: see chapter "Brake hoses or
accident for vehicle user and persons standing cables and lines".
outside:
The following notes and conditions must be
observed to ensure continued compliance with all
requirements of UN-R 13. All modifications are only i
possible in combination with an "electronic brake Any work carried out on the vehicle must comply
system", sales code B1B. Extensions to the with accident prevention regulations.
compressed-air lines are not permissible on vehicles
which are not equipped with an electronic brake
system. Take particular care when working on the
brake system. If necessary, commission a
Mercedes-Benz service partner or specialist i
Comply with all national directives and laws.
workshop.
i
Possible invalidation of operating permit:
After any modifications the brake system must be
tested for proper operation and approved by a
technical inspection station. For further information,
see document "Checks after work on brake
system".
---------------------------------------------------------------------------
When relocating compressed-air reservoirs, use genuine Pay attention to the alignment of the compressed-air
Mercedes-Benz mounting supports. The original location reservoirs, e.g. drain valve at bottom, ensure
of the mounting supports must be observed and accessibility.
retained. The mounting supports have been designed If possible, use genuine Mercedes-Benz tensioning
depending on their position (horizontal or vertical straps. For reservoir volumes > 10 l, always use two
installation of compressed-air reservoirs). If the mounting supports and tensioning straps. The distances
installation position has to be changed, a mounting between them should be as large as possible and the
support with the appropriate alignment must be used compressed-air reservoir should be installed
otherwise the operational durability can no longer be symmetrically. Tensioning straps may not be seated on
guaranteed. The compressed-air reservoirs should be the weld seams. Observe the maximum tightening
mounted as centrally as possible in the mounting torque when tightening the tensioning straps. (See tab
supports. "Technical limit values for planning").
If possible, use Mercedes-Benz compressed-air In addition, the conditions and instructions regarding
reservoirs with the appropriate rated pressure. If other modifications to compressed-air lines specified in (see
compressed-air reservoirs are used, these must document "Brake hoses or cables and lines") must
correspond to the requirements of Directive be observed. If the overall line lengths specified here are
2009/105/EC. not complied with, then compliance with the response
Ensure that the compressed-air reservoirs are installed and pressure rise times as per UN-R 13 cannot be
where they cannot collide with other components. guaranteed.
Doubling connections of trailer brake (2 and 3-axle vehicles...
aWarning
lines

i i
Possible failure of brake systems and risk of For additional information, see document "Brake
accident for vehicle user and persons standing hoses or cables and lines".
outside:
The following notes and conditions must be
observed to ensure continued compliance with all
requirements of UN-R 13. All modifications are only i
possible in combination with an "electronic brake Possible invalidation of operating permit:
system", sales code B1B. Extensions to the After any modifications the brake system must be
compressed-air lines are not permissible on vehicles tested for proper operation and approved by a
which are not equipped with an electronic brake technical inspection station. For further information,
system. Take particular care when working on the see document "Checks after work on the brake
brake system. If necessary, commission a system"
Mercedes-Benz Service Partner or specialist
workshop.
---------------------------------------------------------------------------
Any work carried out on the vehicle must comply with Comply with all national directives and laws.
accident prevention regulations.
---------------------------------------------------------------------------
Duplication of trailer brake connections (2 and 3-axle • The trailer control valve may be moved when this
vehicles) overall length is observed or where the existing line
The following notes must be observed when any lengths are retained.
duplication of the trailer brake connections is required Refer to:
(e.g. on a semitrailer truck to be operated either with a
(Document "Electronic Stability Program ESP®,
trailer or semitrailer):
center of gravity heights, stabilizers").
• The plastic compressed-air lines from the trailer
(Document "Coupling devices → Trailer coupling and
control valve to the supply and brake coupling heads
crossmember").
must have a nominal size of 12x1.5 mm (NG12).
Technical implementation of duplicated trailer brake
• The overall length of the plastic lines, including the
connections on example of ESP® for trailer
coiled pipe for the supply and brake together, must
operation on semitrailer trucks, sales code S1E
not exceed 29.2 m.

• The line lengths should be kept almost identical.

Doubling connections of trailer brake (2 and 3-axle vehicles...
1 First crossmember
2 Crossmember
3 Crossmember at the frame
end
4 1.00 m (size 12 line), circuit
III + one 90° plug
5 EAPU (Electronic Air-
Processing Unit)
6 Trailer control valve
7 2.60 m (size 12 line) + one T-
piece, straight + one 90° plug
8 3.63 m (size 12 line) + one T-
piece, straight + one 90° plug
9 2.60 m (size 12 line) + one
90° plug (without Duomatic)
10 Trailer supply coupling head W42.00-A001-75
11 Duomatic supply coupling Technical implementation: Duplicated trailer brake connections on example of ESP® for
head trailer operation on semitrailer trucks, sales code S1E
12 2.60 m (size 12 line) + four
90° plugs (without Duomatic)
13 Trailer brake pressure
coupling head
14 Duomatic brake coupling
head
15 Semitrailer truck supply
coupling head
16 Semitrailer truck brake
coupling head
Compressed air external filling
Recovery/towing
Descriptions of procedures for filling from an external
source in connection with recovery/towing operations are
published in the relevant operator's manuals.
---------------------------------------------------------------------------
External compressed air holding with vehicle pressure, air is released via the safety valve of the
stationary and ignition off supply unit. Pressure holding at 10 bar is sufficient for
driving (brake system/air suspension if installed) when
Boundary conditions the compressed-air system is intact. On vehicles with air
The vehicle must be parked with the compressed-air suspension, the vehicle may only be moved when the air
system at least partially filled (more than 4.5 bar system suspension is fully operational.
pressure).
Special features of connection 12 and 13
The operator must be informed accordingly through
appropriate measures (operator's manual/warning The compressed air supplied at connection 12 does
labels/instructions). pass through the air drier but this air quantity is not
detected with the ignition off and is not taken into
External filling/pressure holding on a vehicle with or account for regeneration during subsequent operation of
without Air Processing Unit (APU) or Electronic Air- the system. The air humidity must therefore be less than
Processing Unit (EAPU) and the ignition switched off 50% at room temperature. Connections 12 and 13 are
must take place at connection 23 on the APU or 28 on located between the compressor and the APU/EAPU.
the EAPU or connection 12 on the air processing unit. There is a possibility of air escaping via the compressor
No pressure must be released at the external filling during filling. This can result in a higher operating rate of
connection during driving operation. Filling with the the external compressor. Modifications to the original
factory sales code B5N, compressed-air connection at compressor line are prohibited (e.g. installation of check
the front is via connection 12. The compressed air valve).
supplied must be limited to 10 bar ±0.3 bar. At a higher

W42.60-A072-81
Connection 12, 13 and 28 on Electronic Air-Processing Unit
(EAPU)
Compressed air external filling
Special features of connection 23 and 28

The air is fed into the system downstream of the air drier. The air is neither
dried nor filtered by the vehicle. The air must be dry (less than 50% air
humidity at room temperature) and clean as per the criteria of the table
"Minimum compressed-air quality requirements". The operator must be
informed about this.
Electronic air-processing unit, high, sales code B1I, electronic air-
processing unit, mid, sales code B1D, and electronic air-processing unit,
low, sales code B1C
W42.60-A033-01
Connection 12 or 28 on Electronic Air-
Processing Unit (EAPU)
Pressure regulator, 10 bar, sales code B1G
W42.60-A034-01
Connection 12 or 23 on Air-Processing Unit
(APU) or compressed-air drier with four-
circuit protection valve
Minimum compressed-air quality requirements
Residual contamination requirements

Residual contamination specifications and cleaning procedures acc. to DBL 6516
Particle size class Particle size [µm] Contamination code Max. particle qty. per
1000 cm³
F 100 ≤ x < 150 8 250
G 150 ≤ x < 200 6 64
H 200 ≤ x < 400 5 32
I 400 ≤ x < 600 4 16
J 600 ≤ x < 1000 3 8
K 1000 ≤ x 00 0
Pneumatic auxiliary consumers
i i
For reasons of standardization, representations, The test instruction for checking the pressure
code scopes and pre-installations of other model safeguarding function of the GAPU/EAPU is
designations and model series are listed in this described in the Mercedes-Benz Workshop
chapter. Only the information valid for your model Information System (WIS) or can be performed by
designation/model series is to be used. any Mercedes-Benz Service Partner.
Electronic air-processing unit installation location

Depending on the equipment installed in the vehicle, the EAPU (Electronic
Air-Processing Unit) is located either on the outer left longitudinal frame
member after the battery carrier or between the longitudinal frame
members in the area between the transmission and the 1st rear axle.
W42.60-A029-01
EAPU between longitudinal frame members
The exact installation position of the systems can be found in the 2D-
chassis drawings (offer drawings) in the Mercedes-Benz Bodybuilder
Portal.
W42.60-A028-01
EAPU on left longitudinal frame member
Distance to compressed-air drier

(Model 967) To ensure easy
servicing when changing the filter
cartridge of the compressed-air drier,
an adequate distance to the vehicle
body must be maintained. A distance
of at least 50mm from the
compressed-air drier must be
maintained.
(Model 963, 964) To ensure easy
servicing when changing the filter N42.60-A002-04
cartridge of the compressed-air drier, The filter can be changed quickly and easily if the distance to the vehicle body is
sufficient
an adequate distance to the vehicle
body must be maintained. For
compressed-air driers with Electronic
Air-Processing Unit, mid, sales
codeB1H, a distance of at least
50mm must be maintained.
In the case of Electronic Air-
Processing Unit, high, sales codeB1I,
a distance of 150mm must be
maintained. These dimensions are
intended as guideline values in order
to ensure that the cartridge can be
changed quickly and without
considerable cost and effort.
Function description of air-processing unit • Improved compressed-air drying

In general the purpose of the air-processing unit is • Reduction in number of compressed-air reservoirs
• to dry the air from the air compressor and air that has • Intelligent regeneration management, with the
cooled in its line from the engine to the air drier. omission of a separate compressed-air reservoir for
• to regulate the operating pressure in the this function
compressed-air system. • Compressed-air delivery phase during engine
• to secure an intact compressed-air circuit against any overrun before the cut-in pressure is reached
potentially leaking circuit. Connection 24 of the four-circuit protection valve or
• to maintain the supply pressures of all compressed- EAPU is available for auxiliary consumers added by the
air circuits at the specified level. body manufacturer under the conditions listed below.
All vehicles are generally equipped with an Electronic No modifications may be made to the other connections
Air-Processing Unit (EAPU). In vehicles with air-sprung of the air drier, the four-circuit protection valve or the
axles in particular, this can improve the raising and EAPU.
lowering times of the level control system.
Further improvements over a conventional pressure
regulating system are:

Electronic Air-Processing Unit (EAPU), low,
codeB1C, (model 963, 964, 967) and Electronic Air-
Processing Unit (EAPU), mid, codeB1D, (model 963,
964, 967)
All vehicles can generally be ordered with an Electronic
Air-Processing Unit (EAPU). Most vehicles are equipped
with this as standard, e.g.vehicles with air-sprung rear
axle. In these vehicles in particular, this can improve the
raising and lowering times of the level control system.
Further improvements over the pressure regulating
system, 10bar, codeB1G, are:
• Improved drying of the compressed air
• Reduction in number of compressed-air reservoirs
• Intelligent regeneration management, with the
omission of a separate compressed-air reservoir for
this function W42.60-A036-11
Connection 24, circuit 4, auxiliary consumers to pressure control
• Compressed-air delivery phase during engine system, 10bar, code B1D
overrun before the cut-in pressure is reached
i
The EAPU, low, is for vehicles without trailer control.
With the exception of the lack of an internal
controller for the trailer control circuit, this variant
essentially consists of the mid variant. If a trailer
brake connection (e.g.trailer brake, 2-line, sales
code B5B) is required at a later time, the existing
air-processing unit must, if necessary, be replaced
with a mid EAPU in order to ensure the increased
air supply. For further information on how to
proceed, please contact your Mercedes-Benz
Service Partner.
Electronic Air-Processing Unit (EAPU), mid, code

B1H, (model series 949, 959, 963, 964)
The EAPU, mid, is intended for vehicles with normal air
consumption. Due to the existence of the internal control
system, it is suitable for trailer control.
N42.60-A003-10
1 Connection 24, circuit 4, auxiliary consumers to Electronic Air-

Processing Unit (EAPU), medium, code B1H
N42.60-A004-02
Electronic Air-Processing Unit (EAPU), high, code reservoir, and an additional pressure sensor monitors
B1I, (BR 949, 956, 959, 963, 967) the circuit.
The EAPU, high, is intended for vehicles with high air The EAPU1, high, and EAPU2, high, are only available
consumption and differs from the mid variant in that it in the on-road platform vehicles (model 963.0xx). In
has an additional internal control for the air suspension these model designations, the EAPU High is added
circuit. One or more separate compressed-air reservoirs automatically by the presence of the codesA1A (air-
at a pressure of 12.5bar in the air suspension circuit sprung FA) or E4X (Nordland starting-off aid). The
provide a high volume of air. An additional solenoid EAPU, high, is available as standard with the on-road
valve regulates the filling of this compressed-air platform lowliner (air-sprung front axle).
---------------------------------------------------------------------------
Maximum permissible air consumption include all air consumers, e.g. brakes, air suspension,
trailer etc.
Maximum permissible air consumption in
combination with air compressor, sales code M6N, M6M Delivery rate at 2500 rpm and 12 bar back
model 963, 964, 967 pressure approx. 660 l/min.
The air requirement must be checked when the vehicle

is operated under unfavorable conditions, e.g. stop-and-
go traffic and/or if pneumatic auxiliary consumers with i
high air consumption are installed. This total must If the air consumption exceeds the specified delivery
include all air consumers, e.g. brakes, air suspension, rate, air supply problems can occur, e.g. insufficient
trailer etc. air dehumidification or overheating damage.
M6N Delivery rate at 2500 rpm and 12 bar back

pressure approx. 600 l/min. Maximum permissible air consumption in
conjunction with air compressor, sales code M6L,
model 949, 959, 963, 964
i The air requirement must be checked when the vehicle
If the air consumption exceeds the specified delivery is operated under unfavorable conditions, e.g.stop-and-
rate, air supply problems can occur, e.g.insufficient go traffic and/or if pneumatic auxiliary consumers with
air dehumidification or overheating damage. high air consumption are installed. This total must
include all air consumers, e.g. brakes, air suspension,
trailer etc.
Maximum permissible air consumption in
combination with air compressor, sales code M6M, M6L Delivery rate at 600 rpm and 12 bar back pressure
model 956, 963, 964 approx. 250 l/min; at 2500 rpm and 12 bar back pressure
approx. 970 l/min.
The air requirement must be checked when the vehicle
is operated under unfavorable conditions, e.g. stop-and-
go traffic and/or if pneumatic auxiliary consumers with
high air consumption are installed. This total must
i
If the air consumption exceeds the specified delivery
rate, air supply problems can occur, e.g.insufficient
air dehumidification or overheating damage.
Assembly tool for extending

plastic pressure lines
Order designation
1 Press-on pliers 5994506500
2 Tool insert 5994691149
3 Strap assembly pliers
5994521100
N58.20-A000-06
The example below is from Voss.
Connection for compressed air auxiliary consumers the connector on the pick-up valve/switchover valve
in cab directly downstream, for example. A condition which
Basic requirements applies here is that this valve must have a reliable,
permanent pneumatic shutoff function for the inlet
• Tapping should take place only in the cab at circuit 4, line when unactuated or when in the drive positions/
auxiliary consumers, as described below. neutral position. If these requirements are not met,
• The max. operating pressure in circuit 4 is 8.5bar. the connections must be designed with the Schäfer
SDF system for 6x1 lines up to a suitable valve or
• Plastic lines with diameter 6x1 of the specification
end consumer.
PA11PHLY or PA12PHLY in accordance with
DIN74324 must be used. • The line is routed into the cab via the separator plate
under the driver's seat. If the passages in the
• In addition, compressed-air lines as per ISO7628 of
separator plate are not used at the factory, they are
line category 23A are approved.
sealed at the factory with a stop plug. This stop plug
• This type of tap is only permissible for pneumatic can be removed and used as a passage in
auxiliary consumers with a low air requirement. combination with the connection sleeves with
These include master valves, switchover valves for Mercedes-Benz part numbers A0009903978 and
trailers/loading cranes or similar consumers which A0009904278. If all passages are occupied, it is
only consume air during actuation/activation of their permissible to use the sealed spare passages 13, 14,
function. 15 and 16. These must be drilled through and sealed
• The connections must be made with the with sealant after the compressed-air line has been
SchäferSDFsystem for 6x1 lines starting at connector installed.
A6459900378 version B at least up to and including

W42.60-A032-07
Label example:
1 Standard designation 5 Material identification according to ISO1043‑1
2 Line category, max. permissible working pressure 6 Manufacturer identification
at -40℃to+100℃
3 Line category, max. permissible working pressure 7 Time of manufacture
at -40℃to+125℃
4 Outside diameter and wall thickness
Connection strip – position below

driver's seat, Atego, model 967
1 Supply line (A70)
2 Driver's seat/front passenger
seat line (A71)
3 Pipe rupture protection line
(A72)
4 Air horn line (A71)
5 Dump truck supply line (A71)
6 Steering supply line (A74)
N42.60-A014-01 N42.60-A013-01
Distributor rail assignment (example shows Installation location
left-hand drive vehicle)
Connecting point assignment, Atego, model 967

Assignment diagram - Cab connecting point (A9704311540)
N42.60-A017-01
Cab connection plate
N42.60-A018-02
Assignment diagram

N Sales code Consumer
o.
1 P2P/P2Q/P2V/P2W/P2S/P2T Dumper operation 21 (A)
2 B5B Trailer brake control line
3 Parking brake supply
4 B0A Pipe rupture protection control line
5 B2Z/P2P/P2Q/P2V/P2W/P2S/P2T Dumper operation 22 (B)/4-wheel parking brake control line (fire

department)
6 P2P/P2T Auxiliary consumer supply
7 Parking brake control line
8 Cab bleed line
9 Standard/F6R/P2P/P2Q/P2V/P2W/P2 Loading crane control line 2 (C)

S/P2T/D1B/D1C
10 P8Y Dumper trailer 2 (C)
11 Automatic side board 22 (D)
12 Automatic side board 21 (E)
13 Closed
14 Closed
15 Closed
16 Closed

Designation Part number Connections
Connecting point on cab (holder package) A9704311540 1...16
Connecting point on chassis (standard) A9704310042 1...8
Connecting point on chassis (sales code) A9704310142 9 to 16

Sales code abbreviations
B0A Pipe rupture protection, for brake system
B2Z Additional parking brake on front axle
B5B Trailer brake, 2-line
D1B Driver's suspension seat, standard
D1C Driver suspension seat, comfort
F6R Air horns, cab roof
P2P Standard dump truck, 3800x2350x400mm
P2Q Standard dump truck, 4000x2350x400mm
P2S Standard dump truck, 4000x2350x500mm
P2T Standard dump truck, 4000x2350x600mm
P2V Standard dump truck, 4200x2350x500mm
P2W Standard dump truck, 4200x2350x600mm
P8Y Hydraulic connection, dumper trailer
Connection strip – position below

driver's seat, Actros, Arocs, model
963, 964
1 Connecting strip
N42.60-A010-01 N42.60-A011-01
Location of connection strip on cab with Connection strip on cab with flat floor 2500
curved floor 2300 (RHD vehicles in mirror (RHD vehicles in mirror reverse)
reverse)
2 Initial piece
3 Connector A 645 990 03 78
4 Mounting bolt MBN 10105-M6 × 10-8.8
DBL 9440.40
N 910105 006007
(Ma = 7.4 Nm ± 1.4 Nm)
5 End piece
The end piece must be offset by one hole and an additional
connector should be attached to the position which is freed up.
W42.60-A070-01
Design of connection strip
Assignment of connecting point

Standard connecting point, Actros, Arocs, model 963, 964

A simplified cab compressed air connecting point (A9604310440) is
installed as standard. This contains a line leading to the cab distributor rail.
If the vehicle is fitted with one of the following special equipment items, the
separator plates described below are installed according to the steering
type:
• Sales codeB5C, INDEPENDENT TRAILER BRAKE
• Sales codeF3C, CAB SUSPENSION, COMFORT, AIR-SPRUNG
• Sales codeP9A, DUMPER CONTROL IN CAB
• Sales codeP9B, SWITCHOVER, TRAILER OPERATION W42.60-A049-01
Cab compressed air connecting point
(A9604310440)
Actros, Arocs, model 963, 964

Insofar as sales code scopes are not
installed in the vehicle, the relevant
passages are sealed with the stop
plug A1109870039 ex factory. The
passages marked as "sealed" are
reserve passages. The separator
plate is closed here.
N42.60-A015-05
Assignment, separator plate, left-hand drive vehicle A9604310240

Left-hand drive vehicle
No. Sales code Consumer
1 B5C Independent trailer brake supply, connection

11
2 Closed
3 B5C Independent trailer brake ventilation
4 F3C Cab suspension, supply, comfort air

suspension
5 Closed
6 B5C Independent trailer brake control line,

connection 21
7 Closed
8 P9A Dumper valve, valve 21 (A)
9 P9A Dumper valve, valve 22 (B)
10 Distributor rail supply
11 P9F Rear panel claw-type lock, valve 20 (C)
12 P9D Automatic side board, valve 22 (D)
13 P9D Automatic side board, valve 21 (E)
14 Closed
15 Closed
16 P9C Loading crane, valve 20 (C)
17 P9B Trailer, valve 20 (C)
18 Closed
19 Closed
20 Closed
Insofar as sales code scopes are not
installed in the vehicle, the relevant
passages are sealed with the stop
plug A1109870039 ex factory. The
passages marked as "sealed" are
reserve passages. The separator
plate is closed here.
N42.60-A016-05
Assignment, separator plate, right-hand drive vehicle A9604310140

Right-hand drive vehicle
No. Sales code Consumer
1 B5C Brake connection 11
2 Closed
3 B5C Independent trailer brake ventilation
4 F3C Cab suspension, supply, comfort air

suspension
5 Closed
6 B5C Independent trailer brake control line,

connection 21
7 Closed
8 P9A Dumper valve, valve 21 (A)
9 P9A Dumper valve, valve 22 (B)
10 Distributor rail supply
11 P9F Rear panel claw-type lock, valve 20 (C)
12 P9D Automatic side board, valve 22 (D)
13 P9D Automatic side board, valve 21 (E)
14 Closed
15 Closed
16 P9C Loading crane, valve 20 (C)
17 P9B Trailer, valve 20 (C)
18 Closed
19 Closed
20 Closed

Designation Part number Connections
Connecting point on cab (holder package) A9704311540 1...16
Connecting point on chassis (standard) A9704310042 1...8
Connecting point on chassis (sales code) A9704310142 9 to 16

Sales code abbreviations
B0A Pipe rupture protection, for brake system
B2Z Additional parking brake on front axle
B5B Trailer brake, 2-line
D1B Driver's suspension seat, standard
D1C Driver suspension seat, comfort
F6R Air horns, cab roof
P2P Standard dump truck, 3800x2350x400mm
P2Q Standard dump truck, 4000x2350x400mm
P2S Standard dump truck, 4000x2350x500mm
P2T Standard dump truck, 4000x2350x600mm
P2V Standard dump truck, 4200x2350x500mm
P2W Standard dump truck, 4200x2350x600mm
P8Y Hydraulic connection, dumper trailer
Connection of compressed-air auxiliary consumers theSchäferSDFsystem. If other connecting parts are

at chassis used, it is essential to connect an overflow valve without
Basic requirements return flow (7.3bar 0/0.3 bar, part number A0054296444)
between the compressed-air tapping point and the
• Connection may only take place at circuit 4, auxiliary consumer in order to safeguard the other compressed-
consumers of the compressed-air brake system air circuits.
e.g.connection 24 of the EAPU (ElectronicAir-
ProcessingUnit). • If low-strength plastic lines are used, e.g.PA12PHL,
an overflow valve without return flow (7.3bar
• At connection 24 of the EAPU, the maximum line 0/-0.3bar) must be installed between the
cross-section is 16mm. compressed-air tapping point and the auxiliary
• The max. operating pressure in circuit 4 is 8.5bar. consumer in order to safeguard the remaining
compressed-air circuits.
• Plastic lines with a diameter 6x1 of the specification
PA11PHLY or PA12PHLY in accordance with • Up to the input (connection:1) of the overflow valve,
DIN74324 must be used. only the above-mentioned approved connecting parts
and plastic lines arepermissible.
• In addition, compressed-air lines as per ISO7628 of
line category2, 3A are approved. • When additional compressed-air reservoirs are used,
these must be checked in line with EC Directive
• Only connection fittings fromVOSSsystem232 can be
"Simple pressure vessels" EN286‑2 (87/404/EEC).
installed.
Operating instructions must be supplied.
At the distributor rail, compressed-air lines up to 8mm∅
can be connected using connecting parts of

W42.60-A032-07
Label example:
1 Standard designation 5 Material identification according to ISO1043‑1
2 Line category, max. permissible working pressure 6 Manufacturer identification
at -40℃ to +100℃
3 Line category, max. permissible working pressure 7 Time of manufacture
at -40℃ to +125℃
4 Outside diameter and wall thickness
N42.60-A020-02
Distributor rail at EAPU
W42.60-A069-76
Overflow valve without return flow, part number A0054296444
Mercedes-Benz connecting parts for separator plate

N42.60-A022-01 N42.60-A023-01 N42.60-A024-01

Stop plug, A1109870039 Exterior connection sleeve, A0009904278 Interior connection sleeve, A0009903978
Connecting parts for distributor rail

N42.60-A025-01 N42.60-A025-01 N42.60-A026-01

Connector, fir-tree 4mm, A6459900378 Connector, fir-tree 6mm, A6459900478 Screw, connector, N910105006007 MA
=7Nm
Only suitable for connection to
the chassis distributor rail
Checks after work on the brake system
Checks after work on the brake system In principle, the scope of work on the brake system is
Following work on the brake system (also if parts are determined by which checks need to be carried out.
removed), a complete inspection of the entire brake The table below indicates which checks are necessary:
system must be performed.

The following check procedure is required and must be documented
Work procedure Brake circuit Brake value Leak test
safeguarding determination
(safeguarding of
pressure supply)
Removal of lines from air reservoir and/or four-circuit Required

protection valve
Dismantling of brake unit carrier or installation of Required

additional compressed-air reservoirs
Removal due to "shortening/extension" of brake lines, Required; adjustability Required Required

e.g. with changes in wheelbase or repositioning of brake and time-related
unit carrier characteristics of the
brake must also be
checked.
Function test on vehicles which have been non- – Required Required

operational for > 4 months as of final notification
Modifications to front and rear axle involving operations on – Required Required

brake components
Removal due to "shortening/extension" of brake lines for Required; operation of Required Required
trailer brake or on/to trailer control valve, e.g. with coupling heads
changes to frame overhang (exchangeability),
adjustability and time-
related characteristics
of trailer brake must
also be checked.
Brake circuit safeguarding (safeguarding of The test procedure for checking the pressure
pressure supply) safeguarding function of the EAPU is described in the
The EAPU (Electronic Air-Processing Unit) safeguards Mercedes-Benz Workshop Information System (WIS) or
the individual compressed-air circuits with respect to can be performed by any Mercedes-Benz Service
each other. This prevents the other compressed-air Partner.
circuits from being severely impaired if a pressure loss
occurs in one of the compressed-air circuits.
The "ECE function" of the EAPU means that, if a
pressure loss occurs in brake circuit 1, the pressure in
the trailer brake circuit also drops after a delay.

W42.10-A018-09
Figure shows EAPU
1.10 Dual compressor, 30.01 Safety valve B26 Condensation sensor
switchable for compressed-air
system (only with
condensation
monitoring, for
compressed-air
system, sales code
B4A)
6.18 EAPU (high) 38.02 Test connection B97 Temperature sensor
M16x1.5 (EAPU)
7.01 Overflow valve with A18 EAPU control unit
return flow
Leak tightness of compressed-air system • There should be no audible air loss.

Due to the technical equipment on the vehicle, a • The brake pedal is depressed as far as partial
pressure drop can occur after switching off the engine, braking (approx. ½ pedal travel).
caused by auxiliary consumers (e.g. after-blowing • With the brake pedal at a constant position, the
process of the exhaust gas aftertreatment system). indicators on the manometer must not drop visibly
To avoid this pressure drop being included in the during a period of 3 min.
assessment, a waiting time of 5 min must be observed. • The permissible pressure loss on actuation of the
Avoid getting in and out of the vehicle during the test. service brake with 3.5 bar (measurement duration:
During the leak test, note the following: 3 min) is 0.4 bar.
---------------------------------------------------------------------------
Brake force determination The minimum deceleration (service brake system 45 %)
The brake forces are determined on a suitable brake test must be derived by means of extrapolation on the basis
stand. of the test weight of the vehicle.


Uniformity of braking effect
Service brakes Permissible brake value deviation between wheels on one

axle
Front and rear axles 25% of higher value
i
Following modification, extension and replacement
of components of the brake system, e.g. installation
of an additional axle, the brake system must
undergo an acceptance test performed by a
technical inspection station and be checked for
proper operation, otherwise the operating permit for
the vehicle will be rendered invalid.
Tolerances for dent formation on compressed-air reservoirs
Tolerances for dent formation on compressed-air Deformations and irregularities must exhibit the
reservoir following:
The method of attachment using tensioning straps can • There must be no overhangs with an inclination
lead to dent formation on compressed-air reservoirs. The above 25% (14°).
standard DIN EN286-3 describes the permissible • There must be no roundings with a radius of less
denting on compressed-air reservoirs. Reduction of the than half the reservoir knuckle radius (r2) extending
tightening torques/preload is not permissible because it into the surrounding area.
is not permitted to reduce the preload of the tensioning
straps. • If the width of the dent is less than four times the
depth, the depth of the dent must not exceed 1/50 of
Tightening torques the reservoir diameter.
• Cradle-type tensioning strap = 25 (±5) Nm • If the width of the dent is greater than four times the
• Hydac tensioning strap = 22.5 (±)2.5 Nm depth, the depth of the dent must not exceed 1/25 of
the reservoir diameter.
The standard DIN EN 286‑3 G.4.3.1.2 "Jacket wall"
gives the following explanation:

Geometry of dished end

1 Spherical cap
2 Knuckle
3 Curved part
4 Side
W42.60-A042-10
The following table shows the calculated dent formation/

size based on DIN 286‑3.

Diameter If the width of the dent is If the width of the dent is less If the width of the dent is
of less than four times the depth: than four times the depth: more than four times the depth:
compress
ed-air Permissible depth: 1/50 of the Permissible extent of dent [mm] Permissible depth: 1/25 of the
reservoir diameter of the compressed-air diameter of the compressed-air
[mm] reservoir [mm] reservoir [mm]
144 2.88 11.52 5.76
206 4.12 16.48 8.24
246 4.92 19.68 9.84
276 5.52 22.08 11.04
Tolerances for dent formation on compressed-air reservoirs
W42.60-A043-11
Aluminum reservoir dia. 246 mm - secured using Hydac steel
tensioning strap (max. depth of the dent 9.84 mm)
Examples of permissible dent formations
W42.60-A044-11
Steel reservoir dia. 276 mm - secured using Hydac steel
tensioning strap (max. depth of dent 11.04 mm)
Change compressed-air line on compressor
To ensure that the compressed-air drier functions The following line lengths must be observed
properly, it is necessary to cool the compressed air to (+ max. 15%, except Econic):
approx. 65 ℃.
The air is cooled as it passes through the pipe of the
compressed-air line from the compressor to the
compressed-air drier.

1-cylinder air compressor 2-cylinder compressor
Actros (model series 963) 6000 ... 7000 mm
Arocs (model series 964) 6000 ... 7000 mm
Atego (model series 967) 5300 ... 6500 mm
Econic (model series 956) 4100 ... 4800 mm
To keep vibrations of the compressor away from the

downstream compressed-air system and to prevent
connections form being damaged and pipes from
rupturing, a section of the compressed-air line must be
elastic in design. E.g. as a spiral pipe, which can also
serve as a cooler at the same time, or with a hose line.
W42.60-A071-82
Spiral pipe
Change compressed-air line on compressor
If pressure hoses are connected directly to the
compressor outlet, the pressure strength and
temperature resistance must also be assured at 250 ℃.
W42.60-A046-11
Hose line
Also pay attention to the following points detachable parts should be attached to the air
For the model series Actros (model series 963), Arocs compressor line. When the air-compressor line is
(model series 964) and Actros Classic, the piping is installed, it must be ensured that adequate clearance to
always used in the form of steel line according to the above-mentioned lines is provided.
EN 10305‑4‑1.0308‑E235+N, DBL 4044.20 with the Compressed air should never be tapped at the air-
dimension 18 x 1.5 mm. On the Atego (model compressor line!
series 967), a steel line must also be used but with the The leak tightness of the air-compressor line and
dimensions 15x1.5 mm. The material of the air correction operation of the compressed-air preparation
compressor line of the Econic (model series 956) is system must be checked!
either steel or stainless steel (EN 10305‑4-1.0308+N
+DBL4044.20 opt. EN 10217‑7‑1.4301) with the
dimensions 18 x 1.5 mm.
i
The cross-section of the air-compressor line must not be The compressed air cools more slowly on vehicles
reduced. Indentations are not permissible. with increased air consumption and compact design.
To prevent fatigue failures, the air-compressor line must If modifications are made, the lines must be routed
be secured to the chassis using suitable brackets. similar to those on series-production vehicles.
Plastic cable ties are not suitable!
Temperature traps or similar must be avoided.
Owing to heat development, no other lines (e.g. electric
lines, hydraulic hoses, compressed air lines) or other
Vertical compressed-air reservoir
In case of issues concerning installation space,

compressed-air reservoirs may also be installed
vertically.
i
Compressed-air reservoirs must always be secured
with two tensioning straps.
Here, it is important to secure these tensioning
straps as far apart as possible in order to minimize
sensitivity to vibrations.
i
If reservoirs are secured to each other, two
tensioning straps must again be used.
i W42.60-A047-12
A drain screw (screw plug with balance hole) must Vertical installation of compressed air reservoir
be present at the bottom, at the center connection if
possible.
If all connections are assigned, the line to a
consumer must be routed from the center
connection if possible.
Subframe, general
Subframe
Design of subframe Page 489
General auxiliary frame must lie on the load application points.

In these Body/Equipment Mounting Directives, the term Additional fasteners (mounting consoles or shackles)
"auxiliary frame" refers to an additional frame that must be provided if necessary.
performs a load-bearing function and contributes to the • Position auxiliary frame crossmembers above the
overall bending resistance in combination with the vehicle frame crossmembers.
vehicle frame. The term "assembly frame" describes an • For the longitudinal members, use flanged U sections
additional frame which is used, e.g. only to create a or commercially available U sections for vehicle
clearance from the rear axle wheels, and does not construction (not rolled steel sections).
perform a load-bearing function with respect to the
vehicle frame. • The dimensions of the longitudinal members are a
function of the moment of resistance (Wx) required
All bodies require an auxiliary frame or a substructure
for the body and the chassis (see document
that assumes the function of an auxiliary frame to ensure
"Design of auxiliary frame").
a reliable connection between the chassis and the body
(except for self-supporting bodies and assembly frames • The specified moments of resistance and section
acting as floor assemblies). dimensions refer to longitudinal frame members
subjected to identical loads on both sides.
• The auxiliary frame longitudinal members must lie
level on the upper flanges of the vehicle frame and If more than one body is mounted on the same chassis,
follow the course of the vehicle frame. At least e.g. platform and cargo liftgate, the larger of the
85% of the length of the auxiliary frame must lie on specified moments of resistance must be taken to define
top of the vehicle longitudinal frame member. The the auxiliary frame.
Material for subframe
Subframe
Steel auxiliary frame be coordinated with the relevant contact person (see
With U-bolt or bracket mounting (non-positive): document "Advice for body manufacturers").
Elongation at fracture Re = 355 N/mm² The use of an auxiliary frame of higher quality materials
is recommended.
With rigid mounting (positive) using shackles: Elongation
at fracture Re = 500 N/mm². Auxiliary frames made of Observe the instructions given by the aluminum
high-strength steels, e.g. N‑A‑XTRA, must have at least manufacturer.
the same rigidity as steel assembly frames. The The longitudinal members, plank floor, floor panels and
mounting must be non-positive. crossbars must form one self-supporting unit.
Aluminum auxiliary frame The mounting must be non-positive.
The suitability and therefore the use of materials with
lower strength properties, e.g. elasticity modulus, must
Design of subframe
Subframe
Loading crane body
Loading crane body Page 549
Body mountings available ex factory
Body mountings available ex factory Page 500
i
Depictions, code scopes and pre-installations for
other vehicle model designations and model series
W31.20-A051-79
A Start of cutout of vehicle longitudinal frame
member
Start of subframe (model series 963, 964, 983) start of the cutout in the direction of travel, depending on
The subframe may not end directly above the start of the the selected cab variant and/or overall installation space
cutout in the vehicle longitudinal frame member. The end situation. A minimum distance of 50 mm must be
of the subframe must be located in front of or behind the maintained.

Design of subframe (See illustrations "End of subframes 1 to 3"). The

There should be a gradual sectional transition at the edges (particularly those that are in contact with the
forward end of the longitudinal members chassis) must be deburred, i.e. provided with a radius
(R ≥ 5).

Design of subframe
Subframe
W31.20-A000-01 W31.20-A001-01 W31.20-A002-01

End of subframe 1 End of subframe 2 End of subframe 3
1 Vehicle frame 1 Vehicle frame 1 Vehicle frame
2 Subframe 2 Subframe 2 Subframe
Continuous assembly frames are required for: Mercedes-Benz recommends use of the fastening
• Bodies with a high center of gravity elements available ex factory. An overview can be found
in document "Body mountings available from the
• Intense point loading factory".
• One-sided loading For vehicles of model series 967: Always only connect
• Cab superstructures the assembly frame to the vehicle longitudinal frame
members with U section, and do not under any
e.g. for:
circumstances connect them to the flange of the vehicle
• Dumper bodies frame with Z section. On vehicles with a short cab, allow
• Glass transport bodies the subframe to project over the vehicle longitudinal
frame members with U section in the direction of travel.
• Towing bodies If a connection between the body and the chassis is
• Loading cranes necessary in this area for strength reasons, design this
in the same way as the crane body behind the cab using
• Hinged booms
an interior mounting plate (connection to the web of the
• Cargo liftgates Z section) (see document "Loading crane body").
• The longitudinal members must extend as far forward
as possible, but at the very least beyond the rear
front spring brackets.

Design of subframe
Subframe
Subframe as floor assembly
A subframe with continuous longitudinal members is not required if the floor
assembly of the body can take on the load-bearing function of the
subframe.
Section dimensions
The assembly frame and the vehicle frame should have the same material
thickness and flange width.
The diagram in "Illustration of section dimensions for assembly frame
longitudinal members (open U section)" indicates which section dimensions
are possible to achieve a particular moment of resistance Wx.
For non-positive connections, if very high longitudinal members are
required or if low overall frame heights need to be achieved, the U section
can be closed as a box, nested or overlapping.
This causes the moment of resistance, and also the torsional rigidity, to
increase. "Illustration of increase in moment of resistance through section
reinforcement" shows the effect that section reinforcement has on the W31.20-A003-02
moment of resistance. End of box section 1
Ensure there is a good transition from the closed longitudinal member to

the open U section. Two examples are provided in the following illustrations
"End of box section 1" and "End of box section 2".
W31.20-A004-01
End of box section 2
Design of subframe
Subframe
W31.20-A052-09
Section dimensions for assembly frame longitudinal members (open U section)
A Open U-section
No increase in Wx
B Closed U-section
Increase in Wxby factor of
1.25
C Nested U-section
Increase in Wxby factor of
1.75
D Overlapping U-section
Increase in Wxby factor of 1.9
W31.20-A006-05
Increase in moment of resistance through section reinforcement
Subframe mounting
Subframe
Attachment of the subframe • vehicle handling and operating safety
The body should be attached according to the chassis • the durability of the vehicle frame and the body.
type, the planned body and the vehicle's purpose. • On model series 967, carry out longitudinal fastening
• Select the number of attachments to ensure using a shackle mounting in the rear axle area. A
adequate transfer of all brake and lateral forces. shackle mounting at the end of the frame is
Correct attachment is a decisive factor for: recommended for model series 963, 964.

Lateral attachment
• Provide guide plates of sufficient size.
• There must be no gap between the guide plates and
the subframe.
• The guide plate is bolted to the vehicle frame or
subframe on one side. When bolting to the
subframe, a wear pad must be affixed to the
opposite surface on the vehicle frame in order to
prevent surface damage.
• On model series 963, 964, install guide plates in
the area of the first to third mounting support.
1 Vehicle frame
2 Subframe
3 Crossmember
4 Bolts for longitudinal fastening W31.20-A007-11
5 Guide plate for lateral fastening Subframe attachment (Fig. BR 967)
Mounting of systems with exchangeable body
Subframe
Mounting of swap systems coordinated before installation with the relevant contact
The mounting of swap systems (interchangeable person (see document "Advice for body
systems e.g. for dump truck/semitrailer use) must be manufacturers").
Frictional flexible connection
Subframe
Non-positive connection (bracket mounting) • Model 967: Compensate for different distances for
• Movement of the auxiliary frame longitudinal member the other mounting consoles using shims. If this is not
relative to the vehicle longitudinal frame member is possible, ensure that the lateral stability of the
possible to a limited extent. auxiliary frame is sufficient using suitable lateral
guides.
• Carry out the strength calculation separately for each
longitudinal member. • Do not twist the auxiliary frame by tightening the
bolts.
• Divide the bending moment according to the
moments of inertia. • After installation, a top coat must be applied to the
attaching parts.
• Design the front attachment points to be flexible (disk
springs, rubber mounts). If the supplied mounting consoles are used, the
installation instructions provided in document "Body
• The maximum interval between brackets is 1000 mm. mountings available from the factory" must be
• Model 967: A distance of at least 5mm between the observed.
body and the chassis consoles behind the cab to the When using other mounting consoles, we still
steering bracket of the rear axle must be maintained recommend compliance with the mounting specifications
after the bolts are tightened. provided here.
Positive rigid connection
Subframe
Threaded connections Page 136
Positive rigid connection (shackle attachment) • Torsionally stiff bodies, e.g.box bodies, fuel tanks, on
• Movement of the subframe longitudinal member the subframe behind the cab are to be mounted
relative to the vehicle longitudinal frame member is flexibly. Flexible mounting throughout is not
not possible. permitted.
• The subframe longitudinal member follows all of the • Permissible standard shackle interval 500 mm to
movements of the vehicle longitudinal frame member max. 700 mm, measured from the last screw of
(deflection, angular movement). shackle 1 to the first screw of shackle 2.
• Both longitudinal members are viewed as one Longer intervals are permissible in the area of the
component part for the purposes of stress frame kink and in the area of the rear axle. If the
calculation. structural circumstances so require, intervals of up to
800 mm are permissible in these areas. This applies
• For the body on concrete mixer trucks, loading crane once for the frame kink and once for each rear axle.
at rear, rear dumpers and similar bodies, the
subframe must be attached rigidly to the vehicle • Adjust the material strength of the shackles to suit the
frame. forces and weights due to the body:
• Use console mounting in the front area. • Minimum thickness 7 mm
• Continuous shackle attachment into the area of the • Maximum thickness 10 mm

cab, e.g.mounting of heavy-duty loading cranes, • Attach the shackles to the vehicle frame with at least
must be coordinated with the relevant contact person three adjacent flange head bolts (see document
(see document "Advice for body manufacturers"). "Threaded connections and weld joints").
---------------------------------------------------------------------------
Special considerations for model 983 The tightening torque Ma is 225 Nm. An additional
Welding may not be performed on these vehicles in the tightening angle of 90° is not required here. Make sure
area of the wheelbase because of the high-voltage the screw has a hard joint in accordance with ISO 5393.
batteries. The positive-locking shackles are to be welded Apply the topcoat for the positive-locking shackles and
to the subframe either before it is mounted or, if this is the subframe only after bolting has been completed. To
not possible, bolted to the subframe after mounting it. mount the subframe with its previously applied top coat,
see document "Threaded connections".
To do so, use 3x flange head screws M16x1.5
MBN10105 and 3x flange head nuts M16x1.5 (see
document "Threaded connections and weld joints").

Subframe
W31.20-A053-06
Shackle welding
Retrofitting tab mounts (mounting plates) under axle replaced with mounting plates in compliance with the
bearing bracket on air-sprung rear axles conditions listed below.
If necessary, the factory-fitted shims between the axle
bearing bracket and longitudinal frame member can be

Variant 1: Example showing use of

genuine mounting plates with MB
part number.
• Ensure that the axle bearing
bracket makes full contact with
the mounting plate.
• Surface treatment of mounting
plate in contact area of axle
bearing bracket: primed or
cathodic immersion coated.
• All loosened threaded
connections must be completely
replaced.
• All threaded connections between
the axle bearing bracket and
longitudinal frame member are
classified as RA safety
connections.
A Shim (front) under axle
bearing bracket
B Shim (rear) under axle W31.20-A054-76
bearing bracket replaced with
mounting plate (3 holes) A
960 316 23 54
Subframe
A Shim (front) under axle

bearing bracket
C Shim (rear) under axle bearing
bracket replaced with
mounting plate (4 holes) A
960 316 28 54
W31.20-A055-76
Variant 2: Use of mounting plates specific to body manufacturer.

• Material: Steel, elongation at fracture ≥ 500 N/mm², material thickness:
7 ±0.2 mm.
• Ensure that the axle bearing bracket makes full contact with the single-
piece mounting plate.
• Surface treatment of mounting plate in contact area of axle bearing
bracket: primed or cathodic immersion coated.
• All loosened threaded connections must be completely replaced.
• All threaded connections between the axle bearing bracket and
longitudinal frame member are classified as RA safety connections.
W31.20-A009-02
Shackle attachment
Mounting with U-bolts
Subframe
U-bolt mounting
1 Nut
2 Clamping plate
3 Auxiliary frame
4 Vehicle frame
5 U-bolt
6 Intermediate layer
7 Inner frame reinforcement
8 Retainer
a Internal height of vehicle frame:
265mm
W31.20-A010-02
Part description
Implementation instructions • The internal reinforcement must be secured so that it

• At the end of the auxiliary frame a suitable structure cannot be lost.
must be provided to absorb the longitudinal forces • The intermediate layer (6) must be wider than the
(moving off and braking), e.g. a thrust plate at least lower and upper flanges of the longitudinal member.
7 mm thick and 150 mm wide (with 3 flange head • Install the first pair of U-bolts at a distance of
bolts M16x1.5 –10.9). approx. 200...300 mm from the front edge of the
• U-bolt spacing, depending on body type, max. auxiliary frame.
1200mm.
U-bolt tightening torque
• The U-bolts must not rest on the vehicle longitudinal
frame member. • On steel auxiliary frames: Tighten to standard
tightening torque
• The U-bolts should be suitably dimensioned for the
load. • On wooden assembly frames, the tightening torque
must be adjusted according to the size of the
• This caters for the usual driving mode (on-road clamping plate, the species of wood and its condition.
operations); if the body also allows a working mode,
this must be taken into account by the body • When attaching a wooden assembly frame, make
manufacturer. sure that the clamping plate (2) is large enough.
• All component parts which rest on or in the • The body operating instructions for wooden assembly
longitudinal frame member must be free of burrs and frames must mention a regular inspection of the U-
rounded with a radius of at least 1mm. bolt fastenings.
• Additional component parts must not cause any
notching.
Subframe
Positive rigid connection Page 496
Concrete mixer bodies Page 539
Body mountings available from the factory • Fastening parts for cement mixer, sales code C5K,
The following equipment can be ordered depending on for dumper and cement mixer model designations
the vehicle model designation: The sales codes contain mounting supports installed ex
• Fastening parts, for platform vehicle, sales code C5I, factory. Refer to the 2D chassis drawings (offer
available for platform model designations drawings) in the Mercedes‑Benz Bodybuilder Portal for
the mounting position of the mounting supports on the
• Fastening parts, for dump truck, sales code C5J, vehicle frame. (http://bb-portal.mercedes-benz-
available with dumper model designations trucks.com)
• Fastening parts, rigid, sales code C5H, for platform
and dumper model designations
---------------------------------------------------------------------------
Fastening parts for platform vehicle, sales code C5I Recommendation for 1st mounting support on L cab
For all standard mounting supports, the contact surface and 1st and 2nd mounting supports on S/M cab
area for the vertical screw connection must be at least If another type of attachment is used, the tightening
305 mm². torque specified by the manufacturer of the fastener
must not be exceeded.

1 Hexagon head bolt N 000000 005720,

MBN10105-C M14x1.5x100 ‑ 10.9
2 A 940 891 06 17
3 A 000 993 05 26, (16x)
4 A 013 990 29 82, (S = 6 mm)
5 Nut N 000000 003277,
N 13023‑B M14x1.5 ‑ 10 DBL 9440.40
Elongated hole size max. ∅ 16x25 mm.
W31.20-A026-12
Mounting design
• Use tool to tighten until parts meet, slacken off by Recommended value for (a): at least 5 mm.
three turns, remove tool. The tool must be no more Tightening torque: 150 Nm
than 1 mm smaller than dimension (a).

Subframe
The function of the disk spring pack may be replaced by
other, suitable elastic component parts (helical springs,
elastomers).
b 4
W31.20-A027-11
Disk spring pack arrangement (16x A 000 993 05 26)
Alternative mounting for 1st mounting support

This type of mounting is to be used accordingly on 3-
axle and 4-axle vehicles.
Always install the smallest possible number of washers
(3).
Tightening torque: 150 Nm + 90°
1 Hexagon head bolt
N 000000 005521 MBN10105‑C,
M14x1.5x110 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm).
Elongated hole size max. ∅ 16x25 mm
3 A 381 990 03 40 (S = 5 mm) ¹⁾
A 943 990 01 40 (S = 3 mm) ¹⁾
A 943 990 00 40 (S = 1 mm) ¹⁾
4 A 013 990 29 82 (S = 6 mm) ¹⁾
A 002 990 75 50
W31.20-A028-12
Mounting design
¹⁾ Shim as required for max. 1 mm play (the subframe

must lie flat on vehicle frame).

Subframe
Recommendation for 1st mounting support on

vehicle model designation 963.042
MBN10105‑C M14x1.5x160 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 Mounting plate ¹⁾: Dimensions min. 130x40 mm,
distance between center of elongated holes
80 mm
4 A 002 990 75 50
W31.20-A029-12
Recommendation for 1st mounting support in

combination with fender carrier on vehicle model
designation 963.042
The bolt (1) must not touch the fender carrier.
MBN10105‑C, M14x1.5x160 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 013 990 29 82 (S = 6 mm)
4 Mounting plate ¹⁾: Dimensions min. 130x40 mm,
distance between center of elongated holes
80 mm
5 A 002 990 75 50
W31.20-A030-12
Mounting design
Subframe
Recommendation for all body consoles except
1st mounting support on L cab and 1st and
2nd mounting supports on S/M cab
(3).
MBN10105-C, M14x1.5x60 ‑ 10.9
2 A 013 990 29 82 (S = 6 mm)
3 A 381 990 03 40 (S = 5 mm) ¹⁾
A 943 990 01 40 (S = 3 mm) ¹⁾
A 943 990 00 40 (S = 1 mm) ¹⁾
4 Nut A 002 990 75 50 - alternatively
Nut N 000000 003277,
MBN13023‑B‑10 (M14x1.5) DBL 9440.40,
W31.20-A031-12
Mounting design
Recommendation for 2nd mounting support on Recommendation for 3rd and 4th mounting supports
vehicle model designation 963.042 on vehicle model designation 963.042
Please see the note under "Recommendation for Please see the notes under "Recommendation for
2nd mounting support on S/M cab for 2-axle and 3-axle 3rd and subsequent mounting supports for 2-axle, 3-axle
vehicles" (see section "Fastening parts for dump and 4-axle vehicles" (see section "Fastening parts for
truck, sales code C5J"). dump truck, sales code C5J").

Recommendation for mounting support in

combination with fuel tank mounting support,
version A
(2).
Elongated hole size max. diameter 16x25 mm
1 Hexagon head bolt N 000000 005721
MBN10105‑C M14x1.5x60 ‑ 10.9
2 A 381 990 03 40 (S = 5 mm) ¹⁾
A 943 990 01 40 (S = 3 mm) ¹⁾
A 943 990 00 40 (S = 1 mm) ¹⁾
3 A 013 990 29 82 (S = 6 mm) W31.20-A033-11
4 A 002 990 75 50 Mounting design
Subframe
Recommendation for mounting support in

combination with fuel tank mounting support,
version B
(3).
The bolt (1) must not touch the fuel tank mounting
support.
MBN10105‑C M14x1.5x50 ‑ 10.9
2 A 013 990 29 82 (S = 6 mm)
3 A 381 990 03 40 (S = 5 mm) ¹⁾ W31.20-A032-11
A 943 990 01 40 (S = 3 mm) ¹⁾ Mounting design
A 943 990 00 40 (S = 1 mm) ¹⁾
4 Nut N 000000 003277
MBN13023‑B‑10 (M14x1.5) DBL 9440.40
Positive connection • 4‑axle vehicles < 37 t

At the ends of the frame the assembly frame must be The body manufacturer must install a reinforcement at
positively locked. An appropriate plate is supplied for this least 6 mm thick on the body mounting (steel material
purpose (see illustrations). with an elongation at fracture Re = 355 N/mm²).
Valid for: The plate can be moved in the vertical direction. The
• 2-axle vehicles specifications as per the tightening procedure for
existing threaded connections must be observed (see
• 4‑axle vehicles < 37 t document "Threaded and welded connections").

W31.20-A035-11
Mounting plate with reinforcement and slots
Subframe
W31.20-A036-11
Mounting plate with reinforcement and slots
Valid for:
• 3-axle vehicles 33 to 40 t
• 4‑axle vehicles 41 to 48 t
The factory-installed mounting plate has no
reinforcement and no slots for welding to the subframe.
W31.20-A034-11
Mounting plate without reinforcement and without slots
Fastening parts for dump truck, sales code C5J Recommendation for 1st mounting support for 2-
For all standard mounting supports, the contact surface axle and 3-axle vehicles
area for the vertical screw connection must be at least Always install the smallest possible number of plates (3).
305 mm².

Subframe

¹⁾ Shim as required for max. 1 mm play (the subframe must lie flat on
vehicle frame).
MBN10105-C M14x1.5x160 - 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 960 891 01 11 (S = 1 mm) ¹⁾
A 960 891 02 11 (S = 3 mm) ¹⁾
A 960 891 07 11 (S = 4 mm) ¹⁾
A 960 891 03 11 (S = 5 mm) ¹⁾
4 A 002 990 75 50
W31.20-A037-02
Mounting design

vehicle frame).
Recommendation for 2nd mounting support on S/M cab for 2-axle and
3-axle vehicles
Always install the smallest possible number of plates (3).
MBN10105-C, M14x1.5x110 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 960 891 01 11 (S = 1 mm) ¹⁾
A 960 891 02 11 (S = 3 mm) ¹⁾
A 960 891 07 11 (S = 4 mm) ¹⁾
A 960 891 03 11 (S = 5 mm) ¹⁾
4 A 960 891 07 11
Elongated hole size max. ∅ 16x25 mm W31.20-A038-02
Subframe
Recommendation for 2nd mounting support on L cab for 2-axle and 3-
axle vehicles
vehicle frame).
MBN10105-C, M14x1.5x110 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 960 891 01 11 (S = 1 mm) ¹⁾
A 960 891 02 11 (S = 3 mm) ¹⁾
A 960 891 07 11 (S = 4 mm) ¹⁾
A 960 891 03 11 (S = 5 mm) ¹⁾
4 A 960 891 07 11
W31.20-A039-02
5 A 002 990 75 50
Mounting design
Recommendation for 3rd and subsequent mounting supports for 2-

axle, 3-axle and 4-axle vehicles (not for 1st mounting support on the
left and exhaust system, vertical, behind cab, code K7J, in
combination with S cab)
vehicle frame).
MBN10105-C, M14x1.5x60 ‑ 10.9
2 A 960 891 00 19 (d = 16; D = 30; L = 50 mm)
3 A 960 891 01 11 (S = 1 mm) ¹⁾
A 960 891 02 11 (S = 3 mm) ¹⁾
A 960 891 07 11 (S = 4 mm) ¹⁾
A 960 891 03 11 (S = 5 mm) ¹⁾
4 A 960 891 07 11 W31.20-A040-02
Elongated hole size max. ∅ 16x25 mm Mounting design
5 A 002 990 75 50
Subframe
Recommendation for 1st mounting support on S/M cab for 4-axle

vehicles
vehicle frame).
MBN10105-C, M14x1.5x160 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 960 891 04 11 (S = 1 mm) ¹⁾
A 960 891 09 11 (S = 3 mm) ¹⁾
A 960 891 05 11 (S = 4 mm) ¹⁾
A 960 891 06 11 (S = 5 mm) ¹⁾
4 A 002 990 75 50
W31.20-A041-02
Mounting design
Subframe
Recommendation for 1st mounting
support on the left on S cab for 4-
axle vehicles with exhaust system,
vertical, behind cab, code K7J
Always install the smallest possible
number of plates (3).
¹⁾ Shim as required for max. 1 mm
play (the subframe must lie flat on
vehicle frame).
1 Hexagon head bolt
N 000000 005513
MBN10105‑C,
M14x1.5x160 ‑ 10.9
2 A 960 891 00 18 (d = 16;
D = 30; L = 50 mm)
3 A 960 891 04 11 (S = 1 mm)
¹⁾
A 960 891 09 11 (S = 3 mm)
¹⁾
W60.00-A132-06
A 960 891 05 11 (S = 4 mm)
¹⁾
A 960 891 06 11 (S = 5 mm)
¹⁾
Elongated hole size
max. ∅ 16x25 mm
4 A 002 990 75 50
5 Alternatively, depending on
the number and thickness of
the plates (3)
Hexagon head bolt
N 000000 005521 MBN10105
-C, M14x1.5x110 ‑ 10.9 or
Hexagon head bolt
N 000000 005722 MBN10105
-C, M14x1.5x120 ‑ 10.9
The screw (5) must not touch
the mounting support of the
exhaust system.
6 A 001 992 88 05 (d = 16;
D = 30; L = 16 mm)
Subframe
Recommendation for 1st mounting support on L cab

for 4-axle vehicles
Always install the smallest possible number of plates
(3).
MBN10105‑C, M14x1.5x160 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 960 891 04 11 (S = 1 mm) ¹⁾
A 960 891 09 11 (S = 3 mm) ¹⁾
A 960 891 05 11 (S = 4 mm) ¹⁾
A 960 891 06 11 (S = 5 mm) ¹⁾
Elongated hole size max. ∅ 16x25 mm W31.20-A042-11
Recommendation for 2nd mounting support for 4-axle vehicles,

standard
vehicle frame).
MBN10105-C, M14x1.5x110 ‑ 10.9
2 A 960 891 00 18 (d = 16; D = 30; L = 50 mm)
3 A 960 891 01 11 (S = 1 mm) ¹⁾
A 960 891 02 11 (S = 3 mm) ¹⁾
A 960 891 07 11 (S = 4 mm) ¹⁾
A 960 891 03 11 (S = 5 mm) ¹⁾
4 A 960 891 07 11
W31.20-A043-02
5 A 002 990 75 50
6 A 960 316 53 50
Subframe
Fastening parts, rigid, sales code C5H
Mounting supports and rigid plates are installed on the
vehicle frame ex factory. On vehicles with L-cab, sales
code F1R, one mounting support is installed directly
behind the cab. On vehicles with S-cab or M-cab, sales
code F1P or F1Q, two mounting supports are attached
there.
Observe the notes about connecting the first or first two
mounting supports to the subframe (see section
"Fastening parts for dump truck, sales code C5J").
Depending on the vehicle model designation, rigid
plates of 7 mm or 10 mm thickness are attached along
the remaining course of the frame in accordance with
the illustration "Rigid plates, thickness 7 mm
(A 960 316 23 54)" and figures "Rigid plates, thickness
10 mm (A 960 316 50 54)". The plates must be
connected to the subframe with shackle welding (see W31.20-A034-11
document "Positive rigid connection"). Rigid plate, thickness 7 mm (A 960 316 23 54)
W31.20-A034-11
Rigid plate, thickness 10 mm (A 960 316 50 54)
Fastening parts for cement mixer, sales code C5K

The equipment is available for 3 and 4-axle dumper and
cement mixer vehicle model designations.
Rigid plates of varying size are installed from the area
behind the cab to the frame end. These are
dimensioned according to the specifications for the body
(see document "Cement mixer bodies").
Depending on the vehicle model designation, plates of
varying thickness are used.
The plates must be connected to the subframe with W31.20-A044-10
shackle welding (see document "Positive rigid Example for rigid plates of different sizes
connection").
Subframe
Vehicle with exhaust system, vertical, behind cab, Description (see section "Fastening parts for dump
sales code K7J truck, sales code C5J") under "Recommendation for
The vehicles are equipped differently from the 1st mounting support".
description above.
The foremost rigid plate on the left in the direction of
travel is replaced with a mounting support.

Reinforced center bearing plate,

sales code C8Q
The equipment is available for steel-
sprung dump truck chassis 33 t/6x4
and 41 t/8x4. A reinforced rigid plate
is mounted above the rear axle
(center bearing) at the factory.
W31.20-A045-04
Shackle welding of rigid plate, thickness 10 mm, A 960 316 84 54
Code C9S - Omission of attaching parts, on frame
Subframe
C9S Omission of attaching parts, on frame on the left and right of the longitudinal frame member
The equipment is particularly recommended if the body despite the omission of attaching parts. Retrofitting these
manufacturer installs body-specific attaching parts and body attaching parts would be very difficult due to the
the mounting consoles and shackles fitted as standard steering parts for the 2nd front axle!
are not used. On selected 4-axle chassis, CTT can also be used to
On 4-axle chassis with 2 steered front axles, the remove the 1st attaching parts!
1st body mounting console/shackle is always installed

W31.30-A022-78
4-axle chassis with 2 steered front axles (BM 964.x3x) and with code C9S (Omission of attaching parts, on frame): The 1st mounting
consoles/shackles are always installed, even with code C9S!
a Dumper vehicle/platform vehicle b Concrete mixer truck
Code C5M - Pre-installation, for bodies without subframe
Subframe
C5M Pre-installation, for bodies

without auxiliary frame
The pre-installation is required for
bodies without auxiliary frames.
The scope of supply consists of
frame reinforcement brackets
mounted at the factory in the
longitudinal frame member in the
area of the 1st and
2nd crossmembers after the
transmission, as well as internal
frame reinforcement brackets in the
area of the rear axles.
Depending on the chassis model
designation and equipment, the
frame reinforcement brackets can be
continuous or interrupted in the area
between the 2nd crossmember after
the transmission and the tube/plate
crossmember. The size of the
interruption depends on the
wheelbase. W31.30-A018-06
C5M for BM 963.020 with wheelbase 4600 mm
Continuous reinforcing brackets,
from the 1st crossmember after the
transmission to the crossmember
after the trailing axle, are currently
only installed on the 6x2 low-frame
chassis (BM 963.021) with
wheelbase 4900 (C2U) in
combination with the equipment
"C7P Clearance for swap bodies, low
frame".
1 Tube or plate crossmember
before 1st RA
a The size of the interruption
depends on the wheelbase
Code C5N - Frame, for refuse vehicle
Subframe
C5N-Frame for refuse vehicle, rear loader
i
Detailed technical information on the design of the
frame overhang can be found in document
"Modifications to the frame overhang".
The chassis is specially designed for the requirements

of rear loader refuse collection bodies.
For easier adjustment of the frame overhang, the end
crossmember of steel-sprung vehicles is moved in by
about 350 mm. Air-sprung vehicles are delivered without
an end crossmember. Here, however, the last
crossmember in the rear frame is reinforced. An end
crossmember usually does not have to be retrofitted W31.30-A019-81
for refuse collection bodies with rear loader! Frame overhang C5N of air-sprung vehicles using the example of
964.022
The scope of supply also includes vehicle-dependent

frame reinforcement measures, transmission support
arms (G0R) optimized for removal, the frequent-stop
brake (B1X) and omission of the rear underride guard
(C9Y) with tail lamps provisionally mounted on the rear
frame.
With code C5H, body attaching parts for rigid body
mounting on the chassis can be supplied ex factory. The
body attaching parts can be omitted with the equipment
C9S.
W31.30-A020-81
Frame overhang C5N of steel-sprung vehicles, based on example
of 964.000
Design of bodies, general
Design of bodies
aDanger
aDanger
aWarning
Welding Page 130
i i
Fire hazard through igniting of the body or related Possible damage to major assemblies on vehicles
components in event of high-voltage battery fire with conventional drivetrain: Bodies on which the
(model series 983): In the area of the high-voltage transmission can be expected to be exposed to high
batteries below the lower flange of the chassis, do levels of water, e.g. cleaning water (flushing,
not mount any body components (e.g. pumps, overflowing or similar), require an effective cover
hydraulic hoses). Only components that are not over the transmission (transmission protection) that
combustible may be installed within the vehicle will prevent abrupt cooling as well as water ingestion
frame. If necessary, mount shielding or non- through the transmission breather.
flammable protection.
i
i Possible loss of intended function. Loss of control by
Possible thermal overloading of major assemblies the driver possible. Do not modify any screw
and electronic reduction of engine output: Any connections that are relevant to safety, e.g. that are
impairment of the air flow through the engine required for wheel control, steering or braking
compartment, e.g. by covering the front air inlet functions. Re-assemble in accordance with
grilles or using covers or trim pieces behind the cab, Mercedes-Benz service instructions. Use Mercedes-
must be avoided. Benz GenuineParts only.
Design of bodies, general
Design of bodies
i i
For most vehicle model designations in model series Further information about screw connections and
963, 964 and 983, the protrusion of the wishbone weld joints (see "Screw connections and weld
control arms of the rear axle(s) over the top edge of joints" document).
the vehicle frame (OKR) with the suspension
compressed is indicated in the 2D chassis drawings
(offer drawings) in the Mercedes‑Benz Bodybuilder
Portal (http://bb-portal.mercedes-benz-
trucks.com).
---------------------------------------------------------------------------
Welding on the chassis/body may be performed by Semitrailer trucks (model 963.4xx/964.4xx/967.4xx) are
skilled personnel only (see "Welding" document). only suitable to a certain extent for fixed or swap bodies.
Major assemblies installed during work to implements, Modifications to the basic vehicle may be necessary in
bodies, equipment or modifications must comply with the order to guarantee that the vehicle will be safe. These
applicable laws and directives, as well as work safety or must be coordinated with the relevant contact person
accident prevention regulations, safety rules and (see "Advice for body manufacturers" document).
accident insurer leaflets.
---------------------------------------------------------------------------
Model 983 vehicles have been developed for heavy-duty • Waste collection vehicles
distribution haulage. The focus here is firmly on the For other types of body, there may not be any required
following bodies: (special) equipment available. These bodies are
• Platform, box body, curtainsider therefore no longer specified in this body/equipment
• Cargo lift gate mounting directive and the company that implements
them bears responsibility for them.
• Fully-enclosed swap bodies
• Refrigerated vehicles
---------------------------------------------------------------------------
Vehicle frame leveling The body must contact the vehicle frame completely free
Before installing a body on the vehicle frame, the of torsion.
following information must be observed: Work may not be performed on the vehicle frame while a
The vehicle must be parked on a completely flat body is being installed (e.g. loosening of frame
assembly bay; if necessary, check using a spirit level on crossmembers).
the front and rear horizontal frame crossmember. Upon completion, perform the required checks. In
Tension in the chassis (axle tension through cornering particular, this means checking the headlamp
with tandem axle assemblies) must be relieved. This can adjustment, any affected assistance systems such as
be achieved by driving the vehicle forwards and the front radar for Active Brake Assist, side radar, side
backwards a few times before parking it. protection devices and the rear underride guard.
If a body is attached to a vehicle that is not level, there is

a risk of this misalignment being fixed in place.
Dropside
Design of bodies
Dropside end stop
Note
End stops are unavoidable for the side and rear
dropsides of a platform. Therefore all dropsides are
to be fitted with end stops.
In order to protect the vehicle against damage.
Correct designs
N60.30-A000-71 N60.30-A001-71
Correct designs: rear end stop Correct designs: side end stop
Obscured reflectors tail lamps, front and rear turn signal indicators and
Lighting systems may be partially or completely reflectors shall not be hidden more than 50 % by any
obscured when a dropside is opened. component, with or without a light signaling device
installed on it, in any fixed position different from the
According to UN-R 48, para. 5.21, the apparent surface normal position of use.
in the direction of the reference axis of position lamps,

N60.30-A002-71 N60.30-A003-71
Reflectors completely obscured when Obscured tail lamps
dropside is down (from direction of
reference axis)
If any of the obstructions described above exist, a notice The adhesive label can be affixed as shown in the
in the vehicle shall inform the user that in certain picture below.
position(s) of the movable components other road users It must be ensured that the adhesive label is in the
shall be warned of the presence of the vehicle on the appropriate national language for the country of delivery
road; for example by means of a warning triangle or (see the table below).
other devices according to national requirements for use
on the road.
The adhesive label A 639 584 53 38 can be used as an
information label for the driver. In addition, reflectors
must be installed in the area of the platform hinges.

Dropside
Design of bodies
N60.30-A005-01 N60.30-A004-71
Adhesive table A 639 584 53 38 Recommended position for adhesive label
Dropside
Design of bodies

Language version of adhesive label A 639 584 53 38
Language Language code Size W/H in mm
German 90/27
English X42
French X43
Spanish X44
Portuguese X45
Italian X46
Finnish X47
Danish X48
Dutch X49
Swedish X50
Arabic X53
Chinese XR7
Canada, English + French XS7 90/43.5
Russian XS1 90/30
Greek XU4
Turkish XU8
Czech XU2 90/27
Polish XU5
Norwegian XU9
Japanese XR8
Hungarian XU3
Trad. Chinese X63
Korean X62
Romanian XS3
Platform and swap body
Design of bodies
Subframe, general Page 487
Design of subframe Page 489
Exhaust gas aftertreatment system Euro VI Standard Page 268
• To ensure the uniform loading of the vehicle frame, • If the body manufacturer uses his own attaching parts
the body must be attached to the vehicle frame by on the vehicle frame, the specifications in the
means of an subframe (U section longitudinal "Subframe" tab must be complied with.
members). • With point loading or loads concentrated at points on
• The body must have a torsion-free attachment to the the standard platform, e.g. transportation of cable
vehicle frame longitudinal members. drums, coils, etc., reinforce the substructure and
• Position the vehicle on a flat, horizontal surface platform floor as appropriate for the load.
before mounting the body. • Before starting: Weigh the chassis and determine the
• Use the attaching parts, for platform vehicle, sales body length.
code C5I, for attaching the subframe. Connect the • For swap body systems without subframe the
vehicle frame and the subframe in accordance with relevant specifications must be observed.
the specifications in the document "Body
mountings available from the factory".
---------------------------------------------------------------------------
When installing ballast platforms or an auxiliary loading An uneven load distribution (right/left) is not permissible.
area on a semitrailer truck, the overall center of gravity
of the vehicle, body and ballast must be kept as low as
possible.
---------------------------------------------------------------------------
Platform body Please consult the document "Design of subframe"
• Moment of resistance per longitudinal member of for the longitudinal member section dimensions.
subframe: 45 cm³
---------------------------------------------------------------------------
Swap body on model series 967 • Ensure that the forces are applied over a large area
Twist locks: using pressure distribution plates. Use the existing
holes on the vehicle frame where possible.
• Secure the boom with the subframe according to the
load.
• A continuous subframe must be fitted for swap
bodies with twist locks.
---------------------------------------------------------------------------
A swap body without an subframe must be coordinated
with the relevant contact person (see document
---------------------------------------------------------------------------
Bodies without subframe on model series 963, 964 for bodies without subframe - is essential. This sales
If a body without subframe (e.g. fully-enclosed swap code adds the necessary internal reinforcements.
body) is to be installed, sales code C5M - Pre-installation
Platform and swap body
Design of bodies
• The upper flange of the frame must be protected Where possible, it is recommended to configure the
against wear by means of wear pads with a material chassis with
thickness of at least 6 mm. • lowered battery carrier, sales code C7N and
• Wear pads must be placed at all points of load • exhaust system, two-piece mounting support, sales
application and on all crossmembers. The length of code K7P,
the wear pads at all the load application points must
be at least 300 mm and on the crossmembers at (see document "Exhaust gas aftertreatment system
least 150 mm. The wear pads must ensure that the Euro VI Standard").
load carriers sit flat.
• The clearances of moving attachments on the frame
must be guaranteed.

W60.00-A072-11
lowered battery carrier, sales code, C7N
At the rear area of the chassis the body manufacturer • One cross must be made with a thickness of at least
must install a cross or an equivalent structure. The cross 6 mm and a width of at least 50 mm from steel with a
is to be constructed as follows: elongation at fracture of Re = 355 N/mm².
• The maximum length of the cross is 1.5 times the If an equivalent design is to be installed, this should be
frame width. coordinated with the relevant contact person (see
• On vehicles with fully-enclosed swap bodies the document "Advice for body manufacturers").
cross must cover the area from the tubular
crossmember of the last axle as far as the twist lock
carrier. Two crosses should be installed if necessary.
---------------------------------------------------------------------------
Bodies without subframe on model series 983 In individual cases, coordinate the body with the contact
For installation space reasons (vehicle batteries) and the person responsible, and check for possible
lack of any suitable special equipment, a body without implementation (see document "Advising body
subframe is not possible as standard in model series manufacturers").
983.
Self-supporting body
Design of bodies
Panel van and box bodies
A subframe with continuous longitudinal members is not
required on self-supporting panel van or box bodies if
crossmembers are mounted that are a maximum
distance (a) of 600 mm apart. The fuel tank, AdBlue®
tank and battery must be accessible. In the rear axle
fastening area, the maximum distance (a) of 600 mm
may be exceeded if this is necessary to realize tire
clearances (jounce). Make sure that adequate clearance
is provided here for snow chains.
W60.00-A001-11
Panel van and box body
Fully integrated body
Design of bodies
Fully-integrated bodies are all forms of body for which integrated bodies should be coordinated with the
permanent or detachable connections are made relevant contact person (see document "Advice for
between the cab and the body. Camper vans are a body manufacturers").
typical example of a fully-integrated body. Fully-
---------------------------------------------------------------------------
Chassis suitability This must always be observed when selecting a
The chassis was developed for the transportation of Mercedes-Benz truck chassis with respect to the
goods. Further developments in suspension, stability, production of an overall vehicle. The body manufacturer
damping, noise insulation, etc. for passenger transport is the manufacturer of the overall vehicle, meaning that
have not been implemented. In addition, subsystems of they assume all obligations.
the vehicle may not be homologated for vehicle class M.
---------------------------------------------------------------------------
Model series 983 Therefore, there can be no support provided for this type
These vehicles are explicitly not designed and intended of body.
for fully-integrated bodies.
Waste collection vehicle body mounting
Design of bodies
Code C5M - Pre-installation, for bodies without subframe Page 514
Code C5N - Frame, for refuse vehicle Page 515
Equip the vehicles with the following sales codes: Pre-installation, for bodies without subframe" and
Mandatory sales codeC5M (if available): Pre-installation "Code C5N - Frame, for refuse vehicle".
for bodies without subframe. The subframe design for pressed-sheet bodies with non-
Recommendation C5N (if available): Frame for refuse continuous subframe is not valid for rotating drum
vehicle, rear loader. Also see document "Code C5M - bodies.

Subframe design for 2-axle vehicle, with pressed-

plate bodies up to wheelbase 4200mm or 4300mm
1 Front subframe section min.1300mm long,
dimensions of C section 120x70x7 mm, material
steel, min.yield strength 355N/mm². Fastening
with min.2 units, 3‑hole shackles.
2 Rear subframe section min.1600mm long,
steel, min.yield strength 355 N/mm² and
extending at least over the trailing arm bracket of
the drive axle or, on steel-sprung vehicles, as far W31.20-A046-10
as the front rear spring bracket. Fastening with Subframe for 2-axle vehicle
min.3 units, 3‑hole shackles.
Subframe design for 3-axle vehicle, with pressed-

plate bodies up to wheelbase 4200mm or 4300mm
1 Front subframe section min.1300mm long,
steel, min.yield strength 355N/mm². Fastening
with min.2 units, 3‑hole shackles.
2 Rear subframe section min.2500mm long,
steel, min.yield strength 355 N/mm² and
extending forward at least over the trailing arm
bracket of the drive axle or, on steel-sprung W31.20-A047-10
vehicles, as far as the front rear spring bracket. Subframe for 3-axle vehicle
Fastening with min. 4 units, 3‑hole shackles.
Subframe design for 4-axle vehicle (BM964.041),

with pressed-plate bodies, wheelbase 3600mm
1 For this vehicle a continuous subframe is
required, min. dimensions of C section
120x70x7mm, material steel, min. yield strength
355N/mm². Fastening: We recommend using the
equipment codeC5H (Mounting parts, rigid).
W31.20-A048-10
Subframe for 4-axle vehicle
Waste collection vehicle body mounting
Design of bodies
Body mounting on subframe sections

1 Always flexible at the front.
2 If a center section is installed, it is not necessary
to fasten the body on the subframe section.
3 At the rear, the body must always be rigidly
fastened.
W31.20-A049-10
Body on subframe
Tilting body
Design of bodies
aDanger
Risk of death. There is a risk of death to persons located All persons must remain outside the tilting range of the
within the tilting range or underneath the raised dump dump body during its operation. Always secure the raised
body during operation. Risk of injury There is a risk of dump body with the dump body support before starting
body parts being crushed or pinched when the dump any work underneath it.
body is lowered.
aWarning
Selection of chassis Page 45
Usage-dependent limit values for total vehicle mass and Page 122
axle loads
Subframe mounting Page 493
i i
Danger to the operator and others due to inadequate Risk of fire:
vehicle stability: If the exhaust outlet is covered by the body
The body manufacturer is responsible for ensuring (e.g. dropsides) during loading and unloading, hot
the stability of the vehicle. Design the body with this exhaust gases can heat up the body. The exhaust
in mind. Select the correct CoG height and avoid outlet must not be directed towards other component
unequally distributed masses on the left and right. parts. Otherwise, the engine must be switched off
Install stabilizers, if necessary. Parameterize air- before loading. This must be noted in the operating
sprung vehicles so that they are automatically instructions for the body. If necessary, use an
lowered to their hard stop before starting work. exhaust outlet with upright pipe/mouth.
Incorporate safety information into the operator's
manual for the body. Comply with country-specific
laws, policies and regulations (e.g. the DGUV
accident prevention regulation).
i
Stability when tipping is not guaranteed. Operators
or other persons could be injured:
Do not mount dumper bodies on vehicle model
i designation 963.042.
Operational safety and durability not ensured and
risk to operator and other persons:
Lower the trailing axle before operation. Record
information in operator's manual or adapt vehicle
parameterization. Only mount three-way and rear
dumper bodies on the chassis intended for the
purpose.
Tilting body
Design of bodies
i i
Possible damage to the transmission from falling Possible damage to the vehicle frame and chassis
bulk goods: parts on vehicles with sales code C5X:
For vehicles with short cab (sales code F1P) and The vehicle is only suitable for light-duty on-road
exhaust system, vertical behind cab (sales dumper operation (no off-road operation), without
code K7J), no transmission cover is supplied ex subframe as typically occurring in Great Britain. Do
factory for sales code P0W. This must be retrofitted not exceed the maximum permissible gross vehicle
by the body manufacturer. A cover shall be fitted to mass: 3‑axle vehicle model designation 964.214,
the vehicle frame or body. The exact location of the 26000 kg, and 4‑axle vehicle model designation
drivetrain and the existing protective covers can be 964.230, 32000 kg.
found in the chassis drawings in the Mercedes-Benz
Bodybuilder Portal (http://bb-portal.mercedes-
benz-trucks.com).
---------------------------------------------------------------------------
General vehicles are therefore to be equipped with frame
If necessary and where available, install reinforced rear lowering as per the specifications (see document
axle springs and stabilizer bars (Additional stabilizer, "Frame lowering on air-sprung vehicles") because
rear/trailing axle, sales code C6U or Stabilizer, under this includes the integrated "compulsory lowering"
frame, rear axle, sales code C6Y). function.
During the tilting process while stationary, the vehicle If it is possible that engine or transmission components
axles/single axles may be loaded up to no more than could be damaged during operation of the body or by the
their technically permissible maximum static load cargo, e.g. bulk goods, then an appropriate protective
capacity (see document "Usage-related limit values cover must be provided. If necessary, a protective cover
of gross vehicle mass and axle loads"). (e.g. sales code P0W) can be ordered ex factory.
Because of the inline engines, this instruction is
Air-sprung vehicles are to be lowered to their hard stop especially applicable for the short cab.
to ensure that they are stable before work is begun. The
---------------------------------------------------------------------------
Subframe appropriately dimensioned for the loads occurring in the
Observe notes in the document "Subframe, general" area under the tilt shaft/rotary shaft. The (3-hole) rigid
and the document "Attachment of the subframe". plates supplied ex factory are not adequately
dimensioned for the area under the tilt shaft/rotary shaft.
• The subframe must be continuous and made from
steel crossmembers with sufficient dimensions. In combination with sales codes C5J and C5H, the front
Where possible, arrange the crossmembers of the body consoles on the vehicle frame are designed
subframe and the vehicle frame on top of each other. (protruding above the top edge of the longitudinal frame
members) to provide lateral support for the subframe at
• Close the rear area to form a box and reinforce it with the front. The subframe should be shaped so that it
a diagonal cross. positively locks with the insides of the mounting supports
• Connect subframe to vehicle frame as appropriate for on both sides.
the load. For this, the sales codes (see document Alternatively, the body manufacturer must install
"Body mountings available from the factory") are additional lateral support plates at the front.
available from the factory.
Different or alternative fastenings must be coordinated
The design and dimensioning of the factory-installed with the relevant contact person (see document
fasteners are adapted to suit the technically permissible "Advice for body manufacturers").
gross vehicle mass (technically permissible gross mass
code) of the vehicle in question. Section dimensions and subframe moments of
In combination with sales code C5J, the body resistance
manufacturer must install rigid fasteners (rigid plates) The specified values refer to normal operating
appropriately dimensioned for the loads occurring in the conditions. For difficult operating conditions, the relevant
area of the rear axle/center bearing, at the rear overhang contact person (see document "Advice for body
and under the tilt shaft/rotary shaft. (These are not manufacturers") must be consulted.
included in the sales code C5J.)
In combination with sales code C5H, the body
manufacturer must install a rigid fastener (rigid plate)

Tilting body
Design of bodies

Subframe dimensions for three-way dump truck
2-axle vehicle 3-axle vehicle
Vehicle model 964.200 964.211 964.214 964.216

designation 964.201 964.216
964.203 964.224
Permissible 20000 25000 26000 33000

technical gross (18000)
vehicle mass (kg)
Load capacity1) (m3) 6 8 8 12
Wheelbase (mm) 3600 ‑ 3900 3600 ‑ 3900 3300 ‑ 3600 3300 ‑ 3600
Max. overhang 1200 1050 1050 1050

(behind last axle)
(mm)
Subframe U 120 x 70 x 7 With U 180 x 70 x 6 With U 180 x 70 x 6 With U 230 x 70 x 6 With

dimensions (mm) reinforcement plate2) reinforcement plate2) reinforcement plate2) reinforcement plate2)
closed to form box3) closed to form box3) closed to form box3) closed to form box3)
Material Steel with yield strength Re > 355 N/mm2 (e.g. S 355 JR)
Cross bracing A diagonal cross or similar structure in front of rear tilt support

Subframe dimensions for three-way dump truck
4-axle vehicles
Vehicle model designation 964.043 964.230 964.231

964.231
964.238
Permissible technical 32000 32000 41000

gross vehicle mass (kg)
Load capacity1) (m3) 14 11 16
Wheelbase (mm) 3750 4250 ‑ 4850 4250 ‑ 4850
Max. overhang (behind 1050 1050 1050

last axle) (mm)
Subframe dimensions U 230 x 70 x 6 With U 230 x 70 x 6 With U 230 x 70 x 8 With

(mm) reinforcement plate2) closed reinforcement plate2) closed reinforcement plate2) closed
to form box3) to form box3) to form box3)
Tilting body
Design of bodies

Subframe dimensions for rear dumper
4-axle vehicles
Vehicle model designation 964.230 964.231 964.231

964.231
Permissible technical 32000 41000 48000

gross vehicle mass (kg)
Load capacity1) (m3) 11 16 19
Wheelbase (mm) 4250 ‑ 4850 4250 ‑ 4850 4850 ‑ 5150
Max. overhang (behind 1050 1050 1050

last axle) (mm)
Subframe dimensions U 230 x 70 x 6 With U 230 x 70 x 7 With U 240 x 70 x 8 With

(mm) reinforcement plate2) closed reinforcement plate2) closed reinforcement plate2) closed
to form box3) to form box3) to form box3)
1) The reference value "Loading volume" is based on an average vehicle curb weight and body weight and on a cargo of loose (wet) soil
with a density of 1.6 t/m3. Due to the aforementioned variables, the actual permissible loading volume can vary from this data. The
technically permissible individual axle loads and the technically permissible gross mass must be complied with.
2) Material thickness ≥ 5 mm
3) Or alternative section designs with a comparable rigidity and moment of resistance (W)
A certificate of non-objection (CNO) from the relevant manufacturers") is required for combinations which are
contact person (see document "Advice for body not listed in this table.
---------------------------------------------------------------------------
Tilt support must also be taken into account when designing/
• Position the rear tilt support as close to the rear axle dimensioning the subframe.
as possible on three-way tipper and rear dumper • The folded-down dropside must not strike the end of
bodies. the frame, the lighting system or the trailer coupling.
• The connections/bearings of the tilt supports are to • Provide guide brackets for the front tilt supports, so
be integrated in the subframe. The point loads that the tilt supports are guided when the dump body
occurring in the area of the tilt supports when tilting is lowered.
---------------------------------------------------------------------------
Restraining facilities • Connect a "dump body" indicator lamp as a visual
The check cables should sag slightly in the end position. warning when the dump body is not tilted all the way
back (drive position).
• Install a support (e.g. a fold-out support brace), which
prevents the dump body from lowering.
• Secure operating devices against unintended
operation.
---------------------------------------------------------------------------
Dumper lift ram Three-way tippers:
• The connections/bearings of the dumper lift rams are • The point of action of the dumper lift ram must be in
to be integrated in the subframe. The point loads front of the center of gravity of the body and the
occurring in the area of the rams when tilting must payload.
also be taken into account when designing/
dimensioning the subframe.
Tilting body
Design of bodies
---------------------------------------------------------------------------
Tilt-stabilizing measures springs, lowering to the hard stop) for the design of the
The body manufacturer is obliged to furnish proof of and subframe (e.g. cross bracing), the body manufacturer
accept responsibility for the stability of the vehicle during must also provide further additional tilt-stabilizing
the tilting process. If necessary, in addition to the measures (e.g. scissor stabilizer or stabilizing front ram).
available vehicle options (e.g. stabilizer bar/ reinforced
---------------------------------------------------------------------------
Dumper bodies on standard chassis this reason, only transport goods that slip easily.
Dumper bodies can be mounted on standard chassis to Equip the dumper body with a tilt stabilizer and
a limited extent. This body must be coordinated with the secure it exactly over the rear axle or the center of
contact person responsible (see document "Advice for the dual axle.1)
body manufacturers"). The specifications for selecting • Operate the vehicle on surfaced roads only, not on
a suitable chassis must also be observed when planning construction sites.1)
dumper bodies.
• Make sure there is enough installation space for the
• Shape the subframe as a box section from the edge tilting ram inside of the vehicle frame. No specific
of the frame to the dumper lift ram and reinforce it installation space is reserved on platform chassis.
with a diagonal cross. Electrical or pneumatic components are often placed
• The connection of the subframe to the vehicle frame here.
must be rigid, at least up to the dumper lift ram. 1) For vehicle model designation 964.043, these
• Position the rear tilt support as close as possible to specifications may be deviated from. A certificate of non-
the rear axle. objection is not required for this purpose. Order vehicle
with sales code C0G, frame overhang 1050 mm.
• In order to decrease the danger of the vehicle tipping,
restrict the body tilting angle to 35° to the rear. For All specifications for dumper chassis apply equally.
---------------------------------------------------------------------------
Vehicles with disk brakes on the rear axle Protection packages are available for the axles with disk
On models 963, 964: brakes.
---------------------------------------------------------------------------
Pre-installation for on-road tipper body, without The delivery package includes the following:
subframe, sales code C5X • Mounting console for front tilt cylinder (A)
It is possible to configure a vehicle with sales code C5X • Wear brackets (mounting supports) for rubber
as special equipment for selected vehicles/vehicle model bumpers of dumper body (B)
designations/wheelbases and for certain countries of
use. • Box-type end crossmember (C) (trailer coupling not
possible)
Sales code C5X simplifies the mounting of a suitable on-
road dumper body without subframe. • Mounting hole for rotary shaft/tilt support (D) in
longitudinal frame member
It eliminates the need for removing/installing major
assemblies and for fabricating and installing suitable • Modified rear frame overhang (E), frame
mounting consoles, wear brackets, mounting holes for tilt reinforcements, reinforced stabilizer bar on 2nd rear
supports, reinforced end crossmembers etc. axle
The vehicle longitudinal frame member is also protected
by the wear brackets from damage due to the body.

Tilting body
Design of bodies
Component overview of sales code C5X

1 Frame reinforcements
A Mounting consoles for front tilt cylinder
B Wear brackets (mounting supports) for rubber
bumpers of dumper body
C Box-type end crossmember
D Mounting hole for rotary shaft/tilt support
E Modified rear frame overhang
W55.20-A005-11
Component part overview
A: Mounting consoles for front tilt cylinder

A Mounting console for front tilt cylinder with
connecting panel
A1 Screw connections
A2 Connecting panel
W55.20-A006-11
Mounting consoles for front tilt cylinder
Mounting console "A" for front tilt cylinder with and its connection perform the function of a bend-
connecting panel "A2". resistant cross connection.
The bearing brackets for the tilt cylinder can be welded It is permissible to install body load cell systems on the
on to the mounting consoles "A". mounting console.
An additional bend-resistant cross connection between
mounting consoles "A" is not required, if the tilt cylinder

Tilting body
Design of bodies
A Mounting console
A1 Screw connections
A2 Connecting panel
K Tilt cylinder with tilt cylinder bearing
W55.20-A007-02
Tilt cylinder with tilt cylinder bearing
Example In this example, the tilt cylinder/hydraulic oil reservoir

Tilt cylinder with tilt cylinder bearing "K" welded on to and its bearing "K" perform the function of a bend-
mounting console "A". resistant cross connection between mounting consoles
"A".
It is possible to remove the tilt cylinder/tilt cylinder
bearing by removing screw connections "A1" and
mounting console "A" from connecting panel "A2".

B: Wear brackets for supporting

rubber bumpers of dumper body
B Wear brackets
W55.20-A008-01 W55.20-A009-01
Wear brackets for supporting rubber Wear brackets for supporting rubber
bumpers of dumper body bumpers of dumper body
The rubber bumpers of the dumper body must be The requirements regarding the permissible positioning
positioned on the wear brackets. of the body-mounted rubber bumpers on the wear
The wear brackets prevent damage to the vehicle frame. brackets must be observed.

Tilting body
Design of bodies
Requirement for location/dimensions of rubber

bumper (rubber bumper is supplied by body
manufacturer)
1 Rubber bumper
2 Max. 250 mm
3 Min. 75 mm
4 Min. 10 mm
W55.20-A010-11
Location/dimensions of rubber bumper
C: Box-type end crossmember

C Box-type end crossmember
W55.20-A011-10
Box-type end crossmember
• The position of the box-type end crossmember may • It is not possible to retrofit a trailer coupling to the
not be changed. box-type end crossmember.
• The component parts of the box-type end
crossmember may not be changed.

Tilting body
Design of bodies
D: Mounting hole for rotary shaft/tilt support
connection and E: Modified rear frame overhang
1 Area of mounting holes for tilt support
D Mounting hole for rotary shaft/tilt support
E Modified rear frame overhang
W55.20-A012-11
Mounting hole for rotary shaft/tilt support connection and modified
rear frame overhang
• It is not permissible to modify the mounting/ • The frame overhang may not be modified.
attachment holes in the vehicle longitudinal frame
member. It is not permissible to make additional
holes in the vehicle longitudinal frame member.

Example: Installed rotary shaft/tilt support (supplied

by body manufacturer)
1 Tilt support/rotary shaft
W55.20-A013-10
Example: Installed rotary shaft/tilt support
Tilting body
Design of bodies
Geometric illustration and position

on vehicle
The 2D chassis drawings (offer
drawings) in the Mercedes-Benz
Bodybuilder Portal for geometric
illustrations of the component parts
of the pre-installation for on-road
tipper body, without subframe, sales
code C5X, and its location on the
vehicle are available at
http://bb-portal.mercedes-benz-
trucks.com
for viewing.
One example is shown in "Offer
drawing of vehicle with sales
code C5X".
W55.20-A014-06
Offer drawing of vehicle with sales code C5X
Speed limiter, 10 km/h, sales code S5Q 2nd generation, is mandatory. Retrofitting is only
The speed limiter, 10 km/h, sales code S5Q, meets the possible when an XMC is present in the vehicle. If
legal requirements for vehicles with dumper bodies on necessary, the XMC should also be retrofitted.
the Turkish market and can be ordered for vehicle model Dump trucks (vehicle model designation 964.2xx)
designations 963.403, 964.043, 964.201, 964.211,
964.216, 964.231, 964.403 and 964.416. The function of the equipment is requested via the
pressure switch B82 at plug X1 at pins 1 (signal) and
The sales code includes the following functionalities: 2 (+).
• When the dumper indicator lamp is on, the vehicle
speed is limited to 10 km/h. Semitrailer trucks (vehicle model designation
963.4xx and 964.4xx)
• A warning tone also indicates when the system is
triggered. The function of the equipment is requested via trailer
socket X102 at the two pins 10 (signal) and 11 (+).
For sales code S5Q, the SAM with additional functions
(XMC), available under sales code E3W - PSM,
Roll-off container vehicle
Design of bodies
aDanger
body is lowered.
aWarning
axle loads

Tilting body
Tilting body Page 527
i i
Possible frame damage and loss of stability through Possible overloading of chassis and loss of control
lifting of the front axle when picking up and putting when driving due to the higher center of gravity:
down the container. Install outriggers at the end of Observe the permissible specifications for center of
the vehicle if necessary. The stability of the vehicle gravity heights, technical gross vehicle mass, the
must be guaranteed under all operating conditions (static) axle loads when loading and unloading, and
within the technically permissible gross vehicle mass the minimum front axle load (see documents
(weight variant sales code Txx/Wxx). The body "Steerability", "Electronic Stability Program
manufacturer shall be responsible for furnishing ESP®, center of gravity heights, stabilizers" and
proof of this or for the design. "Usage-related limit values of gross vehicle
mass and axle loads").
---------------------------------------------------------------------------
General fasteners are to be provided for this by the body maker
Observe the notes on selecting the correct chassis (in or manufacturer.
particular for use in model series 963). It must be assured that these components are
These Body/Equipment Mounting Directives are to be adequately dimensioned for the loads and reasonably
used correspondingly for roll-off container trucks and installed.
skip loaders. All information in document "Tilting The variants of body mounting available from the factory
body" apply equally. are not suitable for this.
For design reasons, the auxiliary frames of roll-off Because the height clearances of these systems are
container trucks/skip loaders are frequently equipped often small, adequate access to the components on the
with a parallel frame and therefore do not follow the main vehicle must be guaranteed under all operating
frame lines of the vehicle frame. Specially adapted conditions. Appropriate measures, e.g. installation of an
Roll-off container vehicle
Design of bodies
intermediate frame, are to be provided if necessary. It If it is planned to install a swap body system with a lifting
may be necessary to arrange these with the relevant capacity (including capacity reserves) that exceeds the
contact person (see document "Advice for body payload capacity of the vehicle, this can cause the
manufacturers"). operator to violate the technically permissible
Install reinforced rear axle springs and stabilizer bars parameters of the carrier vehicle when loading or
where required and if available. unloading or during the tilting process.
Model series 963/964: Air-sprung vehicles for roll-off As it is hardly possible in practice for the operator of the
container and skip loader bodies must be equipped with system to recognize the weight of the container to be
the additional stabilizer, rear/trailing axle, sales lifted, suitable measures must be taken, e.g. by means
code C6U and/or with Roll Control Assist, sales of appropriate information labels, to ensure that all
code S1F. Vehicles with steel suspension must be boundary conditions are strictly adhered to by the
equipped with the stabilizer, under frame, rear axle, operator.
sales code C6Y.
---------------------------------------------------------------------------
Hydraulic support (model series 963/964) • To avoid notching on the contact surface with the
The installation and use of an additional hydraulic spring, plastic pads must be installed, e.g. at the
support that blocks the rear axle springs on the vehicle piston rod (steel-on-steel contact is not permissible).
(rear axle tandem with center bearing) is possible after • The designed free spring travel to the hard stop must
consultation with the relevant contact person (see not be reduced by the support.
document "Advice for body manufacturers"). • The support must be connected to the vehicle
The following points should be observed: longitudinal frame member with a sufficient number of
• The hydraulic support may only act on the ends of threaded connections appropriate for the loads.
the springs.
Concrete mixer bodies
Design of bodies
Remove/install exhaust flex pipe Page 355
i
Do not exceed gross vehicle mass and axle loads.
The braking distance may increase considerably if
the vehicle is overloaded. Otherwise the vehicle
support structure may be damaged. Observe the
weight variant of the vehicle (sales code Wxx). This
is critical for the specified subframe sizes. If a dump
truck model designation is used (model 964.2xx), the
mounting parts for cement mixer vehicles,
code C5K, must be ordered. The mounting parts
(shackles) are installed at the factory according to
the technically permissible weight variant.
---------------------------------------------------------------------------
Suitable vehicle model designations and equipment The instructions "Remove/install flexible exhaust pipe"
packages are available for cement mixer bodies. These can be found in document "Remove/install flexible
are not permissible on vehicle model exhaust pipe".
designations963.042 and 964.043.
The mounting parts, for cement mixer vehicle, sales
codeC5K, are included as standard with cement mixer Subframe dimensions for cement mixer
model designations. This package consists of factory- Country of use: Germany and Western Europe (A,
installed shackles which can be welded to the subframe CH, F, B, NL, LUX, DK, FIN, GB)
(see document "Body mountings available from the
factory").
If it is necessary to remove the exhaust pipe in order to
weld the shackles, make sure that it is reinstalled
correctly afterwards.

Design of bodies

3-axle vehicle 6x4
Vehicle model designation 964.314 964.316

964.316
964.324
Weight variant 26,000kg 33,000kg
Max. mixer size 7m³ 8m³
Wheelbase 3300 - 3900mm
Max. overhang (behind last axle) 1350mm
Subframe dimensions U 160x70x8mm, U 180x70x8mm,

6mm reinforcement plate, min. 6mm reinforcement plate
3m long (from frame end to front) (continuous)
Material Steel with yield strength Re>500N/mm² (e.g.S500MC)
Cross bracing - -

4-axle vehicle 8x4
Vehicle model designation 964.330 964.331

964.331
964.338
Weight variant 32,000kg 41,000kg
Max. mixer size 9m³ 10m³
Wheelbase 4250 - 4550mm 4550 - 4850mm
Max. overhang (behind last axle) 1300mm
Subframe dimensions U 160x70x8mm, U 180x70x8mm,

6mm reinforcement plate, 6mm reinforcement plate
Min. 3m long (from frame end to front) (continuous)
Material Steel with yield strength Re>500N/mm² (e.g.S500MC)
Cross bracing - A diagonal cross¹⁾

1) The diagonal cross must be positioned in front of the rear drum bearing bracket and must extend to approx. in front of the 1strear axle.
Alternatively: Comparable torsion bracing of the subframe, e.g."boot puller plate".
Design of bodies

Use in export countries
Vehicle model designation 964.216/316 964.216/316 964.230/330 964.231/331 964.231/331

33t - 6x4 33t - 6x4 32t - 8x4 41t - 8x4 41t - 8x4
Permissible gross mass ≥33,000kg 40,000kg ≥35,000kg ≥41,000kg ≥44,800kg
Max. mixer size 8m³ 9m³ 9m³ 10m³ 12m³
Wheelbase 3600 - 3900mm 4200mm 4250 - 4550mm 4550¹⁾ - 4850 - 5150mm

5150mm
Additional mounting X³ X³
plates
Max. overhang (behind 1350mm 1000mm

last axle)
Subframe dimensions U 180x70x8mm,

min. 6mm reinforcement plate closed to form box
Material Steel with yield strength Re>500N/mm²
Cross bracing A diagonal cross²⁾

1) Wheelbase 4250 to 9m³ possible
2) The diagonal cross must be positioned in front of the rear drum bearing bracket and must extend to approx. in front of the 1strear axle.
Alternatively: Comparable torsion bracing of the subframe, e.g."boot puller plate".
3) In addition to the factory-fitted mounting plates as per code C5K, additional mounting plates (B, C) must be retrofitted between the first
mounting plate (A) and the second mounting plate (D). This measure can only be omitted if the drum bearing bracket of the truck mixer
is positioned centrally between the first mounting plate (A) and the second mounting plate (D).
A First mounting plate, code

C5K
B Additional mounting plate (at
least "3 perforated mounting
plates", material thickness
10 mm) installed 1x on right
and left
C Drum bearing bracket of truck
mixer
D Second mounting plate, code
C5K
W60.00-A133-76
Outside the data in the table, the body does not comply be coordinated with the relevant contact person (see
with the Body/Equipment Mounting Directives. This is to document "Advice for body manufacturers").
Tank vehicles and silo trucks
Design of bodies
i i
Possible loss of registration eligibility. Possible damage to vehicle load-bearing structure
For tank vehicles of classes N2, N3, which are from bodies without subframe. If the wheelbase is
intended for the transportation of hazardous goods modified on these vehicles, the relevant contact
according to the definition in the ADR agreement, person (see document "Advice for body
proof of rollover stability according to ECE‑R 111 manufacturers") must be consulted.
must be provided. A tool is available for this purpose
in the Mercedes-Benz Bodybuilder Portal (http://bb-
portal.mercedes-benz-trucks.com).
i
Possible failure to reach minimum front axle load
when partially unloaded, resulting in possible loss of
control while driving due to changes in steering and
braking characteristics on vehicles with multiple tank
chambers. Take the specific fluid weights in the
individual chambers into account for the design. For
every load condition, ensure that the permissible
axle loads are not exceeded and the prescribed
minimum front axle load is achieved (see document
"Steerability"). Attach the loading and unloading
plans to the vehicle in a clearly visible position.
Formulate the operating instructions accordingly.
---------------------------------------------------------------------------
General • Position the fuel tank or dry-bulk body mounts as
• Observe the permissible center of gravity heights close to the spring brackets as possible.
(see document "Load distribution"). • Position the rigid mounts at the rear to ensure good
• Fuel tank and dry-bulk bodies must be equipped with handling characteristics.
a continuous steel subframe. • Do not exceed the distance dimension from the
• The connection between the body and the subframe center of the rear axle to the body mount specified in
or between the vehicle frame and the subframe must the table (see the table "Subframe section moduli
be selected so that the twisting of the vehicle frame is and body mount distances"). Position the front
not impaired. body mount as close as possible behind the cab.

Design of bodies
Subframe attachment
Rigid attachment of the subframe is
recommended. Fastening parts, rigid,
sales code C5H, are available ex
works for model series 963, 964.
1 Vehicle frame
2 Subframe
3 Flexible bearings
W47.10-A012-01 W47.10-A013-01
Front four-point bearing Front three-point bearing
1 Vehicle frame
2 Subframe
4 Mounting support
5 Intermediate block
W47.10-A014-06
Rear rigid mount

Table of subframe section moduli and body mount distances for BR 967
Number of axles Max. distance from center of rear Steel subframe¹⁾ section modulus
axle to body mount behind rear (Wx) per longitudinal member min.
axle [mm] [cm³]
2-axle vehicle 1000 45

1) Minimum yield strength 355 N/mm²
Design of bodies

Table of subframe section moduli and body mount distances for BR 963/964
Number of axles Max. distance from center of rear Steel subframe¹⁾ section modulus
axle¹⁾ to body mount behind rear (Wx) per longitudinal member min.
axle [mm] [cm³]
4-axle vehicle with 3 rear axles 2350¹⁾ 70

1) Install an additional body mount approx. 1800 mm in front of the rear body mount.
2) Minimum yield strength 355 N/mm²
Observe the equipment specifications for the overall • Mark filling levels on the tank so that the permissible
center of gravity position (see document "Load filling quantity is visible. A load indicator with acoustic
distribution"). A certificate of non-objection (CNO) from and visual warning systems in the cab can also be
the relevant contact person is always required for tilting installed on the rear axle.
bodies (see document "Advice for body • Fuel tank and dry-bulk body with separate
manufacturers"). compartments: Loading and unloading plans must be
Transporting cargoes with different specific gravities: attached to the vehicle at a clearly visible position.
---------------------------------------------------------------------------
Fuel tank and dry-bulk bodies without continuous • Both sections should be designed as edge profiles
subframe (minimum dimension 100x65x5mm) with
• Observe the permissible center of gravity heights reinforcement plate and smooth transition (BR 967).
(see document "Load distribution"). • Both sections should be designed as edge profiles
• Install the sales code C5M Pre-installation for bodies (minimum dimension 100x70x6 mm) with a
without subframe, in the vehicle (BR 963/964). reinforcement plate closed to form a box and smooth
transition (BR 963/964).
• Equip the vehicle with reinforced springs and
stabilizer bars (BR 967). • It is not permitted to put the fuel tank on directly
without sections.
• The subframe section must overlap over the front and
rear rear-spring brackets (air suspension supports) • The tank mount must be rigid at the rear and flexible
for sufficient load application on 2-axle vehicles. at the front.
• Provide a length of at least 1000mm for the front • If vehicle vibrations occur after mounting, a subframe
section. with corresponding attachment is required.
Vehicles for transport of hazardous goods
Design of bodies
i i
Risk of tipping of vehicles for transporting hazardous Possible loss of eligibility for registration: When
goods. performing conversions on chassis for hazardous
The operator and persons standing outside the goods, always obtain a certificate of non-objection
vehicle can be injured. Possible environmental from the relevant contact person (see document
damage due to load escaping: Pay particular "Advice for body manufacturers").
attention to till stability. Observe the applicable
safety regulations and national guidelines regarding
the handling of hazardous goods (e.g. ADR
regulations, proof of rollover stability according to
ECE‑R 111).

The following special equipment for vehicles subject to the German regulation concerning the transport of
dangerous goods by road, rail and inland waterways (GGVSEB/ADR) is available for various vehicle model
designations.
Sales code Designation
C5A Chassis design for ADR
E5T ADR class EX/II, including AT
E5U ADR class EX/III, including EX/II and AT
E5V ADR class FL/ including EX/II, EX/III and AT
E5W ADR class OX, including AT
E5X ADR class AT
J1R Digital tachograph, EC, rotational speed, ADR
For tank vehicles of classes N2, N3, which are intended tool is available for this purpose in the Mercedes-Benz
for the transportation of hazardous goods according to Bodybuilder Portal (http://bb-portal.mercedes-benz-
the definition in the ADR agreement, proof of rollover trucks.com).
stability according to ECE‑R 111 must be provided. A
---------------------------------------------------------------------------
Transportation of class 2 and 3 combustible approval for vehicles that are registered in the Federal
materials Republic of Germany. If vehicles are registered outside
The required scope of equipment of the basic vehicle of the Federal Republic of Germany, country-specific
can be delivered from the factory with the relevant technical solutions may be required.
---------------------------------------------------------------------------
Vehicles for transporting aggressive materials compressed-air lines, brake lines and brake hoses as
On vehicles for the transportation of aggressive well as electric lines against chemical influences.
materials, the body manufacturer must protect all
---------------------------------------------------------------------------
Permanent magnet retarder (model 967)
Sales code B3G, Permanent magnet retarder, is not
available in combination with GGVSEB/ADR equipment.
Cargo liftgate/loading platform
Design of bodies
axle loads
i i
Observe the cargo liftgate/loading platform Possible frame damage and loss of stability in work
manufacturer's operating instructions and safety mode:
notes. The vehicle must not be raised using the outriggers.
All national laws, accident prevention regulations, Do not exceed the permissible static rear axle load.
directives and registration requirements must be Design the vehicle accordingly and amend the
complied with! operator's manual.
i i
Operational safety and durability not ensured and Loss of registration eligibility and possible loss of
risk to operator and other persons: control when driving due to modified steering and
Lower the trailing axle before operation. Record braking behavior:
information in operator's manual or adapt vehicle Mounting a cargo liftgate/loading platform produces
parameterization. a rear-end load that must be taken into account
when the designing the vehicle. Observe the
minimum front axle loads in conjunction with rear-
end load (see document "Steerability").
---------------------------------------------------------------------------
Dimensioning and design Mercedes-Benz recommends that only hydraulic
Observe the following when attaching a cargo liftgate: outriggers be used.
• Use calculations to determine the load distribution. On low frame chassis (Low Deck), the combination of a
Take all special equipment into account when doing liftgate on a body without subframe and tongue weight is
so. not permissible.
• If necessary, shorten the body length and the rear S500MC was used as a basis material for the assembly
chassis overhang accordingly. frame during design. If a material with lower strength is
used, e.g.S380MC or S 355MC, correspondingly higher
• Vehicles with an extended frame overhang are only moments of resistance are required.
suitable for the attachment of a cargo liftgate to a
certain extent. Compliance with the points mentioned For cargo liftgates with a load capacity of up to 20kN and
above must be ensured. without outriggers, please note:
• Extend the subframe as far forward as possible and • The manufacturer of the cargo liftgate or of the body
rigidly connect it to the vehicle frame from the end of must draw attention to the increased risk potential
the frame to the front bearing bracket of the rear axle involved in operating a cargo liftgate without
spring or, with air-sprung rear axle, to the front trailing outriggers in their assembly/operating instructions.
arm bracket of the rear axle. • An appropriate information label must be attached in
• When fitting electrohydraulic cargo liftgates, install an a clearly visible place on the cargo liftgate.
alternator and batteries with sufficient output.
• If an assembly frame is not required according to the
cargo liftgate table, mount the cargo liftgate to the
longitudinal frame members.

Design of bodies

Cargo liftgate table (only valid for model series 963, 964)
Vehicle model Wheelbase [mm] Maximum lifting Subframe section Support

force [kN] modulus Wx per
longitudinal member
min. [cm3]1
4x2 L with overhang 3700 … 5800 10 a) -

up to 45% of
wheelbase 3700 … 5800 15 a) -
3700 … 5800 20 a) -
3700 … 4900 30 a) x)
5200 … 5800 30 40 x)

up to 60 % of
wheelbase 4300 … 5500 15 a) -
5800 … 6400 15 40 -
4300 … 4600 20 a) -
4900 … 6400 20 40 -
4300 … 4600 30 40 x)
4900 … 5500 30 60 x)
5800 … 6400 30 80 x)

up to 60% of
wheelbase 4300 … 5200 15 a) -
4300 … 4600 20 a) -
4900 … 5200 20 40 -
4300 … 4600 30 40 x)
4900 … 5200 30 80 x)
1) Possible profile dimensions (see document "Subframe, general → Design of subframe")
a) Subframe not required
x) Outrigger required
Outside the data in the table or for model series 983, the NW060815 Cargo liftgate (LBW) 4x2
body also complies with the Body/Equipment Mounting NW060815 Cargo liftgate (LBW) 6x2
Directives if:
NW060815 Cargo liftgate (LBW) 6x4
the specifications in these Body/Equipment Mounting
Directives are observed, These documents can be found in e.g. the Mercedes-
Benz Bodybuilder Portal
positive proof of the durability of the cargo liftgate in
work mode (vehicle longitudinal frame members and (http://bb-portal.mercedes-benz-trucks.com)
subframe connected rigidly) is provided as per the under the following heading:
following documents and the specifications contained
therein are also observed.
Document for proof of the durability of the cargo liftgate:
Design of bodies
Body/Equipment Mounting Directives → Additional

information for Body/Equipment Mounting Directives:
Calculation
---------------------------------------------------------------------------
Operation with rigid drawbar trailer or center axle Cargo liftgate work mode:
trailer NW 060815 Cargo liftgate (LBW) 4x2
The operation of a rigid drawbar trailer (SDAH) or a NW 060815 Cargo liftgate (LBW) 6x2
center axle trailer (ZAA) in combination with a cargo
liftgate/loading platform is permissible only if the NW 060815 Cargo liftgate (LBW) 6x4
parameters below are met: Driving with additional loads:
• The specifications in these Body/Equipment NW 020216 Driving with additional loads, 4x2
Mounting Directives, in particular (see "Steerability"
NW 020216 Driving with additional loads, 6x2
document) and (see "Operational limit values for
gross vehicle mass and axle loads" document) NW 020216 Driving with additional loads, 6x4
must be observed. The term "additional load" encompasses the entire cargo
• When determining the actual front axle load, the liftgate/loading platform including its fastening parts.
gross vehicle mass and the axle loads, the tongue These documents can be found in e.g. the Mercedes-
weight of the rigid drawbar trailer or center-axle trailer Benz Bodybuilder Portal
at the coupling point of the trailer coupling must be
taken into account. (http://bb-portal.mercedes-benz-trucks.com)
• The vehicle must be factory-fitted with an end under the following heading:
crossmember and a trailer coupling that are approved Body/Equipment Mounting Directives → Additional
for operation with a rigid drawbar trailer or center axle information for Body/Equipment Mounting Directives:
trailer. The tongue weight, Dc and V value must be Calculation.
entered at the factory in the registration
If at least one of the boundary conditions is not satisfied,
documents/COC documents.
the body does not comply with the body/equipment
• The ex-factory horizontal distance from the center of mounting directive. This should be coordinated with the
the front axle to the center of the coupling point of the relevant contact person (see "Advice for body
trailer coupling (as for EC dimension (A)) must not be manufacturers" document). It is recommended to
enlarged. submit the body for a non-objection check.
• Depending on the vehicle (axle configurations), the Additional information is required for checking for a
following operational durability verifications must be certificate of non-objection (see document "Certificate
performed for cargo liftgate work mode and driving of non-objection").
with additional loads. The specifications contained
therein must be complied with.
Loading crane body
Design of bodies
aDanger
body is lowered.
aWarning
axle loads
Selection of chassis Page 45
Tank vehicles and silo trucks Page 542
Loading crane body
Design of bodies
i i
Danger to the operator and others due to inadequate Stability when the loading crane is operating is not
vehicle stability: guaranteed. Operators or other persons could be
The body manufacturer is responsible for ensuring injured:
the stability of the vehicle. Design the body with this Do not mount loading crane bodies on vehicle model
in mind. designation 963.042.
Restrict the swivel range of the crane.
Place the safety information and the loading crane
manufacturer's operator's manual in the vehicle and
inform the user.
Parameterize air-sprung vehicles so that they are
automatically lowered to their hard stop before
starting work.
Have an inspection carried out by an appraiser
before taking into service.
Incorporate safety information into the operator's
manual for the body.
Comply with country-specific laws, policies and
regulations (e.g. the DGUV accident prevention
regulation).
---------------------------------------------------------------------------
The content regarding the stability of the vehicle with a specifications contained therein are also observed.
loading crane body described in the following text must Documentation of proof of durability of loading crane:
be taken into account in the design. PN 141014 SF, PN 141014 SW. This document can be
The body meets the body/equipment mounting directives found e.g. in the Mercedes-Benz Bodybuilder Portal
provided that: the specifications of these body/ (http://bb-portal.mercedes-benz.com) under the
equipment mounting directives are observed, positive following heading: Body/Equipment Mounting
proof of the durability of the vehicle longitudinal Directives → Additional Information on Body/Equipment
members and subframe in loading crane work mode is Mounting Directives: Calculation.
provided as per the following documents and the
---------------------------------------------------------------------------
The specifications of the crane manufacturer must also frame lowering system as per the specifications in the
be observed when planning crane bodies. The stability document "Frame lowering on air-sprung vehicles"
of the vehicle must be guaranteed by sufficient supports. because this includes the integrated "compulsory
A certificate of non-objection from the responsible lowering" function. Observe the information about
department is required for quadruple crane support. determining the size of the chassis (see document
Vehicles with air suspension are to be equipped with a "Selecting the chassis").
---------------------------------------------------------------------------
Loading crane body behind the cab • Do not lift the vehicle with the support fixture,
• The loading crane and supporting devices must not otherwise the frame can be damaged.
impair the function of other major assemblies. • Support fixtures that protrude over the vehicle outline
• Secure the loading crane to a subframe made of in stationary operation must be marked with warning
steel. stripes; as an option, these can also be marked with
warning lights.
• Observe the specifications for the material quality of
the subframe (see document "Subframe, general").
---------------------------------------------------------------------------
Subframe section to a U section must be gradual and suitable for
Extend the longitudinal member under the cab. On the load. Provide outriggers for each loading crane. It is
vehicles with a long cab, extend as far as the rear front recommended to use the fastening parts for front loading
spring bracket. In the loading crane area, arrange the crane, sales code C5G.
longitudinal members as a box. The transition from a box
---------------------------------------------------------------------------
Loading crane body
Design of bodies
Pre-installation for loading crane dumper The contour markings on the dumper body are not
For 2‑axle dump trucks (vehicle model designation included.
964.200/201/202/203/207/208), it is possible to configure Loading crane attachment
a "loading crane dumper" pre-installation package by
combining various special equipment items. The drawing below, "Loading crane attachment"
illustrates one possible principle for mounting a loading
This pre-installation package simplifies the mounting of a crane and shows the limit values and dimensions which
suitable loading crane behind the cab. must be adhered to.
The pre-installations/equipment features which can be U-bolt mountings other than those illustrated may also
configured include the following: be designed and used provided that the minimum sizes
• Standard three-way crane dump truck, and dimensions stated in the drawing are maintained or
4000 x 2420 x 600 mm, sales code P1A or exceeded.
alternatively standard three-way crane dump truck, Depending on the size of crane selected, the
4200 x 2420 x 600 mm, sales code P1B, (including requirements of the crane manufacturer regarding the
lengthened and reinforced subframe, two bolted crane mounting may even be substantially higher/greater
crossmembers in the area of the crane and a larger than the minimum dimensions specified in the "loading
hydraulic oil reservoir under the dump body) crane attachment" drawing.
• Fastening parts for front loading crane, sales The body manufacturer installing the crane is solely
code C5G (crane side plate) responsible for the design/dimensioning and for
• Meiller pump, 7-piston, type 270/63, sales code N8J demonstrating the appropriate strength of the
• Pneumatic dumper control, in cab, sales code P9A components and weld seams of the crane/U-bolt
mounting (in compliance with the minimum sizes and
• Pneumatic crane operation switchover in cab, sales dimensions shown in the "loading crane attachment"
code P9C drawing).
• Optional: Free space for crane outrigger feet, sales U-bracket mountings for loading cranes are not provided
code C7Q for and are not permissible.

W60.00-A074-09
Loading crane attachment
Loading crane body
Design of bodies
a Fillet weld 6 mm (weld seam) g Maximum 45 mm (center of U-bolt to crane plate)

b Minimum distance 400 mm h Minimum 60 mm (width of crane mounting on
crane plate)
c 25 mm (upper edge of weld seam/upper edge of i Example of crane plate variant (8 mm), fastening
subframe) parts for front loading crane, sales code C5G
d Minimum length 160 mm j Compensator for thickness of crane plate, from
body manufacturer
e 30 mm (lower edge of weld seam/lower edge of k Example of welded U-bolt mounting
subframe)
f Minimum distance 50 mm (outer edge of crane
plate/start of crane mounting)
Maximum permissible U-bolt forces maximum permissible static U-bolt force at any U-bolt is
On 2-axle vehicles with dumper body/standard three- 285 kN.
way crane dump trucks, sales codes P1A and P1B, the
---------------------------------------------------------------------------
Maximum permissible total crane moments • Three-point mounting crane (without pivot): 115 kNm
The following static total crane moments¹⁾ are
permissible:
• Four-point mounting crane (with pivot): 170 kNm, with
a maximum distance of 155 mm from center of pivot²⁾
to vehicle center
---------------------------------------------------------------------------
¹⁾ Static total crane moment = static weight moment of travel. The offset of the center of the pivot pin to the
loading crane + static lifting moment of loading crane vehicle center can be either to the left or right of the
²⁾ The crane pivot can be located both towards the front vehicle in the direction of travel.
and towards the rear of the vehicle in the direction of
---------------------------------------------------------------------------
Subframe crossmember in vicinity of crane
The diagram illustrates the ex-factory installation position
of the subframe crossmember in the vicinity of the crane.

Loading crane body
Design of bodies
Distance from center of crane U-bolt to subframe
crossmember
The center of the crane U-bolt must be inside the area
A.
If necessary, the crossmembers can be relocated within
the existing hole patterns in the subframe. If the
crossmembers are relocated, new bolts as per
MBN 10105 and new nuts to MBN 13023 must be used.
Existing sockets/shims must be reused.
Tightening procedure: Tightening torque 225 Nm and
tightening angle 90°.
Appropriate anti-corrosion protection measures must be
taken.
A 310 mm
B Max. 80 mm
W60.00-A075-12
¹⁾ The hydraulic oil reservoir is filled at the factory with

the oil type/filling quantity necessary for dumper/trailer
operation (60/73 l). Depending on the loading crane
used, it may be necessary for the body manufacturer to
change the oil type/oil filling capacity. Observe the oil
recommended by the dumper and crane manufacturers.
Hydraulic interfaces for loading crane

C Return connection, G1 (female thread)
D Pressure connection, M30 x 2 (male thread),
marked "Crane", pressure setting 400 bar,
tolerance + 10 bar
E Hydraulic oil reservoir under dump body:
Maximum capacity for crane operation 120 l¹⁾
Filled at the factory with hydraulic oil as per the
specification: DBL 6651; e.g. Renolin B3¹⁾
F Not illustrated. Meiller pump, 7 pistons, W60.00-A076-11
model 270/63, sales code N8J (delivery rate 63 l/ Distance from center of crane U-bolt to subframe crossmember
1000 rpm)
Fastening parts for front loading crane, sales Sales code C5G simplifies the installation and rigid
code C5G mounting of a suitable loading crane.
For selected vehicles/vehicle model designations with 2- It may also render unnecessary the removal/installation
axle, 3-axle and 4-axle chassis, it is possible to configure of major assemblies (AdBlue® tank, exhaust system,
fastening parts for front loading crane, sales code C5G, battery carrier) and the manufacture and installation of a
as special equipment. suitable attachment angle bracket or suitable crane side
The delivery package consists of one left-side and one plate and reinforcement for the lower flange.
right-side attachment angle bracket.
These are already installed at the factory behind the cab
on the vehicle longitudinal frame member.

Loading crane body
Design of bodies
Variant overview of 2/3-axle chassis
Rear axle steel suspension
W60.00-A077-10
2-axle and 3-axle vehicles, S and M cab, without sales code K7A
(Exhaust system, tailpipe upward)
W60.00-A078-10
2-axle and 3-axle vehicles, S and M cab, with sales code K7A
W60.00-A079-10
2-axle and 3-axle, L cab
Loading crane body
Design of bodies
Rear axle air suspension
W60.00-A080-10
2-axle and 3-axle vehicles, S and M cab, without sales code K7A
W60.00-A081-10
2-axle and 3-axle vehicles, S and M cab, with sales code K7A
W60.00-A082-10
2-axle and 3-axle, L cab
Loading crane body
Design of bodies
The following is valid in the diagrams illustrated here:

• L-shaped attachment angle bracket
• Material: Steel EN 10149‑2‑1.897, yield strength
700 N/mm²
• Material thickness: 10 mm
• Lower flange width: 90 mm, in area of frame drop/
cutout 69 mm
Further information on dimensions, position on the
vehicle etc. (see 2D chassis drawings (offer
W60.00-A083-10
drawings)) in the Mercedes‑Benz Bodybuilder Portal
Example for 2-axle and 3-axle, S and M cab
W60.00-A084-11
Example of crane plate with S cab
W60.00-A085-11
Example of crane plate with L cab
Loading crane body
Design of bodies
Supplementary information - Variant overview of 2-
axle chassis in combination with sales code P1A/
P1B²⁾
In combination with the standard three-way crane dump
trucks, sales code P1A/P1B²⁾, equipped for the retrofit
installation of a loading crane, special/adapted fastening
parts for the front loading crane are supplied, sales
code C5G. This contains one crane side plate without
additional folding.
W60.00-A086-10
2-axle vehicles, S and M cab, without sales code K7A (Exhaust
system, tailpipe upward) in combination with sales code P1A/P1B²⁾
These special/adapted fastening parts for the loading

crane are only available in combination with sales
codes P1A and P1B.
W60.00-A087-10
2-axle vehicles, S and M cab, with sales code K7A (Exhaust
system, tailpipe upward) in combination with sales code P1A/P1B²⁾
¹⁾ Sales code K7A: Exhaust system, tailpipe upwards ²⁾ Sales code P1A: Standard three-way crane dump
truck, 4000 x 2420 x 600 mm, sales code P1B: standard
three-way crane dump truck, 4200 x 2420 x 600 mm

Variant overview of 4-axle chassis
Rear axle steel suspension

The following is valid in the diagrams illustrated here:
• L-shaped attachment angle bracket
• Material: Steel EN 10149‑2‑1.897, yield strength
700 N/mm²
• Material thickness: Side plate 10 mm, lower flange
reinforcement 15 mm
• Lower flange width: 100 mm, in the cutout areas W60.00-A088-10
min. 52 mm 4-axle, 8x4, S and M cab
Loading crane body
Design of bodies
W60.00-A089-10
4-axle, 8x8, S and M cab
W60.00-A090-10
4-axle, 8x4, L cab
W60.00-A091-10
4-axle, 8x8, L cab
Rear axle air suspension

Loading crane body
Design of bodies
W60.00-A092-10
4-axle, 8x4, S and M cab
W60.00-A093-10
4-axle, 8x4, L cab
W60.00-A094-10
Example for 4-axle, 8x4, S and M cab
Loading crane body
Design of bodies
Permissible position and number

of U-bolt attachments for loading
crane on 2-axle/3-axle chassis,
model series 963/964
e Minimum distance ≥ 100 mm
g Center of U-bolt mounting
(crane U-bolt)
h Example of fastening parts for
loading crane (crane plate), 2-
axle/3-axle vehicles
k In this area, max. 2 U-bolt
attachments "g" are
permissible on each side of
the vehicle. The minimum
distance between the U-bolt
mountings "g" must be
≥ 600 mm. W60.00-A095-05
Permissible position and number of U-bolt mountings for loading crane on 2/3-axle
chassis
Permissible position and number

of U-bolt mountings for loading
crane on 4-axle chassis,
BR 963/964
e Minimum distance ≥ 100 mm
g Center of U-bolt mounting
(crane U-bolt)
h Example of fastening parts for
loading crane (crane plate), 4-
axle vehicles
k In this area, max. 2 U-bolt
attachments "g" are
permissible on each side of
the vehicle. The minimum
distance between the U-bolt
mountings "g" must be
≥ 600 mm. W60.00-A096-05
Permissible position and number of U-bolt mountings for loading crane on 4-axle chassis
Maximum permissible U-bolt forces Body manufacturers who plan and install the crane are
The maximum permissible static U-bolt force at any responsible for:
permissible U-bolt mounting "g" is 600 kN. • Designing/ dimensioning and assuring the
This figure refers exclusively to the transferable U-bolt appropriate fatigue strength of the components.
force with regard to the factory-installed threaded • The weld seams of the crane/U-bolt mounting on the
connections between the crane plate and the vehicle attachment angle bracket.
longitudinal frame member. This guarantees the • Dimensioning of the subframe required and the
durability of the factory-fitted screw connections. attachment of the subframe.
Notes and supplementary specifications • Any additional reinforcements which may be
Because of the wide variety of possible combinations of necessary on the lower flange of the vehicle frame.
vehicle type, crane, total crane moment, type of support, Coordination with the relevant contact person may be
design of subframe, stability etc., it is not possible to necessary (see document "Advice for body
specify a maximum permissible total crane moment for manufacturers").
the fastening parts, for loading crane, front, sales code U-bracket mountings for the loading crane are not
C5G. provided for and are not permissible in combination with
sales code C5G.
Loading crane body
Design of bodies
When additional lower flange reinforcements (provided Weld joints between the fastening parts, for loading
by the body manufacturer) are necessary on the vehicle crane, front, sales code C5G, and the additional lower
longitudinal frame member for the planned loading crane flange reinforcement (provided by the body
body to connect to the fastening parts for the front manufacturer) are not permissible.
loading crane, suitable measures must be implemented Coordination with your contact person may be necessary
to guarantee/assure proper connection of the two (see document "Advice for body manufacturers").
reinforcements (the factory-installed sales code C5G
delivery package and the new lower flange
reinforcement delivery package from the body
manufacturer).
---------------------------------------------------------------------------
Loading crane body mounted at the rear • NW 020216 Driving with additional loads, 6x2
The stability of the vehicle must be guaranteed by • NW 020216 Driving with additional loads, 6x4
sufficient supports. The term "additional load" encompasses the entire rear-
The distance between crossmembers in the overhang mounted loading crane including its fastening parts.
may not be greater than 900 mm. An additional The listed documents can be found e.g. in the
crossmember must be installed if necessary. Mercedes-Benz Bodybuilder Portal (http://bb-
The permissible rear axle load must not be exceeded. portal.mercedes-benz-trucks.com) under the following
Clearly mark outriggers that protrude beyond the vehicle heading: Body/Equipment Mounting
outline when the vehicle is stationary using conspicuous Directives → Additional Information on Body/Equipment
colors, reflectors and warning lights. Mounting Directives Book II: Calculation.
The operation of a rigid drawbar trailer (SDAH) or a If at least one of the boundary conditions is not satisfied,
center-axle trailer (ZAA) in combination with a rear the body does not comply with the body/equipment
loading crane is permissible only if the parameters below mounting directive. This should be coordinated with the
are met: relevant contact person (see document "Advice for
body manufacturers"). It is recommended to submit
• The specifications in these Body/Equipment this for a non-objection check.
Mounting Directives must be observed (see
documents "Steerability" and "Usage-related limit Additional information is required for checking as part of
values of gross vehicle mass and axle loads"). a CNO (see document "Certificate of non-
objection").
• When determining the actual front axle load, the
gross vehicle mass and the axle loads, the tongue Subframe
weight of the rigid drawbar trailer or center-axle trailer • Secure the loading crane to a subframe made of
at the coupling point of the trailer coupling must be steel.
taken into account.
• The yield strength of the subframe should be as high
• The vehicle must be factory-fitted with an end as that of the vehicle frame.
crossmember and a trailer coupling which are
approved for operation with a rigid drawbar trailer or • There should be a gradual transition from the box
center axle trailer. The tongue weight, Dc value and V section to the U section.
value must have been entered in the registration/CoC • Rigidly connect the subframe to the vehicle frame
documents at the factory. (e.g. by means of tabs).
• The ex-factory horizontal distance from the center of • Provide diagonal struts in the rear area of the
the front axle to the center of the coupling point of the subframe.
trailer coupling (as for EC dimension (A)) must not be
• The length of the diagonal strut must be at least 1.5
enlarged.
times the frame width. This increases the torsional
• Depending on the vehicle (axle configuration) and the rigidity of the vehicle frame.
mounting of the subframe (rigid or non-positive), the
• If a diagonal strut is not possible e.g. in the area of
following operational durability verifications must be
the shock absorbers or spring-loaded brake
performed for operation of the loading crane and for
cylinders, inclined braces or tubular crossmembers
driving with additional loads. The specifications
can be installed.
contained therein must be complied with.
• The chassis equipment must be fitted according to
• Loading crane in operation:
the position of the center of gravity.
• PN 141014 SF or PN 141014 SW
• Observe the minimum front axle load (see document
• Driving with additional loads: "Steerability").
• NW 020216 Driving with additional loads, 4x2
---------------------------------------------------------------------------
Loading crane body
Design of bodies
Vehicles with a raised trailing axle (lift axle) • The load specifications must be supplemented in the
• The trailing axle must be lowered before operation. vehicle operator's manual depending on the
compliance with the minimum front axle loads,
• Do not exceed permissible axle loads (even with a including with respect to the lift axle use options.
raised trailing axle).
• The lift function can be disabled by changing the
• Comply with the minimum front axle load in all parameters in the level control (CLCS) control unit.
operating statuses (including when the trailing axle is This must be carried out if, with the vehicle unladen
raised) (see document "Steerability"). and the trailing axle in the lift position, more than
• During vehicle handover, the vehicle owner must be 80% of the permissible axle load of the drive axle(s)
informed that it may not be possible to raise the lift is already reached.
axle if a loading crane is mounted on the rear.
Loading crane test
Design of bodies
diagrams
Crane bodies in single-invoice transactions This supersedes a rule from 1995 which stipulated that
According to Para. 25 BGV/GUV‑V D6, the loading an expert inspector was sufficient.
crane must be inspected by an appraiser before initial A detailed version of the loading crane inspection in a
commissioning. According to Para. 28 BGV/GUV‑V D6, single-invoice transaction and an example document
apart from appraisers from the technical monitoring containing the vehicle documents can be found in the
body, only appraisers authorized by the trade Bodybuilder Information Bulletin (see document
association are allowed as crane inspection appraisers. "Overview of documents/catalogs/instructions/
The document produced during inspection must be wiring diagrams").
added to the vehicle documents and submitted to • Crane inspection in single-invoice transaction
Daimler Truck AG when a vehicle inspection is 2015/03
performed.
Fixed and swap bodies on semitrailer trucks
Design of bodies

Semitrailer truck vehicle model designations (963.4xx/ • Electronic Stability Program, minimum requirements
964.4xx/967.4xx) are only conditionally suitable for fixed (see document "Stability Control Assist, ESP®,
or swap bodies. Modifications to the basic vehicle may center of gravity heights, stabilizers")
be necessary in order to guarantee that the vehicle will
• Air suspension (travel sensor)
be safe. These must be coordinated with the relevant
contact person (see document "Advice for body • Brake system
manufacturers").
Modifications to, e.g. the following components and
functions may be necessary:
Other body
Design of bodies
i
Stability in working operation not assured due to the
governing behavior of the air suspension. Operators
or other persons could be injured:
Vehicles with model designation 963.042 are not
permitted to be fitted with bodies which cause the air
suspension to make adjustments while operating.
This is the case e.g. with outriggers such as are
used for cherry pickers, elevating work platforms,
firefighting turntable ladders or concrete pumps.
---------------------------------------------------------------------------
Apply these Body/Equipment Mounting Directives relevant contact person (see document "Advice for
accordingly for other special bodies, e.g. waste body manufacturers").
collection vehicles, municipal vehicles or fire-fighting Particularly on vehicles of model designation 967.067,
vehicles. bodies which require support during working operation,
These Body/Equipment Mounting Directives must be such as cherry pickers, elevating work platforms,
applied accordingly for bodies that are not explicitly turntable ladders for fire brigades or concrete pumps,
listed here. For consultation and advice, contact the must be agreed upon in advance.
Code C7P - Clearance for swap bodies, low frame
Design of bodies
C7P Clearance for swap bodies,

low frame
The equipment can be ordered for
selected low frame chassis
(BM 963.004 and BM 963.021).
The vehicle is prepared ex works for
a swap body without subframe (body
manufacturer solutions may vary).
The EAPU is offset from the left side
between the longitudinal frame
members, which creates clearance
for the twistlock locks on the outside.
Information on the vehicle
dimensions can be found in the
corresponding 2D chassis drawings
in the Mercedes-Benz Bodybuilder
Portal.
W31.00-A018-72 W31.00-A019-72
Clearance for swap bodies, low frame Mounting example with clearance for swap
body
Code C7Q - Clearance for crane support feet
Design of bodies
C7Q-Clearance for crane support feet
The clearance for the crane support feet for vehicle
model designation 963, is approx. 600 mm in the x-
direction . On vehicle model designation 964, the
clearance is approx. 500 mm due to the front axle, offset
by 100 mm to the rear as standard.
a Approx. 600 mm
W31.00-A020-81
C7Q for BM 963.020 (right side of the vehicle)
For most vehicles, the equipment is only available

together with the "Battery carrier, stacked batteries"
(C7K). The equipment can be combined ex works with
the attaching parts for loading crane (code C5G).
The equipment may eliminate the need for costly
conversion work by the body manufacturer by creating
the necessary clearance ex works. In order to obtain
more space for crane support feet, it may be necessary
to subsequently relocate the battery carrier and the
exhaust system again.
Information on the dimensions on the vehicle can be
found in the 2D chassis drawings in the Mercedes-Benz
Bodybuilder Portal.
b Approx. 500 mm
W31.00-A021-81
C7Q for BM 964.020 (left side of vehicle)
Code C7R - Clearance on frame, right
Design of bodies
C7R-Clearance on right of frame

The clearance on the right side of the frame allows the
installation of customer-specific tank and silo
compressors, refrigeration units or stowage boxes. The
clearance in the x-direction is at least 750 mm
depending on the vehicle and extends under and inside
the longitudinal frame member up to the propeller shaft.
Technical information on mounting additional
assemblies on the longitudinal frame member can be
found in document "Installation of compressors".
Information on the dimensions of the clearance can be
Bodybuilder Portal.
Clearances behind exhaust system:
• for semitrailer trucks: approx. 750 ‑ 900 mm
W31.00-A022-81
• for platform/dumper models: approx. 1500 mm (with
C7R for BM 963.403 with wheelbase 4000 mm (C2C)
wheelbase 4000 mm)
wheelbase ≥ 4300 mm)
Depending on the vehicle, the clearance is at least
750 mm and extends under and inside the longitudinal
frame member up to the propeller shaft.
Code C7S - Clearance on frame, left
Design of bodies
C7S-Clearance on left of frame

The clearance on the left side of the frame allows the
attachment of customer-specific detachable parts such
as major assemblies or stowage boxes. The clearance
is at least 750 mm in the x-direction and extends under
and inside the longitudinal frame member up to the
propeller shaft.
Technical information on mounting additional
assemblies on the longitudinal frame member can be
found in document "Installation of compressors".
W31.00-A023-80
Information on the dimensions of the clearance can be C7S for BM 963.020 with wheelbase 4900 mm (C2U)
Bodybuilder Portal.
Clearances in front of left rear axle:
• for semitrailer trucks: approx. 750 ‑ 900 mm
wheelbase 4000 mm)
wheelbase ≥ 4300 mm)
The clearance is at least 750 mm, depending on the
vehicle and equipment, and extends under and inside
the longitudinal frame member up to the propeller shaft.
Code C7U - Clearance for swap bodies, ground clearance 1120 ...
Design of bodies
C7U clearance for swap bodies, ground clearance

1120 mm
The equipment can be ordered for selected air-sprung
standard frame chassis (model designation 963.003 and
model designation 963.020).
The vehicle is prepared at the factory for fully-enclosed
swap body superstructures with 150 mm subframe and
a ground clearance of 1120 mm (solutions at the body
manufacturer may differ here). The EAPU is offset from
the left side of the vehicle between the longitudinal
frame members, which creates clearance for the W31.00-A024-80
twistlock locks on the outside. Clearance on the left side of the longitudinal frame member
through C7U
Information on the dimensions of the clearances on the
vehicle can be found in the 2D chassis drawings in the
Mercedes-Benz Bodybuilder Portal.
Code E9H - Pre-installation for cargo liftgate control
Design of bodies
E9H-Pre-installation for cargo liftgate control wiring harness is routed from the cab to the end of the
The scope includes the switch in the cab, an indicator frame. The wiring harness is fitted with a 7-pin electrical
lamp in the Classic Cockpit (J6A) or in the Multimedia interface at the frame end according to VDHH standard.
Cockpit (J6B/J6C) depending on the equipment, and the The standard 6-chamber tail lamps are generally
electrical wiring harness up to the end of the frame to suitable for mounting a cargo liftgate.
activate the cargo liftgate.
The switch is located in the switch panel next to the
steering wheel and has an indicator lamp. The electrical

W54.25-A065-77
1 Cargo liftgate switch in switch panel next X164.7 Electrical interface according to VDHH
to steering wheel
2 Example of indicator lamp for cargo
liftgate in Classic Cockpit
Circuit diagram of Actros 5, Arocs 5 & eActros

(model designation 963.x/964.x/983.x)

W54.30-A112-09
PE55.40-W-2000-97FA
Code E9H - Pre-installation for cargo liftgate control
Design of bodies
Circuit diagram of Atego (model

designation 967.x)
W54.30-A114-06
PE55.40-W-2000-97NHA
Code K7V - Exhaust system, 80 mm lowered
Design of bodies
K7V Exhaust system, 80 mm lowered
The lowered exhaust box can be ordered for 4x2 and
6x2 platform vehicles with engines of the OM 470 (Z5D)
or OM 471 (Z5E) model series depending on the
equipment.
The exhaust box is lowered by approx. 80 mm to create
clearance between the body and the exhaust box,
e.g. to operate the twistlock locks on swap body
vehicles.
The equipment is particularly recommended for fully-
enclosed swap body subframes with height-adjustable
twistlock locks.
W49.10-A006-81
Exhaust box lowered by approx. 80 mm
Code P9A - Dumper control, in cab
Design of bodies
i
Escape of compressed air from compressed-air lines
that are not sealed with stop plugs:
The dumper and switchover valves in the chassis
are not supplied. The ends of the compressed-air
lines are not sealed with stop plugs; when actuating
the dumper switching valve without connected
valves, compressed air can escape in an
uncontrolled manner.
---------------------------------------------------------------------------
P9A Dumper control, in cab Furthermore, the electric line for connecting the dumper
In the case of cabs with an engine tunnel, a door trim indicator lamp is also preprepared. The electrical
with cutout (code P0S-Clearance for operating unit) is connector is located on the inside right longitudinal
installed ex works in the area of the dumper switching frame member, in the area in front of the 1st rear axle.
valve. In all cases, the compressed-air lines from the actuating
The scope of equipment P9A includes the Meiller valve in the cab to the vehicle frame are routed into the
dumper switching valve and all pneumatic lines for area of the 1st crossmember after the transmission! The
dumper control. The lines are routed from the dumper compressed-air lines are equipped with plug connections
switching valve into the chassis in the area behind the on the chassis side and are protected against dirt and
1st crossmember after the transmission. moisture with a plastic bag.

W55.20-A016-77
1 Compressed-air lines in area of Y 1st rear axle
1st crossmember behind transmission
2 Installation location of electric line for dumper P9A Dumper switching valve
indicator lamp in area in front of 1st rear axle
A Direction of travel
Code P9B - Trailer operation switchover
Design of bodies
i
P9B Trailer operation switchover

All pneumatic lines and the pneumatic sensor for
operating the dump truck and for trailer operation are
installed on the left next to the driver's seat. This allows
the driver to choose between operation of the dump
body of the towing vehicle or the trailer by means of a
selection switch. The equipment is only available in
combination with the pre-installation of dumper control in
the cab P9A.
In all cases, the compressed-air lines from the actuating
valve in the cab to the vehicle frame are routed in the
area of the 1st crossmember after the transmission! The
compressed-air lines on the chassis are equipped with
plug connections from the Schäfer SDF system.
The compressed-air lines are protected from dirt and
moisture ex factory with a plastic bag.
W55.20-A017-81
Dumper switching valve with trailer operation switchover valve
Code P9C - Crane operation switchover
Design of bodies
i
P9C-Crane operation switchover

operating the dumper, trailer operation and crane
operation are installed on the left of the driver's seat.
The driver can choose by means of a selection switch
between operation of the dump body of the towing
vehicle or the trailer. Another selection switch controls
the operation of the crane or the dumper.
The equipment is only available in connection with the
pre-installation of dumper control in the cab P9A.
The compressed-air lines are protected from dirt and W55.20-A018-81
moisture ex factory with a plastic bag. Dumper switching valve with crane operation switchover valve
Code P9D - Pre-installation, automatic side board switchover
Design of bodies
i
P9D-Automatic side board switchover

operating the dumper and the automatic side board are
installed on the left of the driver's seat. The equipment is
only available in connection with the pre-installation of
dumper control in the cab P9A.
W55.20-A018-81
Dumper switching valve with automatic side board switchover
valve
Code P9F - Rear panel claw-type lock switchover
Design of bodies
i
P9F-Rear panel claw-type lock switchover

operating the dumper and the automatic side board are
installed on the left of the driver's seat. The equipment is
only available in connection with the pre-installation of
dumper control in the cab P9A.
W55.20-A018-81
Dumper switching valve with rear panel claw-type lock switchover
valve
Electrics/electronics - General, wiring diagrams, interfaces...
Electrics/electronics
diagrams
i
All wiring diagrams for electrics, the "Equations and
parameters" manual and the instructions for the
body CAN are available in the Mercedes-Benz
Bodybuilder Portal:
Direct links to the documents are available in
document "Overview of documents/catalogs/
instructions/wiring diagrams".
---------------------------------------------------------------------------
Wiring diagrams, interfaces, body CAN

Use of wiring diagrams

1 Information type
2 Function group
3 Function subgroup
4 Production ID
5 Sequence number
6 Information unit number
7 Validity letter(s)
W54.00-A007-01
Wiring diagram number
1 Line cross section in mm²

2 Basic color
3 Identification color
W54.00-A008-01
Line identification
1 Abbreviated designation of electrical connector

2 18-pin
3 Contact cavity 2 (pin no. 2)
W54.00-A009-01
Electrical connector, e.g.cab/chassis
1 Abbreviated designation of control unit

2 Electrical connector at control unit
3 18-pin
4 Contact cavity 1 (pin no. 1)
W54.00-A010-01
Electrical connector e.g.control unit

Line colors
English abbreviation English designation German abbreviation German designation
BK black sw schwarz
PK pink - rosa
BN brown br braun
RD red rt rot
BU blue bl blau
TR transparent - naturfarben
GN green gn grün
VT violet li violett (lila)
GY grey gr grau
WH white ws weiß
OG orange - orange
YE yellow ge gelb
Functional reliability support safety-relevant functionalities in the context of

The signals/functions provided by the vehicle, e.g. via ISO 26262.
the ASAM and XMC control units, do not by default
The body manufacturer must check and ensure considerations which may be described in these body/
compliance with the requirements on the functional equipment mounting directives must also be taken into
reliability of the body. The special functional account.
Work on electrical system
aDanger
Product safety and product liability Page 38
Vehicle safety Page 15
Electrical consumers up to 250 A in total
Electrical consumers up to 250 A in total Page 629
i i
Heightened risk of accident and injury for vehicle Observe the notes on vehicle and product safety
operators and others standing outside the vehicle (see documents "Vehicle safety" and "Product
due to reduced operational safety of the vehicle: safety and product liability").
Modifications to the electrical system, electronic
component parts, their software or wiring can impair
their functioning and/or the functioning of other
networked components. Safety-relevant systems, in
i
particular, may also be affected. Therefore, they may Disconnect the on-board electrical system from the
no longer function correctly. Never carry out any battery before working on the electrical system.
modifications to the wiring and electronic component
parts or their software. Always have work on
electrical and electronic equipment carried out by
qualified personnel/workshops only. Comply with
accident prevention regulations when working on the i
vehicle and configuring the body. Comply with On vehicles with steering, Servotwin, sales code
country-specific policies and regulations! C6H, additional buffer batteries may be installed in
the vehicle depending on the vehicle equipment.
Retrofitting a battery disconnect switch in these
vehicles invalidates the operating permit or makes
the vehicle ineligible for registration. Any
i modifications or additional taps are not permissible.
Invalidation of the operating permit or loss of
eligibility for registration: Do not install a battery
disconnect switch in vehicles with "Steering,
Servotwin", sales code C6H. Depending on the
vehicle equipment, additional buffer batteries may be i
installed in these vehicles. Any modifications or Possible damage to engine and transmission
additional taps are not permissible. components and the ground line:
Return the ground via the vehicle frame only for the
vehicle models and equipment described.
---------------------------------------------------------------------------
Vehicle mass – model 956, 963 (without sales code but by wiring via a defined central ground point or via the
C7T), 964, 967 actuating electronic system.
The ground return for the electrical consumers is not
conducted via the vehicle frame (potential-free frame),
• If the auxiliary/assembly frame of a body is used for • The ground line is connected directly to the battery
ground return, it must be connected correctly to the sensor or standard battery clamp. Installation location
ground point on the battery clamp to prevent see document "Electrical consumers up to 250 A
damage. in total".
---------------------------------------------------------------------------
Vehicle ground – Model 963 (with sales code C7T, as correctly to the knurled stud on the vehicle frame to
of 01.10.2021), 983 prevent damage.
The ground return conductor for electrical consumers is • The ground line can be connected optionally, directly
established through the vehicle frame or through knurled to the battery sensor or standard battery clamp.
studs. Installation location see document "Electrical
On model 983 only the left longitudinal member may be consumers up to 250 A in total".
used.
• If the auxiliary/assembly frame of a body is used as a
ground return conductor, it must be connected
---------------------------------------------------------------------------
Batteries • Never start the engine without a firmly connected
• Never place any metal objects or tools on the battery (battery terminals tightened).
batteries. • Do not loosen or disconnect battery clamps while the
• There is a risk of short circuit if the positive terminal engine is running.
of the connected battery comes into contact with • If the batteries are flat, the engine can be jump-
vehicle parts. This can cause the highly volatile air- started using jumper cables connected to the
fuel mixture to ignite. You and others could be batteries of another vehicle. Observe the operator's
seriously injured. manual. Do not use a quick charger for starting
• To protect the data of the control units, the battery assistance.
may only be disconnected after a minimum waiting • Only tow-start the vehicle with the batteries
time of five minutes after the ignition is shut off. connected
• When disconnecting the batteries, always disconnect • Only quick-charge the batteries after disconnecting
the negative terminal first and then the positive them from the on-board electrical system. Both the
terminal. positive and negative terminals must be
• When connecting the batteries, always connect the disconnected.
positive terminal first and then the negative terminal.
• Incorrect polarity of the supply voltage can cause
irreparable damage to the control units.
---------------------------------------------------------------------------
Lines, electrical connectors and control units probes, wire ends, etc.). This may lead to contact
• Electrical connectors must not be unplugged from or problems due to the formation of transitional
plugged into the control units while the ignition is on. resistance. Use suitable test lines.
• Lines must be protected from heat by means of • Electric lines are to be routed from the chassis to the
appropriate insulation. cab only via the electrical connectors provided at the
connecting point in order to allow subsequent
• Chafing of electric lines must be avoided. removal of the cab.
• The cable lugs used must conform to DIN46234 or a • When performing drilling or other chip removing work,
technically equivalent quality. the shavings or chips produced must always be fully
• Route cables in such a way that chafing cannot cleared away to protect the wiring harnesses.
occur, particularly at crossover points and sharp • The air intake louvers on the electrical compartment
edges. If necessary, use line ducts or guide tubes. must never be closed off. They must remain open
• Consultation with the TE/ORB-B department is and clear at all times.
required for the aftermarket installation of a battery • Avoid fastening high-current electric lines directly to
main switch. the high-frequency lines of the CAN bus and signal
• Never attach electric lines to battery lines, brake lines (twisted wires).
lines, a compressor line, hydraulic lines and • The use of in-line fuses, insulation connectors
compressed-air lines. (insulation piercing connectors), etc. is to be avoided.
• Do not carry out measurements at the contacts of We recommend using the approved parts and tools
electrical connectors using unsuitable tools (test described on the following pages.
---------------------------------------------------------------------------
Tapping of lines to control units e.g.about the tachograph signal and supply lines, is
It is prohibited to tap lines to control units. The control available at the interfaces provided.
unit could malfunction. Required information such as,
---------------------------------------------------------------------------
Power tap for auxiliary consumers – model 405, 437 document "Electric interfaces". On vehicles without
For electrical connection of consumers with a current an equipment socket, currents of less than 40 A can also
requirement of up to 40 A, use a 32-pin equipment be tapped at the power distributor.
socket (code E87).
For currents higher than 40 A, use the power distributor.
For detailed information on the power distributor, see
---------------------------------------------------------------------------
Cable set design/fuses • Do not connect additional consumers to fuses
Basic information: already assigned.
• All components such as fuse holders, electrical • Do not connect additional lines, e.g.with insulation
connectors, cable lugs and connections must be displacement terminals, to existing lines.
designed for the respective maximum current. • Provide sufficient protection for consumers using
• The fuse should be positioned as close as possible to additional fuses.
the power tapping point.
• The continuous current load should not exceed
70%of the rated fuse value.
---------------------------------------------------------------------------
Maximum load capacity


Load capacity of insulated lines with copper core based on VDE 0298-4 (3 groups)
VDE 0298-4; Group 1 VDE 0298-4; Group 2 VDE 0298-4; Group 3
Nominal cross- Load capacity Fuse protection Load capacity Fuse protection Load capacity Fuse protection
section
mm² A A A A A A
0.5 - - 7 5 - -
0.75 - - 13 10 16 16
1 12 10 16 16 20 20
1.5 16 16 20 20 25 25
2.5 21 20 27 25 34 30
4 27 25 36 30 45 50
6 35 35 47 40 57 50
10 48 40 65 60 78 70
16 65 63 87 80 104 100
25 88 80 115 100 137 125
35 110 100 143 125 168 150
50 140 125 178 160 210 200
70 175 160 220 200 260 250¹⁾
95 210 200 265 250¹⁾ 310 300²⁾
120 250 250¹⁾ 310 300²⁾ 365 350²⁾

1) Power tap with time limit:
On vehicle model designation 963/964, limited to max.60s
On vehicle model designation 967, limited to max.15s
2) Not permissible; power tap greater than max. permissible
The voltage drop in the conductors must be taken into should be avoided because of the low strength of the
consideration when defining conductor cross-sections. If conductor. The positive and negative line must have the
the voltage drop is too large, the conductor may heat up same cross section. Information is available in
and this may result - under certain circumstances - in a specialized literature with regard to the electrical
cable fire. Conductor cross-sections of less than 1 mm² conductors to be used or about their particular suitability.
---------------------------------------------------------------------------
Additional information Group 3:
Group 1: • Single-core lines installed in exposed state with a
• One or more single-core lines installed in tubing, not gap at least equal to the line diameter between lines
normally used in vehicles and single-core lines in switching/distribution
equipment and busways.
Group 2:
• Multi-core lines, e.g.jacketed lines, moving lines
Networking
i
Depictions, code scopes and pre-installations for
other vehicle model designations and model series
---------------------------------------------------------------------------
Advanced signal acquisition and actuation module • Interior lighting
(ASAM) control unit • Lighting functions of the exterior lighting
The advanced signal acquisition and actuation module • Reading in of the fill level sensor
(ASAM) control unit is an electronic unit that is
connected to other control units over a CAN data bus • Switch modules in instrument panel
system. The following functions are realized over the • Cab power distributor monitoring (Cab PDU)
ASAM, e.g. :
• Power take-off control NA1, at transmission end
• Wiper control
• Processing of large logical blocks
• Terminal control
The information is distributed over the CAN bus systems
• Body manufacturer interface by the central gateway (CGW) control unit.

Model series 956

The ASAM central control unit is located in the
electronics compartment (electrical compartment)
behind the driver's seat.
W54.00-A069-81
Installation location for ASAM (A7) in electrical compartment
behind driver's seat (shown on model series 956)
Networking
Model series 963, 964, 967, 983
The ASAM is located behind the footwell trim on the
front passenger side and is also known as the electrical
compartment.
All-wheel drive vehicles always have the SAM with
additional functions (XMC) installed as an extra.
1 ASAM cover
W54.00-A021-11
Location of electrical compartment (shown on model series 963,
964, 983)
The integration of other control units or electronics

modules in the CAN bus architecture of the vehicle is
only possible through the XMC control unit available as
special equipment or the functions of the CGW control
unit.
Other connections or CAN bus signal taps are not
permitted.
W15.00-A001-11
Electrical compartment (shown on model series 963, 964, 983)
Battery line, low voltage
aDanger
i
Potential risk of fire when the vehicle is in use due to
heating of the battery lines:
Failure to observe the relevant specifications or
improper implementation of them can increase the
transitional resistances.
---------------------------------------------------------------------------
Battery lines, low voltage The overall length of both battery lines (positive and
Aluminum battery lines must not be shortened or negative) must always be taken into account. In other
extended. Copper battery lines may not be lengthened. words, the length of the line from the battery positive
The existing line must be replaced with a new one of the terminal to the power distributor, plus the length of the
desired length. Only genuine Mercedes‑Benz wiring line from the coupling housing stud to the battery
harnesses and cable lugs are allowed to be used. All negative terminal.
connections must be firmly connected.
The required minimum line cross-section must be
chosen as per the following table depending on the
required length of battery lines.

Table of copper lines
Cable cross-section of copper line Cable cross-section of aluminum Overall length [mm]
[mm²] line [mm²]
70 120 ≤ 9200
95 160 > 9200
Direct tapping from battery lines is not permissible, either Potential distribution is only permissible at the intended
by cutting open the lines or by using commercially points (see document "Electrical consumers up to
available potential distributors. 250 A in total").
Installation of indicator/warning lamps in instrument cluste...
aDanger
Remove/install instrument cluster control unit (ICUC)
i
For standardization reasons, this chapter uses
diagrams, code scopes and pre-installations from
other model designations and model series. Use
only the information valid for your model designation/
model series.
---------------------------------------------------------------------------
Installation of indicator/warning lamps, hard wired, A sheet (A 002 584 44 38) with various symbol panels
in Classic Cockpit instrument cluster (sales can be ordered from the Mercedes-Benz Service
code J6A) Partner. The symbols are perforated and can be stuck
Up to five indicator lamp positions (see 6 in the figure onto the symbol panel individually as required.
below), which can be fitted with the corresponding The lamps are supplied with power via a pulse width
symbol panels using the symbol panel A 960 446 47 21, modulated signal at the instrument cluster. The output is
are available to the body manufacturer (the symbol dimmable and can be loaded with a total power of 10 W
panel and socket with bulb must be retrofitted). (all five lamps together). The indicator lamps are
Exception: With pre-installation for trailer coupling, sales switched by a ground circuit, e.g., by means of a switch
code Q9A (model series 963, 964 only), the symbol on the body.
panel and the indicator lamp for the trailer coupling are If pre-installed at the factory, the dumper indicator lamp
fitted into the instrument cluster at the factory and they and the indicator lamp for the cargo liftgate are shown in
can be connected to plug X177.4 Pin 1 in the area of the virtual indicator lamp (see 5 in the figure below) in
the trailer sockets. the bottom left part of the display.

A1 Instrument cluster
(ICUC) control unit
A1 p1 Multifunction display
1 Main menu, menu bar
2 Submenu menu bar
3 Text bar
4 Menu and event
window
5 Virtual indicator lamps
6 Installation locations W54.30-A059-04
(for additional indicator Additional indicator/warning lamps
lamps)

Mercedes-Benz item numbers for body manufacturer indicator lamp positions
Component part Item number Description
Socket A 000 545 33 19 2-pin
Bulb N 049846 000001 24 V/0.03 A
Sheet with symbols A 002 584 44 38
Symbol panel A 960 446 47 21 2x yellow, 2x red and symbols for trailer
coupling (center)
Symbol panel A 960 446 97 21 2x yellow, 2x red and symbols for trailer
coupling (left)
N54.30-A002-71 N54.30-A004-71 N54.30-A003-01

Symbol panel (part number Instrument cluster with retrofitted symbol Symbol panel (part number
A 960 446 47 21) panel (part number A 960 446 47 21) A 960 446 97 21)
W54.30-A100-80
Symbol lens (part number A 000 584 98 21)
Installation/removal instructions for model series 963/964 instrument cluster
from the Workshop Information System:
AR54.30-W-7100H
Installation/removal instructions for model series 956 instrument cluster
from the Workshop Information System:
AR54.30-W-7100NE
N54.30-A005-03
Curved section with symbol panel (part
number A 002 584 44 38)
If all slots are occupied, in

exceptional cases it is possible to
attach an indicator lamp to the switch
panel. The function of the lamp(s)
must be permanently and clearly
identifiable, e.g., with an appropriate
pictogram or label.
N54.30-A006-71 N54.30-A007-71
Correct: An indicator lamp with an Incorrect: Indicator lamp was installed in
appropriate pictogram could be installed trim; and trim was damaged as a result
thus on a switch panel. (pictogram would be OK).
Indicator lamp circuit example on model series 956

On vehicles with the "Wiring harness pre-installation for
body manufacturer, sales code E9C", the pulse width
modulated signal should be picked up at the body
manufacturer interface X74 pin 18 in the electrical
compartment behind the driver's seat. The power supply
can be connected with the respective pin of the indicator
lamp at the body plug X71.
The lamp is activated via a switched ground connection,
which must be created at the respective pin of the cab/
chassis body plug X74 in the electrical compartment.
1 Body function switch
2 Scope with code E9C
3 Body manufacturer scope
A1 Instrument cluster
A2 Body function indicator lamp W54.30-A101-81
FF-X74.18 Cab/chassis connector (only for Indicator lamp circuit example
code E9C)
FF-X71.18 Cab/chassis connector (only for
code E9C)
W54.30-A053-77
Illustration of principle of actuation of virtual indicator lamps and body warning messages
1 ABH popup warning message A151 Instrument cluster (IC) control unit
2 Configurable virtual indicator lamps CAN 2 Interior CAN
(tell tales)
A2 Central gateway control unit (CGW) CAN 3 Frame CAN
A7 Advanced signal acquisition and actuation CAN 8 Body manufacturer CAN
module (ASAM) control unit
A22 SAM with additional functions (XMC) X11.52 Connector
Multimedia Cockpit, only for model series 963,964, • 10‑inch screen, sales code J6B, Multimedia Cockpit
983 (Sales code J6B, J6C) • 12‑inch screen, sales code J6C, Multimedia Cockpit,
Two variants of instrument clusters with full-screen LCD interactive
screens are offered:

W54.21-A009-78
Front view of the new display
Both variants offer the possibility of showing displays In the digital instrument clusters, up to five positions are
and warning messages (indicator lamps and pop-ups) provided for body indicator lamps. Each position is
virtually on the display. The retrofitting of your own actuated via dedicated inputs. A digital input (active to
lamps in the instrument area is not intended to be ground) at the ASAM or a CAN signal at the XMC is
possible. available for this purpose.
The displays must be parameterized with XENTRY
Diagnosis.

The following table shows the assignment:
Indicator lamp position on Digital input from ASAM CAN signal from XMC
instrument cluster
1 X11.52/02 GPM2B, byte 1, bits 0..1
2 X11.52/17 GPM2B, byte 1, bits 2..3
3 X11.52/04 GPM2B, byte 1, bits 4..5
4 X11.52/24 GPM2B, byte 1, bits 6..7
5 X11.52/22 GPM2B, byte 2, bits 0..1
The document "Equations and parameters", which can Pop-ups can only be activated via CAN signals from the
be accessed in the Mercedes-Benz Bodybuilder Portal, XMC (from GPM2B, byte 2, bits 2..3 to GPM2B, byte 4,
lists all the available symbols and texts that can be used bits 4..5). Each signal controls the associated display
for indicator lamps and pop-ups for bodies and symbol.
detachable assemblies. In addition, a text from the existing database of the
For some pre-installation codes, the digital inputs on the instrument cluster can be parameterized.
ASAM and displays are already configured at the As with the Classic Instrument, in vehicles equipped with
factory: New HMI (J6B/J6C), it is not possible to transfer the
• Cargo liftgate, pin X11.52/02 speed signal from the transmission output to the
• Fifth-wheel coupling lubrication, pin X11.52/17 instrument cluster, if a digital tachograph is not installed.
• Trailer coupling closed/fused, pin X11.52/04
Switches, general information
General information on the modular switch panel • Night design of search lighting (SB): yellow,
• Operating temperature: -40℃ to +85℃ dominant wavelength: 587nm (typical)
• Rated voltage: 24V‑DC • Readiness display (FA): red, fit for daylight,
dominant wavelength: 633nm (typical)
• Supply voltage: 8V...32V
The modular switch panel (MSF) consists of control
• Protection class: IP5K3 in installed state elements (e.g.light switches) and individual rocker
• Rocker color: Deep dark gray, color number: 9174, switches, which are combined in groups of four or in a
luster: 5(±0.5), group of eight in "MSF slaves", and connected to the
SAM.
• Symbol laser-etched, maximum area: 10x10mm
The following pictures show the available switches:
• Illumination:
• Day design: White

W54.25-A028-01
Signal switch
A Connections 1 to 6, only for load switches
W54.25-A029-10
Load switch
A Connections 1 to 3
W54.25-A030-10
Special switches, e.g.Emergency Off

Load switch capacity table
Load type Permissible current strengths
Lamp load 500mA to 5A
Inductive load 500mA to 11A
Ohm load 500mA to 16A
Connection: male spade connector 3x0.8(±0.025)

Designation A-item number
Plug housing A0135456026
Pins/contacts 0.75 to 1.0mm² A0135457526 (items on reel)
A0135457626 (individual items)
1.5 to 2.5mm² A0135457726 (items on reel)
A0135457826 (individual items)
A Readiness display (FA) laser-etched, determine position and

number of readiness displays by wiring diagram
B Limit for lasered symbol (not laser-etched)
C Symbol, laser-etched
W54.25-A031-01
Symbol arrangement
Functional principle of modular switch panel

MSF switches have their own bus system which they
use to receive and transmit signals. There are three
types of switch: signal, load and special switches.
W54.25-A032-11
Functional principle of MSF
Signal switch • The signal switches and the MSF slave modules may
• The MSF master cyclically scans the states of all the be arranged as desired.
individual switches and transmits their status over the • Signal switches may be plugged into the MSF slave
CAN bus. modules or into the MSF master.
• The MSF master receives all the necessary signals • The majority of switches installed in the vehicle are
concerning function indication and search lighting on signal switches.
the CAN bus, and transmits these requests to the
individual switches.
---------------------------------------------------------------------------
Load switch • Load switches may only be plugged into MSF slave
• The load switches allow loads to be switched on and modules, not into the MSF master.
off directly. Load switches do not send a CAN signal about their
• Load switches are also connected via the bus system switching state.
to the MSF master because this is how the dimming Special switches
level for the search lighting is specified.
Special switches have a cap, e.g.EMERGENCY OFF.
• The wiring involved means that the load switches can
be freely arranged to a limited extent only. It may be
necessary to lengthen the load connection.

W54.25-A033-10
MSF master, front
1 Supply and CAN
2 SSL (Stalk Switch Left)
3 Rotary light switch
4 CLPC (Chassis Level Panel Cab, level control
operating unit)
5 Differential lock rotary switch
6 MSF slaves
7 MSF slaves
8 MSF slaves
9 MSF slaves W54.25-A034-10
10 MSF slaves MSF master, pin assignment
11 Vacant
12 SWB (Steering Wheel Buttons)
Available MSF basic switches with symbol

Designation Item number Description
Other make body 1 A0115459507 Latching NO contact (NO latching)
1-pin
1xSB (backlighting)
1xexternal readiness display (external

indicator)
W54.25-A035-04

1-pin
1xSB (backlighting)

indicator)
W54.25-A036-04

1-pin
1xSB (backlighting)

indicator)
W54.25-A037-04

Retrofit 1 A0125450207 Latching CO contact (CO latching)
2x -pin (2x1-pin)
2xSB (backlighting)
2xFA (indicator)
W54.25-A038-04

2x1-pin (2x1-pin)
2xSB (backlighting)
2xFA (indicator)
W54.25-A039-04

1-pin
1xSB (backlighting)
1xFA (indicator)
W54.25-A040-04

Rotating beacon A0115459407 Latching NO contact (NO latching)
1-pin
1xSB (backlighting)
1xFA (indicator)
W54.25-A041-04

Automatic tire chains A0115459607 Latching NO contact (NO latching)
1-pin
2xSB (backlighting)
1xFA (indicator)
W54.25-A042-04

Retrofit axles A0125450507 Latching CO contact (CO latching)
2x1-pin (2x 1-pin)
2xSB (backlighting)
2xFA (indicator)
W54.25-A043-04

Single-circuit hydraulics A0175456107 Latching CO contact (CO latching)
2x1-pin (2x 1-pin)
W54.25-A044-04

Designation Item number Description CAN signal
Retrofit 1, function pins A0115459707 Latching NO contact (NO latching) FctPinSw1_Rq
1-pin
1xSB (backlighting)
W54.25-A045-04

1-pin
1xSB (backlighting)
W54.25-A046-04

1-pin
1xSB (backlighting)
W54.25-A047-04

Retrofit 4, function pins A 0125450007 Latching NO contact (NO latching) FctPinSw4_Rq
1-pin
1xSB (backlighting)
W54.25-A048-04

Retrofit 5, function pins A0125450107 Momentary-action NO contact (NO FctPinSw5_Rq

momentary)
1-pin
1xSB (backlighting)
W54.25-A049-04
A discrete CAN signal is assigned to the signal switches of them to control the relevant function in the same
via the respective switch numbers (1-5). Multiple manner. Multiple installation of the same switch numbers
installation of switches of the same number will cause all should therefore be avoided.
---------------------------------------------------------------------------
Available MSF basic switches without symbol painted black. These switches are intended to enable
Basic switches are switches manufactured without a any symbol to be engraved on them.
symbol. The switch rocker is made of translucent plastic

Basic switch A01354558 07 Latching NO contact,
Latching NC contact (NO NC latching)
2-pin (2-pole)
1 x SB (backlighting)
1 x FA (indicator)
W54.25-A050-04

Basic switch A01354560 07 Latching NO contact (NO latching)
1-pin
1 x FA (indicator)
W54.25-A051-04

Basic switch A01354562 07 Latching CO contact (CO latching)
2 x 1-pin (2 x 1-pin)
2 x FA (indicator)
W54.25-A052-04

Basic switch A01354563 07 Momentary-action CO contact (CO momentary)
2 x 1-pin (2 x 1-pin)
W54.25-A053-04

Basic switch A01354567 07 Momentary-action CO contact (CO momentary)
1-pin
W54.25-A054-04

Basic switch A01354557 07 Latching CO contact (CO latching)
1-pin
W54.25-A055-04
Various caps can be purchased for these basic switches.

These already bear symbols and readiness displays.
The Bodybuilder Portal shows the most up-to-date status
of the available caps (https://bb-portal.mercedes-
benz-trucks.com).
Additional and virtual switches
i
Risk of accident for the vehicle user for safety-
relevant functions:
Do not use the virtual switches for safety-relevant
functionalities.
---------------------------------------------------------------------------
Virtual switches in the secondary display display with touch detection. Numerous multimedia
Vehicles with sales code J6B (Multimedia Cockpit) or functions such as navigation, radio and telephone can
J6C (Multimedia Cockpit, interactive) have a secondary be controlled via the screen.

W54.21-A012-79
Secondary display on instrument panel
The virtual switches partially replace the conventional The virtual switches must be configured or
mechanical signal switches for vehicle operation in the parameterized with XENTRY Diagnosis. Virtual switches
modular switch panel MSF. can be configured in an even number only. An additional
It is also possible to display a total of up to eight virtual switch without function may need to be mapped.
switches for operating bodies.

In order to be able to map the entire range of functions Vehicles that are only equipped with ASAM have a
of the virtual switches, the vehicle must be equipped with maximum of five virtual switches, which can only be
an XMC which, together with the ASAM, acts as an used as pushbutton switches, and can only be evaluated
interface to the body. via function pins.
---------------------------------------------------------------------------
The following five pins are available on the ASAM as • X12‑40/32 (up to 0.7 A)
outputs for virtual switches: The following three pins are also available on the XMC
• X2‑52/39 (up to 0.7 A) as outputs for virtual switches:
• X2‑52/25 (up to 0.7 A) • X2‑52/09 (up to 2 A)
• X2‑52/49 (up to 0.7 A) • X2‑52/07 (up to 2 A)
• X2‑52/44 (up to 0.7 A) • X3‑21/02 (up to 5 A)
For virtual switches, the switch status can be displayed • X1‑40/20
by parameterization via XENTRY Diagnosis with a virtual • X1‑40/28
LED on the switch surface. The XMC is mandatory for
this functionality. • X1‑40/37
Feedback channels for switches 1 to 8: • X1‑40/38
• X1‑40/08 • X1‑40/39
• X1‑40/09 All symbols for virtual body switches from the vehicle
database are listed in the document "Equations and
• X1‑40/10 parameters", which is available in the Bodybuilder Portal.
• X1‑40/19

Emergency stop switch for body

manufacturers in instrument panel
(sales code E5F)
The E5F equipment integrates an
emergency stop switch, wired as far
as the cab/chassis interface, into the
instrument panel. The emergency
stop switch can be used to shut
down the body in an emergency.
The switch functions as a pushbutton
switch, i.e. the emergency stop N82.00-A000-01 N82.00-A001-01
function can be activated simply by Emergency stop switch Installation position of emergency stop
pressing it. It can only be switched switch in instrument panel
on again by unlocking the emergency
stop switch (by turning it).
The wiring of the switch is factory wired up to the cab/chassis interface

(plug X82, pins 20 to 23). Additional wiring must be installed by the body
manufacturer.
The emergency stop switch fitted ex factory prevents any subsequent
disassembly of the instrument panel or the engine tunnel for additional line
installation.
The emergency stop switch may be energized up to max. 200 mA and is
only intended for the use of relays or control unit inputs.
N82.00-A002-03
Connections between emergency stop
switch (NC contact) and cab/chassis
interface
Slot for four additional mechanical switches (sales with up to four additional MSF switches (load and/or
code E5L) signal switches).
With equipment code E5L, an additional switch module
is installed ex factory, which can be used for retrofitting

This also enables a large number of slots for mechanical switches in

combination with the Multimedia Cockpit (sales code J6B/J6C).
The additional switch module is easily accessible for the driver and is
located in the instrument panel.
The connections for signal switches (via LIN bus) are preinstalled ex
factory.
Wiring for the retrofitting of load switches, however, is not available ex
factory.
N82.00-A003-01
Mounting position of the additional switches
in the instrument panel
Cable glands on cab walls
Routing of electric lines, compressed air lines and fuel Page 84
lines
i i
When routing the lines, it is important to make sure When routing lines, it must be ensured that the
that the cover can be mounted again without requirements for routing electrical lines are observed
problem and that the lines are not crushed! Chafe (see document "Routing of electrical lines,
marks must be avoided by means of suitable compressed-air and fuel lines").
measures, e.g. using foam material or similar. Any
installation residue must be removed before the floor
mat is installed.
In the case of cable boots in the cab walls, e.g. for additional headlamps or
rotating beacons, it must be ensured that the cable boots are watertight.
Cable glands with protection class IP 67 and IP 69K or higher must be
used in the case of cable holes that lead directly into the vehicle interior.
These cable glands provide durable protection against water penetration.
In the case of additional work lamps attached to the front of the vehicle,
glands made of rubber can be used, provided that they do not lead directly
into the cab and no risk of water penetration exists.
N60.80-A001-01
Cable glands
No water can penetrate into the cab at this point. No water spots can form
on the roof lining.
N60.80-A000-01
Correct
Here, there is a risk of water penetration, causing damage to the interior

trim of the cab rear panel or corrosion under the floor mats.
N60.80-A002-01
Incorrect
Cable duct into cab

For model series 963 and 964 (Actros and Arocs), the
existing blind plug A 000 998 26 56 (see the following
figure) must be used as the cable gland.

Basic requirements
• Make a hole in the existing blind plug so that cable can be passed
through.
• Seal blind plugs and cables with a suitable corrugated hose (see
example 1).
• Seal the corrugated hose with a suitable heat-shrinkable tube (see
example 2).
• Complete sealing with permanently elastic sealing material is also
possible.
N54.18-A000-01
Blind plug A 000 998 26 56
Insertion of the cables through a

corrugated hose NW 23.5
A 000 546 19 30 is also permissible.
The folding shell-type gland
A 000 546 06 85 is also available as
an alternative for inserting large
plugs.
Cables passed through the blind plug
A 000 998 26 56 to the cab/chassis
panel. Heat-shrinkable tube is used
for sealing.
N54.18-A001-01 N54.18-A002-01
Example 1, correct Example 2, correct
Cable ducting through floor panel electrical lines into the cab through the floor panel on the
If the space available for feeding cables through the cab/ front passenger side. For this purpose, holes can be
chassis connector plate into the electrical compartment drilled into the panel (steering shaft opening intended for
is insufficient, there is the possibility of guiding the right-hand drive vehicles).

Basic requirements
• The drill hole must be given
effective protection against
corrosion.
• Feed-through grommets should
be used for cable ducting into the
cab.
• Watertight cable ducting must be
assured.
Opening is only permissible at the
N54.18-A003-01 N54.18-A004-01
marked areas, otherwise the type-
Example Example
approval certificate for the cab will be
rendered invalid.
Basic requirements
• Before drilling, remove the cover
in front of the front passenger
seat (1) and the water deflector
(2) above it.
• Guide the wiring harness (3) in
the gap between the cover in front
of the front passenger seat (1)
and the floor panel and into the
electrical compartment.
1 Cover in front of the front N60.80-A003-01 N60.80-A004-01
passenger seat Footwell in front of electrical compartment Footwell in front of electrical compartment
(floor covering removed) (cover removed)
2 Water repellent piece
3 Wiring harness
Line entry at A-pillar retrofitted, it is possible to insert the cable directly

To avoid the body manufacturer having to route the line through the driver footwell and into the cab. When doing
from the front passenger footwell to the instrument so, a number of requirements need to be met.
cluster through the cockpit if indicator lamps are

Specifications
• All secured lines only via the cab/chassis connector
plate.
• Only ground lines may be used.
• Pay attention to clearance:
• Operation of the pedal assembly must not be
impaired.
• The cable length must be adapted to enable
tilting of the cab.
N54.18-A005-10
Provide a connecting point on the cable: This area is intended for line entry.
• It is recommended to move this connecting point into
the cab.
• The cab must then again be sealed against water
and dirt.
• No additional holes may be drilled in the cab.
Extending electric lines
When modification work is carried out on Mercedes- If no suitable line extension is available in the Mercedes-
Benz chassis, it may be necessary to extend the electric Benz parts range, a self-fabricated line extension can be
lines. used in the cases listed below.
Always use extensions kits from the Mercedes-Benz
interface parts catalog.

Overview
Cable Number of strands Installation situation/notes Repair or extension
possible?
CAN bus 4 twisted strands Integrated into wiring Replace¹)

harness
Black jacket
CAN bus 2 twisted strands Integrated into wiring 1x extension or repair

harness possible
Without jacket
Brake lining wear sensor 3 twisted strands Separate cables Replace

Black jacket
Brake lining wear sensor 3 twisted strands Integrated into wiring Repair possible
harness
Without jacket
Anti-lock braking system 2 twisted strands Black jacket Replace
Anti-lock braking system 2 twisted strands Integrated into wiring Repair possible
harness
Without jacket
Airbag 2 twisted strands Integrated into wiring Replace

harness
Speedometer line with 4 strands Black jacket Repair possible

MTCO
Antenna line for radio, GPS, Coaxial cable Integrated into wiring Replace
GSM harness
Other cables 1 strand Integrated into wiring Repair possible

harness
High-voltage lines Warning color: orange Replace

1) If no suitable wiring harness is available, e.g. when moving the brake modulator of the rear axle to a different position, a wiring
harness must be prepared using genuine Mercedes-Benz lines and clamping parts. The use of lines from accessory outlets is not
permissible (safety-relevant component).
Observe the following when extending electrical supply • At the ends of the lines, use only plugs that have
lines: been checked and approved for the vehicle model.
• Use only FLR lines with the same cross-section and • Only connect electric lines using junction boxes or
the same basic and identification colors as the extension cables provided specifically for this
standard lines (see also DIN 76722). purpose, and with electrical connectors that have
• The lines must be jacketed with an insulating hose been checked and approved for the vehicle model.
(on vehicles subject to the German regulation • Do not change standard connections, including
concerning the transport of dangerous goods by ground connections.
road, rail and inland waterways (GGVSEB/ADR)).
• If line lengths are changed or if further lines are • Cables for the ABS may only be extended with wiring
installed, water-proofed plugs must be used. harnesses that have been checked and approved for
• If the installation position of electrical or electronic the vehicle model.
components is changed, the length of the electrical All modifications to the wiring harness in the chassis and
cable must be adapted. Small excess lengths for the drivetrain area (except the cab/chassis connecting point)
lines can be compensated for with corresponding must fulfill the protection class specification IP69k.
routing. Excess lengths must not be routed into rings The class of IP40 is specified for the interior of the cab
or loops. (except in the doors). Valid for the doors is the class of
• When routing cables from one side of the frame to IP54.
the other, select one of the existing holes to do so. The body manufacturer must route the lines in such a
An additional hole should only be made when there is way that no moisture can penetrate into the electrical
no other possibility of having a cable gland through connectors.
the frame. The hole is to be given an edge guard to
protect the lines against damage.
When extending electrical signal/CAN lines, observe the
following and the basic specifications listed below:
---------------------------------------------------------------------------
Basic requirements • Extension of a line within a curved section of line is
The following boundary conditions must be met when not permissible.
extending lines: • If multiple lines in a subharness are to be extended,
• The extension of electrical wiring harnesses by the connecting points must be positioned offset
inserting sections is permissible in the cases named relative to each other. The offset between the
above (maximum 2 connecting points). connecting points must be approx. 40 mm.
• If possible, always use electric lines with the same • The repair methods described in the Mercedes-Benz
color coding as the lines to be extended. The original Workshop Information System (WIS) must be used to
colors must always be used in the case of single- connect the individual cables.
colored lines. • Connection of the cables using simple twisted wires
• Extension using lines with a different color coding is or by means of insulation piercing connectors is not
permissible for multi-colored lines if a line with the permissible.
same color coding is not available. In this case, use • If lines on new vehicles were damaged or kinked
labeled plain white lines. during the course of body mounting, they must
• If a different color coding is used, do not attach the always be replaced.
line extensions directly to the electrical connectors • The cable lugs used must conform to DIN 46 234 or a
(allows easier diagnosis in the event of damage). technically equivalent quality.
• Extended lines or wiring harnesses should not be
located in a visible area.

1 Field for identification
N54.18-A006-11
Additional information on extension of electric lines

Mercedes-Benz part numbers for line connectors
Designation Part number
Line connector for cable cross-section up to 4.0 mm² A 001 546 97 41
Line connector for cable cross-section up to 2.5 mm² A 001 546 96 41
Line connector for cable cross section up to 1.5 mm² A 001 546 88 41
Line connector for cable cross-section up to 3.15 mm² (Ø up to 2 mm) A 002 546 16 41
Line connector for cable cross-section up to 1.33 mm² (Ø up to 1.3 mm) A 002 546 15 41
Line connector for cable cross-section up to 0.5 mm² (dia. up to 0.75 mm) A 002 546 14 41
Line connector for cable cross-section up to 0.2 mm² (Ø up to 0.5 mm) A 002 546 13 41
i
Solder sleeve connections
should not be used on cables
that are subject to movement.
N54.18-A007-71 N54.18-A008-71
Crimp-type connector End sleeve
N54.18-A009-71 N54.18-A010-71
Crimp-type connector with neat crimping Connecting points are offset
and sealing (approx. 40 mm); sealed line connectors
used
Relocating the main battery
aDanger
i
Further information (see "Working on the electrical
system → Battery lines" document).
---------------------------------------------------------------------------
Battery boxes can be relocated to a certain extent only. person is required (see "Advice for body
The specifications for charging cables must be complied manufacturers" document). Important standards must
with. be guaranteed in terms of crash safety, and this can only
Battery boxes installed at the factory on the side of the be established during the course of a non-objection
chassis may be installed at a different location on the check.
longitudinal member. Installation on the frame overhang In vehicles equipped with a battery sensor (model series
is not possible. 963, 964), pay particular attention to ensuring that the
Batteries in the rear area (integral rear area) may only sensor is correctly fastened on the negative terminal of
be relocated into a standard side-mounted battery box. the battery.
If the batteries have to be positioned above the top edge

of the frame, the prior consent of the relevant contact

The length and cross-section of lines 1 and 3 between the connector plug
(see figure) and the sensor must not be modified, otherwise the
measurement values will be false.
W54.10-A037-01
Plug connector
Relocating the main battery

PIN Signal
1 +12 V
2 LIN
3 +24 V
The battery sensor mating connector is available under

part number A 028 545 42 26 from your Mercedes‑Benz
Service Partner.

W54.10-A038-03
Extract from wiring diagram
Code E5A/E5B/E5C - Switch no. 1/2/3, other make body electri...
E5A-Switch no. 1, for other make body electrics the FF interface at the X81.15 and X82.40 plugs (model
Pre-installation for the connection of an electrical designation 963.X, 964.x, 983.x), or X63 plug (model
consumer with 24 V supply voltage and a power designation 967.x) behind the front-end flap.
consumption of 15 A in/on cab or body. The switch has a function indicator lamp (LED) that can
The fused electric lines of the 24 V connecting point are signal to the driver whether the connected consumer is
routed from the load switch in the instrument panel up to functional.

Position of electrical connections E5A on FF

interface
Model designation 963.x, 964.x, 983.x

• X81.1: +24 V (tml. 30; RD/VT)
• X81.13: Ground connection (tml. 31; BN)
• X82.14: Function feedback (BN/YE)
The X82.14 pin must be connected to the ground
connection for the switch indicator lamp function.
Model designation 967.x

• X63.7: +24 V (tml. 30; RD/VT)
• X63.8: Function feedback (BN/YE)
The X63.8 pin must be connected to the ground W54.25-A056-81
connection for the switch indicator lamp function. Switch E5A (1) installation location next to steering column
E5B-Switch no. 2, for other make body electrics The fused electric lines of the 24 V connection points are
routed from the load switch in the instrument panel to the
E5C-Switch no. 3, for other make body electrics FF interface on the plug X81.15 and X82.40 behind the
The equipment can be ordered for all chassis of the front-end flap.
Actros 5 & Arocs 5 (BM 963/964) model series
depending on their equipment.
With the pre-installation, electrical consumers with 24 V
supply voltage and a power consumption of up to 20 A
can be connected in/on the cab or body.

Position of electrical connections E5B on FF

interface
• X81.2: +24 V (tml. 30; RD/GY)
• X82.15: Function feedback (BN/GN)
W54.25-A057-81
Switch E5B (2) installation location next to steering column
Position of electrical connections E5C on FF
interface
• X81.3: +24 V (tml. 30; RD/BN)
• X82.16: Function feedback (BN/WH)
When using switch no. 2 (E5B) and switch no. 3 (E5C)
in parallel/simultaneously, only a total current of 20 A
can be tapped for both switches. (Common use of 20 A
fuse).
W54.25-A058-81
Switch E5C (3) installation location next to steering column
E5A-E5C Switch no. 1-3, for other

make body electrics
Circuit diagram of Actros 5 &

Arocs 5 (BM 963.x/964.x)
PE54.18-W-2200-97F
W54.18-A020-06
Atego wiring diagram (BM 967.x)

PE54.18-W-2200-97NHA
W54.18-A109-05
Connection of electrical consumers
Electrics/tap
i i
Depictions, code scopes and pre-installations for Increased risk of accidents and injuries for vehicle
other vehicle model designations and model series operators and external persons due to limited
are listed in this chapter for reasons of operational safety of the vehicle:
standardization. Only use the information valid for Modifications to the electrical system, electronic
your vehicle model designation/model series. components, their software or wiring can impair their
functioning and/or the functioning of other networked
components. Safety-relevant systems in particular
may also be affected.
i Because of this, they may no longer function
Possible damage to control units or fault entries in properly and/or compromise the operational safety of
the system, possible deep discharging of the battery: the vehicle.
At a higher current draw the alternator cannot There is a heightened risk of accident and injury!
prevent battery discharging. A permanently higher Never carry out any modifications to the wiring and
current draw leads to complete battery discharging. electronic components or their software.
Make sure that when power is tapped with the Have all work on electrical and electronic equipment
vehicle at a standstill and the engine shut off, the carried out at a qualified specialist workshop.
state of charge of the battery is sufficient to start the
engine. Observe accident prevention regulations (UVV)
when working on the vehicle and designing the
body.
Observe country-specific guidelines and laws!
---------------------------------------------------------------------------
General Battery terminals and other exposed live parts (e.g. fuse
The following must be observed when retrofitting cubes) must be completely covered using suitable
electrical consumers: components.
Mercedes-Benz offers various sales codes for The use of multiple fuses for protecting various electric
connecting electrical consumers on the vehicle, e.g.: circuits is permissible.
• Pre-installation for electrical equipment, sales The on-board electrical system specification permits
code E9G 10 mAh in the first hour after tml. 15 OFF. After this time,
the value of 0.2 mA must not be exceeded.
• Pre-installation for cargo liftgate control, sales
code E9H If automatic circuit breakers, sales code E2J, are
installed ex factory instead of blade-type fuses, then any
• Pre-installation of body interface, behind cab, sales additional fuses must also be automatic circuit breakers
code E4D (see document "Electrical interfaces → Automatic
Parts installed in the electrical system must be short- circuit breakers").
circuit-proof. If additional inductive resistors are retrofitted
Retrofitted consumers must be protected by adequately (e.g. solenoid valves, relays), the freewheeling current
dimensioned fuses. when switching off must be conducted along a defined
route. For this reason, only solenoid valves and relays
No additional consumers may be connected to factory-
with integrated freewheeling resistor may be used.
fitted fuses.
During retrofits and when work is carried out by body
The cable cross-section must be sufficiently
manufacturers, only relays with freewheeling diodes/
dimensioned for the connected consumer.
resistors may be used.
It is not permissible to connect the electrical ground to
When switched off, relays without a freewheeling path
the chassis (potential-free frame).
can briefly induce voltages of up to 600 V into the on-
No electrical consumers may be connected to the power board electrical system, and by doing so, destroy control
supply of control units. units.
No additional lines may be connected to existing lines The following relay with freewheeling diode/resistor is
(e.g. with insulation displacement terminals). available, for example, from the Global Logistics Center:
The power to 12 V equipment may only be supplied by • A 004 545 75 05 Micro relay (24 V, break contact
means of a voltage converter. Power tapping at just one 10 A / make contact 15 A)
battery is not permissible.
• A 000 982 21 23 Mini relay (24 V, break contact
10 A / make contact 20 A)
• A 003 545 57 05 Mini relay (24 V, 20 A)
Electrics/tap
• A 001 545 54 05 Relay (24 V, 50 A)

W54.00-A011-12
Mini-relay with freewheeling resistor, changeover contact 24V,
A0009822123
• A 12 V trailer socket (adapter) and batteries and

alternators with higher power output are available as
special equipment ex factory.
• The power to 12 V equipment may only be supplied
by means of a voltage converter. Power tapping
directly at the battery or at the terminal clamps of the
battery is not permissible.
• Electrical connection of auxiliary consumers may only
be made at the connections specified by
Daimler Truck AG.
• If additional inductive resistors are retrofitted to
tractor and trailer vehicles, e.g.solenoid valves,
relays, the freewheeling current when switching off
must be conducted along a defined route, otherwise
voltage spikes in excess of 75V can cause damage
to the on-board electronics.
• The use of inductive resistors with a diode as the
freewheeling path is prohibited.
W54.00-A043-12
Mini-relay with freewheeling resistor, changeover contact 24V,
A0045457405
Euro VI vehicles of model series 963 with OM 470 and ‑ Sales code E1U
471 engines are equipped with controlled electric Alternator, regulated 24/30 V/150 A
alternators.
The charging voltage of the alternators is regulated in
‑ Sales code E1T the range from 22 to 31 V depending on the operating
Alternator, regulated 24/30 V/100 A
Electrics/tap
status of the vehicle with the aim of optimizing fuel The parameterization (under function "Operating mode,
consumption and battery life. alternator with LIN bus") takes place in the ASAM control
In combination with auxiliary batteries installed in the unit and can be carried out on site by a Mercedes-Benz
body, temporary interruptions of the charging process Service Partner.
may occur depending on the electronic charge regulator
that is used.
In cases where the charge balance for the auxiliary
batteries is unsatisfactory, it is possible to parameterize
a constant charging voltage of 28.3 V in XENTRY.
---------------------------------------------------------------------------
Basic design for power tapping The operator/user must be informed about these
The overview shows the overall maximum current circumstances using appropriate measures (information
permanently available for auxiliary consumers. label in vehicle, information in operator's manual of body/
attachment).
The specifications are provided for general information
purposes only and the actual values may be lower
depending on the battery status and ambient conditions.

Model series 956, 963, 964
Vehicle status Alternator type Available current [A]
Stationary vehicle; engine operation; >650rpm Alternator 28V/100A, sales code E1N Max. 50A
(standard)
Special equipment with sales code E1M Max. 60A

(28V/150A)
Driving vehicle; engine operation; >650rpm Alternator 28V/100A, sales code E1N Max. 50A
(standard)
Special equipment with sales code E1M Max. 80A

(28V/150A)

BR 967
Vehicle status Alternator type Available current [A]
Stationary vehicle; engine operation; >650rpm Alternator 28V/100A, sales code E1N Max. 50 A
(standard)
Driving vehicle; engine operation; >650rpm Alternator 28V/100A, sales code E1N Max. 50A
(standard)
Electrics/tap
i
Possible damage to the on-board electronics caused
by voltage spikes > 75 V: If inductances
(e.g. solenoid valve, relay) are retrofitted, the
freewheeling current when switching off must be
conducted along a defined route by means of a
resistor. Diodes are not permissible.
---------------------------------------------------------------------------
Electrical consumers up to 10 A in total currents of all additional consumers must not exceed
The cable connector X15 on the cab power distributor in 200 µA. This total includes all additional consumers
the electrical compartment can be used for the power which are supplied via cable connector X15, the positive
supply of retrofitted consumers. power distributor, via the additional pre-installation in the
cab (E9G) or via the 12 V voltage converter.
The current draw of all retrofitted consumers connected
to cable connector X15 must not exceed 10 A. With the ignition switched off, the no-load current limit for
all additional consumers should be reached or undershot
If the respective special equipment is installed, power at the latest five minutes after the shutdown of all
can also be tapped via plug X81-X83 at the cab/chassis additional consumers and after completion of all
interface. necessary run-on functions, e.g. fan, heater, etc.
When all additional consumers have been shut down
and the ignition switched off, the total of the quiescent

Example of tap for additional consumers up to 10A

1 Plug X15 or signal source from connecting point
X81-X83
2 Additional fuse in electrical compartment
(supplied by body manufacturer)
3 Retrofit switch (supplied by body manufacturer)
4 Additional indicator lamp (supplied by body
manufacturer)
W54.00-A012-11
Example of power tap
Electrics/tap
Example of tap for additional consumers up to 10A
1 Plug X15 or signal source from connecting point
X81 and X83
4 Additional lighting/engine (supplied by body
manufacturer)
5 Additional relay (supplied by body manufacturer)
W54.00-A013-11
Additional positive and negative studs at cab

connecting point, Vehicle exterior - with sales
code E9G, Pre-installation for electrical devices
1 Positive terminal (sales code E9G)
2 Negative terminal (sales code E9G)
3 Cab/chassis interface
4 PDM Cab positive and negative supply
connections
- Additional tapping of positive and negative not
permitted
- Loosening of threaded connections not
permissible (except for repair purposes)
5 Plug X15
6 Cab power distributor
W54.00-A022-11
Cab power distributor, view from outside
Plug X15; explanation of cable connector (contact cavity assignment)

The mating connector corresponds to the number A 013 545 60 26.
The contact (1.5...2.5 mm²) corresponds to the number A 014 545 13 26.
W54.00-A023-01
Plug X15 in cab power distributor
Electrics/tap

Explanation of cable connector (contact cavity assignment)
Pin Terminal Max. current draw Minimum cable Fuse position Fuse rating (A)
no. [A] cross-section
Pin1 Tml. 31 ‑ 2.5 mm² ‑ ‑
Pin2 Tml. 15 5 1.5 mm² F04 7.5
Pin3 D+ 7 1.5 mm² F17 10
Pin4 Tml. 31 ‑ 2.5 mm² ‑ ‑
Pin5 (not used) ‑ ‑ ‑ ‑
Pin6 Tml. 30 7 1.5 mm² F16 10
Electrics/tap
aDanger
aCaution
Risk of injury caused by burns to skin and eyes. Risk of Work in well ventilated rooms only. Wear safety glasses
poisoning caused by inhaling fumes when working with with side protection and protective gloves.
heat-shrinkable tubing.
Connection of electrical consumers Page 623
i i
Possible fire hazard during vehicle operation due to Possible risk of fire when the vehicle is in use due to
lines heating up: overloading of lines:
Connecting electrical consumers with high current Due to the ground return conductor, a maximum of
draw can result in lines being overloaded or 200 A (time-limited to 60 s and max. 250 A) in total
becoming very hot. Electrical consumers with a high may be tapped continuously at all aforementioned
current draw must not be supplied or connected connections.
through the terminal studs of the cab/chassis or
through the cab power distributor under any
circumstances, as the wiring or the main supply lines
have a maximum cross-section of 16 mm².
i
Possible water entry into power distributor frame and
thereby possible risk of short circuit and fire:
The electrical connection lines must be routed in
i such a way that the straightest possible exit from the
Possible damage to the on-board electronics due to power distributor frame is achieved over a line length
voltage spikes > 75 V: of at least 50mm. The sealing concept may fail in the
If inductive resistances are retrofitted (e.g. solenoid case of lines that are led out at an angle or that are
valves, relays), the freewheeling current when badly bent.
switching off must be conducted along a defined
route by means of a resistor. Diodes are not
permissible.
i
Possible damage to the on-board electronics:
The conical screw connection of the battery clamp
may not be used for additional components, since a
loss of clamping force may inevitably occur at the
battery clamp. The clamp can slip or fall off.
---------------------------------------------------------------------------
Electrics/tap
Electrical consumers up to 250A in total • Tapping power at the screw bolts of the battery
On vehicles subject to the German regulation concerning terminal is not permitted.
the transport of dangerous goods by road, rail and inland • None of the existing electrical connections may be
waterways (GGVSEB/ADR): separated for connections by the body manufacturer.
The GGVSEB/ADR regulations and country-specific Power tapping for additional consumers in or at the
laws and regulations must be observed! cab
• The additional stud on the battery clamp must be Under the sales code E9G, Mercedes-Benz offers a pre-
used to supply power to electrical consumers with a installation for electrical equipment in the cab with a
high current draw. The additional stud on the maximum current draw of 80 A.
standard battery clamp must also be used for the The terminal studs are located at the cab/chassis
ground connection for currents of over 10A. The connecting point. Do not use the terminal studs in the
installation locations and connection options are cab power distributor.
described in detail below.

Example of power tap for additional consumers

over 10A
1 Plug X15 or signal source of connecting point
X81-X83
7 Additional tml. 30 terminal connector at
additional stud of battery
9 Additional fuse in battery box/power distributor
10 Additional pump (supplied by body
manufacturer)
W54.00-A016-11
Positive power tap (tml. 30) at the power distributor The power distributor at the longitudinal frame member
in/on the battery box is designed for the supply of power
to electrical consumers with a high current draw.

Tap for positive line at positive power distributor
W54.00-A044-11
Example: Power distributor with jump start
Electrics/tap
Installation points
W54.00-A045-10
Installation position: Integral rear area
On semitrailer trucks
• With integral rear area, sales code C7T
• Side battery carrier, sales code C7J

W54.00-A046-11
Installation position: Side battery carrier
On platform/dump truck/cement mixer vehicle chassis

with side battery carrier and batteries side by side, sales
code C7J
W54.00-A047-11
Installation position: Batteries stacked
On all vehicles with batteries stacked, sales code C7K • Minimum cable cross-section requirement (see
Connection options: "Work on the electrical system → Wiring harness
layouts/fuses" document).
Electrics/tap
• Minimum requirement for cable seals specified as per • Cable lugs must be designed for the maximum
Daimler LV 112‑1. The protection class IP 67 6K9K current strength.
must be observed (see "Item numbers of power
distributor panel seals" table).

¹⁾ Depending on the battery position on the vehicle

X1 Batteries or cab power distributor¹⁾
X2 Electric parking air conditioner (EPAC)
X3 Cab power distributor
X4 Aftertreatment Control Module (ACM)
X5 Pre-installation, sales code E9G
X6 Auto Pilot System (APS)
X7 Cab tilt pump
X8 (not used)
X9 (not used)
X10 (not used)
X11 Body manufacturer
X12 Body manufacturer
X13 Starter or cab power distributor¹⁾
X14 Batteries or starters¹⁾ W54.00-A025-11
Power tap for body manufacturers
Connection X12, power tap for body manufacturers The maximum current draw must be observed.
• The tap for positive potential is provided for the body The current tap is permanently max. 200 A. Please also
manufacturer at connection X12 of the power observe the specifications regarding continuous power
distributor panel. The housing outer wall must be tapping (see "Power tapping for auxiliary
equipped with a predetermined fracture point for this consumers" document).
purpose (break through using a blunt punch). After Only fuse links of type SF51 (M8) as per MBN 8820‑5
this, check the housing for damage. Connection X11 may be used (see "Fuse links SF30 and SF51" table).
is also available to the body manufacturer.
• Screw connection of fuse with max. torque of
16 ± 3.2 Nm.
---------------------------------------------------------------------------
Connection X11 Connection X2 to X7
• The current can be tapped at connection X11. • The current tap can be implemented at the
• Screw connection of fuse with max. torque of connections X2 to X7, provided that these have not
8 ± 1.6 Nm. been assigned at the factory.
The current tap is permanently max. 80 A. Please also Technical boundary conditions are the same as for
observe the specifications regarding continuous power connection X11.
tapping (see "Connection of electrical The new power distributor does not need a separate clip
consumers" document). to fix the cable seal in place, as this is already integrated
Only fuse links of type SF30 (M6) as per MBN 8820‑5 in the cover.
may be used (see "Fuse links SF30 and SF51" table).

Electrics/tap

Fuse links SF30 and SF51
Item number Amps
N 000000 006620 150 Midi fuses SF 30
N 000000 006621¹⁾ 200
N 000000 006622¹⁾ 30
N 000000 006623 40
N 000000 006624 50
N 000000 006625¹⁾ 60
N 000000 006626¹⁾ 70
N 000000 006627 80
N 000000 006628¹⁾ 100
N 000000 006629 125
N 000000 006633 25
N 000000 000593 100 Maxi fuses SF 51
N 000000 000594 125
N 000000 000595 150
N 000000 000596¹⁾ 175
N 000000 000597 200
N 000000 000598 225
N 000000 000599 250
N 000000 000600¹⁾ 300

1) The marked item numbers are not installed by Mercedes-Benz and can therefore only be procured from parts distributors.
Electrics/tap

Item numbers of seals for power distributor panel
Item number Connection Outside Color Line cross- Outside line
diameter [mm] section diameter
A 000 016 32 80 X12 24 Green 95 mm² 16.7 (‑1) mm
A 000 016 33 80 X12 24 Blue 70 mm² 14.4 (‑1) mm
A 000 016 34 80 X12 24 Yellow 50 mm² 12.2 (‑0.9) mm
A 960 546 14 86 X12 24 Gray 35 mm² 11.6 (‑1.5) mm
A 960 546 35 86 X12 24 Red 25 mm² 10.4 (‑1.2) mm
A 003 997 90 86 X12 24 Black Blind plug ‑
A 000 016 29 80 X11 18.4 Gray 35 mm² 11.6 (‑1.5) mm
A 960 546 32 86 X11 18.4 White 16 mm² 8.3 (‑0.6) mm
A 960 546 31 86 X11 18.4 Yellow 10 mm² 6.5 (‑0.6) mm
A 960 546 29 86 X11 18.4 Green 6 mm² 5.0 (‑0.6) mm
A 960 546 38 86 X11 18.4 Orange 4 mm² 3.7 (‑0.3) mm
A 960 546 30 86 X11 18.4 Black-gray 2.5 mm² 3.1 (‑0.4) mm
A 960 546 39 86 X11 18.4 Orange 6 mm² 5.0 (‑0.6) mm
A 960 546 40 86 X11 18.4 Gray 4 mm² 3.7 (‑0.3) mm
A 960 998 00 50 X11 18.4 Black Blind plug ‑
Required connection material

Component part
Component part Connection Properties Item number
Hexagon nut X12 ISO 4035‑M 8‑A2‑70 N 304 032 008 011
Spring washer X12 DIN 137‑A 8- N 000 137 008 107

X 12 CR NI 17 7
Hexagon nut X11 ISO 4035‑M6‑A2‑70 N 304 032 006 009
Spring washer X11 DIN 137‑A 6- N 000 137 006 108

X 12 CR NI 17 7
There is a risk of corrosion, short circuits and fire!

Electrics/tap
Richtig: Appropriate fuse used at input X5.
W54.00-A027-11
Falsch: Fuse of type SF51 as per MBN 8820

has not been used.
W54.00-A028-11
Richtig: Seal used at input to power

distributor panel.
W54.00-A029-11
Electrics/tap
Falsch: No seal has been used - risk of water

entry.
W54.00-A030-11
Negative potential tap On vehicles with four axles and sales code C7K, Daimler
Discontinuation of body manufacturer box Truck AG still supplies the ground distributor; however,
this is connected to the batteries via the 6 mm threaded
As of May 2015, the ground distributor at the chassis is pin at the negative terminal.
no longer supplied for many vehicles. The ground
distributor is only being used in vehicles with four axles This means that on vehicles with a ground distributor as
and two front axles with the battery carrier, batteries of production month 05/2015, the permissible total power
stacked, sales code C7K. consumption (with suitable cable lugs and cable cross-
sections) is 200 A. Up to 250 A are permissible for max.
Please note: 60 seconds!
---------------------------------------------------------------------------
Negative power tap (tml. 31) at the battery terminal In both cases, an M6 threaded pin is attached for the
Depending on the equipment, a standard battery clamp connection of electrical consumers.
or a battery sensor is installed directly at the negative
terminal of the battery in the vehicle.

Installation location of batteries
W54.00-A048-11
Battery installation location on semitrailer trucks with integral rear
area, sales code C7T
Electrics/tap
W54.00-A049-11
Battery installation location with side battery carriers and batteries
side-by-side, sales code C7J
W54.00-A050-10
Battery installation location with side battery carriers and batteries
stacked, sales code C7K
Power tap
1 Ground tap for body manufacturers threaded pin
M6
W54.00-A051-11
Battery unit terminal
Electrics/tap
Required connection material for threaded pins:

• Hexagon nut EN 1661‑M6‑8 (N 910112 006001)
• Spring washer: DIN 137‑A 6‑X 12 CR NI 17 7
(N 000137 006108)
• Maximum tightening torque: 7.4 (±1.4) Nm
1 Ground tap for body manufacturers threaded pin
M6
W54.00-A052-11
Battery unit sensor
Ground conducting frame – Model 963 with code will be possible from production month 10.2021 onward
C7T, model 983 to run the ground return conductor over the vehicle
For vehicles in model series 963 equipped with sales frame. On model 983, only the left longitudinal member
code C7T, Integral rear area, and model series 983, it may be used.

W54.00-A105-72
Ground tap in vehicle frame
Electrics/tap
W54.00-A106-80
Stud installation only within frame holes in the center with diameter
17.5 mm
1 Nut M16 x 1.5: A 005 990 78 50 (tightening

torque: 225 Nm)
2 Shim: A 005 990 71 82 (for use with 6 or 7 mm
frame)
3 Knurled stud for frame ground: A 001 990 40 16
4 M10 cap nut, connection for cable lug
W54.00-A107-80
When the knurled stud is inserted from the inside The knurled stud may only be inserted once. If the
outward, the M16 nut and (depending on frame position is wrong, a new knurled stud has to then be
thickness) the shim must be bolted on at the outside. used. If the knurled stud has to be removed, the painting
The M10 cap nut must be bolted on at the inside and of the frame hole used has to be renewed because of
only 1 or no more than 2 cable lugs may be connected. the risk of corrosion.
Installation of relays and fuses in the electrical compartme...
Electrics/tap
i
Possible risk of fire when the vehicle is in use due to
overloading of electric lines resulting from faulty
design:
Use only specified new fuses with the correct
amperage.
---------------------------------------------------------------------------
Installation of relays and fuses in the electrical Use only approved relays! (see document "Electrical
compartment consumers up to 10 A in total").
Depending on the equipment variant, additional relays, If automatic circuit breakers (sales code E2J) are
fuses and diodes may be installed on the outside of the installed ex factory instead of blade-type fuses, then any
electrical compartment carrier (see the document additional fuses must also be automatic circuit breakers
"Working on the electrical system"). The components in cases where Daimler Truck AG is the general
specified below must be used for this. Relay and fuse contractor.
strips fit into all of the assembly frames on the left and
right next to the ASAM or cab power distributor.

1 Assembly frame, 3-row

(Part number:
A 967 545 00 19)
2 Fuse holder
(Part number:
A 942 545 00 60)
3 A31: Micro relay strip
(Part number:
A 942 542 97 40)
4 Cab power distributor control
unit
5 Cube relay strip:
(Part number:
A 961 542 76 40)
6 Assembly frame, 1-row
(Part number: W54.00-A033-05
A 960 545 52 40)
Electrics/tap
Assembly frame, 3-row, part number: A 967 545 00 19
W54.00-A034-11
Assembly frame (see Atego), 1-row, part number:

A 960 545 52 40
W54.21-A106-11
A1: Fuse holder, part number: A 942 545 00 60
W54.00-A035-10
Electrics/tap
A31: Micro relay strip, part number: A 942 542 97 40

A33: Micro relay strip, part number: A 946 542 23 40
W54.21-A105-10
A32 Cube relay strip, part number: A 961 542 76 40
W54.21-A108-10
Automatic circuit breakers This only applies for fuses above 5 A. The following
If automatic circuit breakers, sales codeE2J, are table provides an overview of the automatic circuit
installed ex factory instead of blade-type fuses, then any breakers which can be procured from your Mercedes-
additional fuses must also be automatic circuit breakers. Benz Service Partner:

Automatic circuit breakers
Designation Amps N item number
Fuse module MBN 10243‑R‑5A‑HS 5 N 000000 001659
Fuse module MBN 10243‑R-15A‑HS 15 N 000000 001664
Electrics/tap

Designation Amps N item number
Automatic circuit breaker MBN ISO 5 N 000000 008835

10924‑CB15 C‑Fast‑5

10924‑CB15 C‑Fast‑10

10924‑CB15 C‑Fast‑15

10924‑CB15 C‑Fast‑20

10924‑CB15 C‑Fast‑25
Automatic circuit breaker MINI MBN ISO 5 N 000000 008831

10924‑CB11 C‑Fast‑5
Automatic circuit breaker MINI MBN ISO 10 N 000000 008833

10924‑CB11 C‑Fast‑10
Installation of a mechanical battery disconnect switch
Electrics/tap
Code E9D - Pre-installation, double-pole battery circuit Page 695

breaker
On vehicles with pre-installation for twin-pole battery

i disconnect switch, sales code E9D (see document
Invalidation of registration permit and risk of damage "Code E9D - Pre-installation for bipolar battery
to electronic components: In combination with the disconnect switch"), this line is already installed in the
MirrorCam, code F6T, installation of a mechanical vehicle.
battery disconnect switch is not permitted. After switching off the ignition and before actuating the
battery disconnect switch, the user must wait for a
certain period of time to elapse. On the one hand, this
Installation of a mechanical battery disconnect will ensure fault-free shutoff (sleep mode) of all control
switch units and, on the other hand, will ensure cooling of the
A mechanical battery disconnect switch can be installed AdBlue® injection valve in the exhaust gas aftertreatment
on vehicles which are not equipped with an electronic unit. Various time periods must be observed depending
battery disconnect switch (BESO). on the vehicle equipment and temperature of the
exhaust gas aftertreatment unit. These must be
If a TCO is installed in the vehicle, this must still be described on a sign on the installed battery disconnect
supplied with power even if the power supply is switch.
disconnected. A 1 A fuse is required for the TCO supply.
---------------------------------------------------------------------------
• Engine OM 93x (sales code Z5B, Z5C) The following illustration shows the corresponding
Run-on time: ≥ 5 minutes electrical circuit diagram of the mechanical battery
disconnect switch.
• Engine OM 47x (sales code Z5D, Z5E or Z5F)
Run-on time: ≥ 45 minutes

1 Batteries
2 Fuse 1 A
3 TCO
4 Mechanical battery disconnect switch
5 On-board electrical system
W54.21-A109-01
Electrical circuit diagram of mechanical
battery disconnect switch
The battery disconnect switch must be installed near the • Switching current: 1500 A, at least 250 A
batteries and effectively protected from moisture, splash • Main circuit: Two M10 connections
water and the influence of foreign objects.
• Effective debouncing during switch-on and switch-off
Optionally, the battery disconnect switch with part
number A 000 545 55 08 can be used. The aim of these measures is to prevent damage to the
vehicle control units.
The following should be observed when using a different
switch:
Pre-installations/switches/connections
Electrics/interfaces
Pre-installations/switches/connections Descriptions and connection options for the equipment
Various pre-installations/switches/connections are items are available in the specified circuit diagrams in
available ex factory. Parameterization may be necessary the Mercedes-Benz Bodybuilder Portal.
to activate the pre-installation scopes. (http://bb-portal.mercedes-benz-trucks.com)

Pre-installations/switches/connections (model series 963, 964, 983)
Sales code Electrical interfaces Wiring diagram
E3B Connection 12 V/15 A for auxiliary consumers PE54.10-W-2000-97FG
E4B Fleet management system (FMS) PE82.85-W-2006-97F
E5A Switch no.1 for other make body electrics PE54.18-W-2200-97F
E5B Switch no. 2 for other make body electrics PE54.18-W-2200-97F
E5C Switch no. 3 for other make body electrics PE54.18-W-2200-97F
E9F Pre-installation for 2nd level control operating unit PE54.25-W-2144-97F
E9H Pre-installation for cargo liftgate control PE55.40-W-2000-97FA
E9I Pre-installation for lift axle switch on semitrailer PE31.19-W-2006-97F
J9J Pre-installation for reversing camera PE54.65-W-2102-97F
J9P Pre-installation and display for up to 4 cameras PE54.65-W-2102-97F

Pre-installations/switches/connections (BR 967)
E3B Connection 12 V/15 A for auxiliary consumers PE82.00-W-2201-97NHA
E5A Switch no.1 for other make body electrics PE54.18-W-2200-97NHA
E5D Main switch, electrical accessories PE54.18-W-2200-97NHA
E9H Pre-installation for cargo liftgate control PE55.40-W-2000-97NHA
J9J Pre-installation for reversing camera PE54.65-W-2102-97NHA
Pre-installations/switches/connections

Pre-installations/switches/connections (model series 983)
E3B Connection 12 V/15 A for auxiliary consumers PE54.18-W-2200-97X
E4B Fleet management system (FMS) PE82.85-W-2006-97X
E5A Switch no.1 for other make body electrics PE54.18-W-2200-97X
E5B Switch no. 2 for other make body electrics PE54.18-W-2200-97X
E5C Switch no. 3 for other make body electrics PE54.18-W-2200-97X
E9F Pre-installation for 2nd level control operating unit PE54.25-W-2144-97X
E9H Pre-installation for cargo liftgate control PE55.40-W-2000-97X
E9I Pre-installation for lift axle switch on semitrailer PE54.18-W-2200-97X
J9P Pre-installation and display for up to 4 cameras PE54.65-W-2103-97X
W54.21-A119-11
Main switch for electrical auxiliary consumers on battery box, sales
code E5D (BR 967)
ASAM function pins
Interfaces on cab-chassis connecting point (FF)
Interfaces on cab-chassis connecting point (FF) Page 652
ASAM function pins • Input condition 2: Retrofit switch 1¹⁾ (CAN) actuated
Upon customer request, further functions can be • Logic operation type: AND
implemented by a Mercedes-Benz Service Partner at the • Input condition 3: Not used
ASAM via the four function pins at plug X2 (X2 52/39,
X2 52/25, X2 52/49 and X2 52/44). The CAN-capable • Input condition 4: Not used
retrofit switches 1 to 5 and CAN events can be used for X2 52/49
this.
• Input condition 1: Retrofit switch 2²⁾ (FCAN) actuated
Function pins may be loaded with max. 0.7 A.
• Input condition 2: Not used
These are pre-programmed in the as-delivered state as
• Logic operation type: OR
follows:
• Input condition 3: Not used
Information concerning the positioning of plug X2 in the
ASAM (see document "Interfaces at the cab-chassis • Input condition 4: Not used
connecting point"). X2 52/44 (pin is already in use on vehicles with pre-
X2 52/39 (In vehicles with sales code L9C installation for cargo liftgate control, sales code
E9H)
‑ Pre-installation for additional headlamps, roof, the
pin is already in use) • Input condition 1: Not used
• Input condition 1: High beam (FCAN) actuated • Input condition 2: Not used
• Input condition 2: Retrofit switch 1¹⁾ (FCAN) actuated • Logic operation type: OR/AND
• Logic operation type: AND • Input condition 3: Not used
• Input condition 3: Not used • Input condition 4: Not used
• Input condition 4: Not used ¹⁾ Part number of retrofit switch 1: A 011 545 97 07 as
locking push-button switch: Since the switch is a locking
X2 52/25 (in vehicles with sales code L9C
switch, the switch position serves as feedback.
‑ Pre-installation for additional headlamps, roof, the
²⁾ Part number of retrofit switch 2: A 011 545 98 07 as
pin is already in use)
locking push-button switch: Since the switch is a locking
• Input condition 1: Standing lights (FCAN) actuated switch, the switch position serves as feedback.

ASAM function pins
A Switch signal
B Switch signal
C Other function signals
D FCAN
E Potential pin tml. 30 (PDM
Cab X15 6/6), max. amps
(see document "Electrical
consumers up to 10 A in
total")
F Function pin 1 (X2 52/39)
Function pin 2 (X2 52/25)
G Additional headlamps
2 ASAM
5 CAN W54.21-A093-05
6 FCAN result Example of the use of function pins (current draw of operating circuit max. 10 A)
(parameterizable)
7 FCAN result
(parameterizable)
8 Yes/No
9 Or/And
10 FCAN result
(parameterizable)
11 FCAN result
(parameterizable)
12 Yes/No
13 Or/And
14 Or/And
15 Yes/No
16 Yes/No
ASAM function pins
A Switch signal
B Other function signals
C FCAN
D Voltage tap, negative (tml.
31)
E Additional ground line
F Clamping connection, tml. 31
at PDM Cab
G Function pin 1 (X2 52/39)
H Voltage tap, positive (tml. 30)
K Additional fuse in electrical
compartment
L Auxiliary pump W54.21-A094-05
2 ASAM Example of the use of function pins (current draw of operating circuit over 10 A)
5 CAN
6 FCAN result
(parameterizable)
7 FCAN result
(parameterizable)
8 Yes/No
9 Or/And
10 FCAN result
(parameterizable)
11 FCAN result
(parameterizable)
12 Yes/No
13 Or/And
14 Or/And
15 Yes/No
16 Yes/No
Standard rpm and vehicle speed signal at plug X2
Interfaces on cab-chassis connecting point (FF) Page 652
SAM with additional functions (XMC) and body/trailer Page 665

CAN
Standard rpm and vehicle speed signal at plug X2 checked and, if necessary, adjusted on the ASAM
If the vehicle is not equipped with a SAM with additional control unit. Your Mercedes-Benz Service Partner can
functions (XMC) (see document "SAM with additional assist you with this.
functions (XMC) and body/trailer CAN"), the rpm or The parameters are to be adjusted using XENTRY.
vehicle speed signal can be tapped at plug X2, pin 51 The possible settings are given in the information
(see document "Interfaces at the cab-chassis window within the parameterization.
connecting point"). For this purpose, the parameters
concerned (interface for body manufacturers) must be

Rpm signal
• Signal type: "Frequency"
PPM signal
Frequency:
Pulse width:
T = 400 μs
• Distance pulse count: 1
• Limp-home rpm: 0
W54.21-A110-01
The signal can be changed as follows by a Mercedes-Benz Service

Partner:
• Signal type: "Alternator"
• PPM signal
Frequency:
W54.21-A111-01
Standard rpm and vehicle speed signal at plug X2
Pulse width:
The following parameters can be entered for limp-home mode:
• Range of values:
0‑4000 rpm
• Value resolution:
0.16 rpm
W54.21-A112-01
Vehicle speed signal

• PPM signal
Frequency
Pulse width:
T = 2 ms
The following parameters can be entered for limp-home mode:
• Range of values:
0‑125 km/h (0‑77.5 mph)
• Value resolution: W54.21-A113-01
0.5 km/h (0.3107 mph)

The same function is offered in the XMC on pin X2 52/10. This means that
if it is necessary to use both signals, the XMC must be ordered and the
corresponding parameterization must be adapted in both control units.
A7 ASAM in electrical
compartment in front of front
passenger seat
W54.21-A040-76
Cab-chassis (FF) and ASAM body interfaces connections" and "Pre-installations for the
The relevant body signal pins are listed in this document. attachment of lamps" document).
For a detailed description of the functions, see electrical The following table shows a summary of all relevant
circuit diagrams (see "Pre-installations/switches/ body pins on the ASAM:


PIN Function Max. power tap (A) Minimum
cable
cross-
section
X2‑52/4 Stop lamp 2 1 mm²
X2‑52/8 Terminal 58 2 0.75 mm²
X2‑52/10 Left turn signal lamp²⁾ 1 0.75 mm²
X2‑52/11 Right turn signal lamp²⁾ 1 0.75 mm²
X2‑52/25 Function pin 2 0.7 0.5 mm²
X2‑52/49 Function pin 3²⁾ 0.7 0.5 mm²
X2‑52/51 Rpm or speed signal 0.05 0.5 mm²
X2‑52/52 Reversing lamp 2 0.75 mm²
X9‑6/6 Trailer stop light (redundant) 4 1 mm²
X10‑52/8 Trailer ABS plug¹⁾ 0.02 0.5 mm²
X10‑52/41 Trailer stop lamp 4 1 mm²
X11‑52/2 Virtual indicator lamp 1¹⁾ 0.02 0.5 mm²
X12‑40/32 Virtual switch output 0.7 0.5 mm²

¹⁾ Input pins, or no current tap, but maximum current present
²⁾ Only installed in ASAM high version, including with sales codes E4C, E4D or L9D
W82.00-A000-12
ASAM control unit and positioning of the relevant body plugs
Contact socket for plugs X2, X10, X11 and X12: A 005 545 76 26 (0.50 to
0.75 mm²)
W54.21-A125-01
Contact socket for plug X9: A 014 545 11 26 (0.5 to 1.0 mm²)
W82.10-A029-01
W82.00-A001-05
Pin assignment on cab/chassis connector plate - left-hand drive vehicles
W82.00-A002-05
Pin assignment on cab/chassis connector plate - right-hand drive vehicles
The following table shows a summary of all body-

relevant pins at plug X43 of the cab-chassis interface
depending on the vehicle's equipment code:


Pin Function Code Wire size range Technical information
1 Camera 4: J9P 0.5 mm² Connected at Video Switch (A163) X1-40/1

Shield

Video-in

Shield

Video-in
5 - - - -

Power¹⁾

Power

Power

Power

Power

Video-in

Shield

Video-in

Shield
15 - - - -

GND¹⁾
17 Camera 4: GND J9P 0.5 mm² Connected at Video Switch (A163) X1-40/17
21 - - - -
22 - - - -
23 - - - -
24 - - - -
25 - - - -
26 Function pin J9P 0.5 mm² Connected at Video Switch (A163) X1-40/26
IN5¹⁾
IN3¹⁾
IN1¹⁾
29 - - - -
30 - - - -
OUT4¹⁾
OUT3¹⁾
OUT2¹⁾
OUT1¹⁾
OUT5¹⁾
36 - - - -
IN4¹⁾
IN2¹⁾
39 - - - -
40 - - - -
1) These pins are assigned ex works and connected with the Video Switch; nevertheless, they have no function and should not be
considered for body systems
Plug X43: A 009 540 30 81

Contact socket: A 005 545 76 26 (0.50 to 0.75 mm²)
N82.60-A000-01

relevant pins on plug X81 of the cab-chassis interface

1 Switch for other E5A/E5B/ 1.5 mm² Max. current draw 9 A at cab power distributor (A8)
make body E5C X5-21/3
electrics 1
2 Switch for other E5B/E5C 1.5 mm²

make body
electrics 2
Max. current draw 15 A for both pins at cab power
distributor (A8) X6-21/9
3 Switch for other E5C 1.5 mm²
make body
electrics 3
4 Weld XR-Int¹⁾ E3W 0.75 mm² Connected at battery package 2 (A402b) X1/20
5 Weld XR-Int¹⁾ E3W 0.75 mm² Connected at battery package 2 (A402b) X1/21
6 Terminal 30c (12 E3W 0.5 mm² Max. current draw 1 A at cab power distributor (A8)
V)¹⁾ X8-24/3
7 Terminal 31 (GND E3W +- 0.5 mm² Connected to the interface at the front passenger dash
for tml. 30c 12 V)¹⁾ E4D support ground point
8 - - - -
9 - - - -
10 12 V interface E3B 1.5 mm² Max. current draw 18 A at voltage converter (T1) X1-9/3
11 12 V interface E3B 1.5 mm² Ground for pin 10 at voltage converter (T1) X1-9/2
12 - - - -
13 Switch for other E5A/E5B/ 1.5 mm²

make body E5C
electrics 1
14 Switch for other E5B/E5C 1.5 mm²

Connected to the interface at the front passenger dash
make body
support ground point
electrics 2
15 Switch for other E5C 1.5 mm²

make body
electrics 3
1) Exclusively for vehicle model 983
Plug X81: A 013 545 63 26
Contact 0.50 to 1.00 mm²:
A 014 545 11 26
A 014 545 13 26
W54.00-A067-05



1 2nd level control E9F +- 0.5 mm² Connected at ASAM (A7) X10-52/16
operating unit I6W
operating unit I6W
operating unit I6W
4 Alarm system with F8Z 0.5 mm² Connected at the anti-theft alarm system (A6) X1/20
interior sensing¹⁾
5 - - - -
6 - - - -
7 External intermediate E3W 0.5 mm² Connected to the switch supply dash support
transmission interface
8 External intermediate E3W 0.5 mm² Max. applied current 0.02 A at XMC (A22) X1-40/20
transmission
9 External intermediate E3W 0.5 mm² Max. applied current 0.02 A at XMC (A22) X1-40/19
transmission
10 Tachograph additional J1O/J1Q/J 0.5 mm² Connected at tachograph (P1) D1

recorder 1 1R/J9R
11 Tachograph additional J1O/J1Q/J 0.5 mm² Connected at tachograph (P1) D2

recorder 2 1R/J9R
12 - - - -
13 - - - -
14 Switch for other make E5A/E5B/ 0.5 mm² Max. current draw 9 A at cab power distributor (A8)
body electrics 1 E5C X5-21/3
15 Switch for other make E5B/E5C 0.5 mm²

body electrics 2
Max. current draw 15 A for both pins at cab power
distributor (A8) X6-21/9
16 Switch for other make E5C 0.5 mm²
body electrics 3
17 Reversing camera¹⁾ J9J 0.75 mm² Max. current draw 6 A at cab power distributor (A8)
X2-40/23
18 Reversing camera¹⁾ J9J 0.75 mm² Connected to the interface at the front passenger
dash support ground point
19 Reversing camera¹⁾ J1C + J2H 0.75 mm² Max. current draw 6 A at cab power distributor (A8)
+ J9J X2-40/33
20 Emergency stop E5F 0.75 mm² Max. available current 0.02 A at emergency stop
switch switch (S99) X1-4/1
21 Emergency stop E5F 0.75 mm² Max. applied current 0.02 A at emergency stop
24 Reversing camera¹⁾ J1C + J2H 0.75 mm² Connected to the interface at the front passenger
+ J9J dash support ground point
25 - - - -
26 - - - -
27 - - - -
28 Coupling, remote- G5F + G5 0.5 mm² Max. available current 0.02 A at XMC (A22)
controlled G + E3W X2-52/39
29 Coupling, remote- G5F + G5 0.5 mm² Max. applied current 0.02 A at XMC (A22) X2-52/36
controlled G + E3W
30 Reverse gear lock S5I + E3W 0.5 mm² Max. applied current 0.02 A at XMC (A22) X2-52/51
31 Reverse gear lock S5I + E3W 0.5 mm² Max. applied current 0.02 A at XMC (A22) X2-52/26
32 - - - -
33 - - - -
34 - - - -
35 - - - -
36 - - - -
37 - - - -
38 - - - -
39 - - - -
40 - - - -
1) Exclusively for vehicle model 963, 964
Plug X82: A 009 540 30 81

Contact socket: A 005 545 76 26 (0.50 to 0.75 mm²)
N82.60-A000-01



1 Left turn signal L9B/E4D/ Max. current draw 1 A at ASAM (A7) X2-52/10
lamp E4C 0.5 mm²
2 Right turn signal L9B/E4D/ Max. current draw 1 A at ASAM (A7) X2-52/11
lamp E4C 0.5 mm²
3 Terminal 58¹⁾ L9B/E4C

0.5 mm²
For both pins max. current draw 2 A at ASAM (A7)
X2-52/8
4 Terminal 58¹⁾ L9B/E4C
0.5 mm²
5 Additional L9B Connected to the interface at the center dash support

headlamps¹⁾ 2.5 mm² ground point
6 Additional L9B Max. current draw 3 A at ASAM (A7) X10-52/45

headlamps¹⁾ 0.75 mm²



10 Tail lamp E4D/E4C For all pins max. current draw 2 A at ASAM (A7)
0.5 mm² X2-52/52
11 Taillamp¹⁾ (E4D/E4C)
+J9J 0.5 mm²
J9J+-E4D
+-E4C
12 Taillamp¹⁾ J1C+J2H
+J9J 0.5 mm²
13 Stop lamp -E4C+E4D 0.5 mm² Max. current draw 2 A at ASAM (A7) X2-52/4
E4C+
(J1V/J8W)
E4C+-
(J1V/J8W)
14 Trailer stop light E4C 0.5 mm² Max. current draw 4 A at ASAM (A7) X9-6/6
(redundant)
15 - - - -
1) Exclusively for vehicle model 963, 964
Plug X81: A 013 545 63 26

A 014 545 11 26
A 014 545 13 26
W54.00-A067-05
SAM with additional functions (XMC) and body/trailer CAN
Connection of control units with ISO 11898 Page 671
i i
Depictions, code scopes and pre-installations for Possible auto-down feature during vehicle operation
other vehicle model designations and model series and associated loss of control of vehicle:
are listed in this chapter for reasons of When the automotive engine is started by means of
standardization. Only use the information valid for an external request via the ASAM or XMC, it
your vehicle model designation/model series. switches itself off automatically according to the time
value of 30 minutes stored in the electronic ignition
lock (EIS) at the factory. This value can be increased
up to 14 hours by means of parameterization via the
XENTRY diagnostic system. The setting is to be
adjusted to suit the relevant requirements of the
body application. Unnecessarily long switch-off
intervals in combination with the engine idling can
have a negative effect on the charge balance of the
starter battery. A general driving operation with the
externally started engine is not permissible due to
the stored switch-off function. Formulate the
operator's manual accordingly and attach
information labels.
---------------------------------------------------------------------------
SAM with additional functions (XMC or PSM2) and • Outputs, e.g. pulse-pause-modulated engine speeds
body/trailer CAN • CAN bus-compatible control units in bodies or trailers
To give body manufacturers the ability to access The XMC control unit is connected to the frame CAN
individual CAN bus data, the XMC was developed and is and therefore has access to all messages sent by the
available under PSM, 2nd generation, sales codeE3W. linked control units (e.g. idle throttle switch active,
The CAN interface of the body CAN is designed in parking brake active, service brake active, vehicle speed
accordance with the standard ISO 11898; the CAN C3, engine speed).
interface of the trailer CAN is designed in accordance On the other hand, individual signals can also be
with the standard ISO 11992. monitored or generated at analog and digital inputs and
The XMC can read data from the high-speed CAN bus outputs.
messages and translate this data e.g. into switching Example
signals at the outputs provided (output to "high" or "low")
or into pulse width modulated (PWM) signals which can The drive control (CPC) control unit sends the rotational
be used by the body electronics. speed in a message, which can be read by the XMC
control unit. The XMC control unit converts the engine
The XMC provides a clearly defined, diagnostics- speed information into a pulse-pause modulated (PPM)
compatible and EMC-tested (electromagnetic signal and makes this available at an output.
compatibility tested) interface between the vehicle and
the body. The cabling on the vehicle must not be In the opposite direction, the XMC can convert the
tampered with, as this would lead to error messages position of a hand-throttle actuator into a high-speed
from the other control units on the CAN bus. CAN message and thus request the desired rotational
speed.
Examples of customer-specific requirements here are:
• Inputs, e.g. external engine start and stop

W54.00-A070-81
Installation location for XMC/PSM2 (A22) in electrical
compartment behind driver's seat (shown on model series 956)
W82.00-A003-11
Installation location for XMC in electrical compartment (shown on
model series 963, 964, 983)
If the vehicle is equipped with an automated manual When a start-off gear is engaged, the transmission
transmission and a transmission power take-off, it is changes to the appropriate "splitter box" of the selected
possible by means of parameter modifications in the start-off gear regardless of the settings in the ASAM.
ASAM control unit to shift the desired "splitter box" (low/ This functionality must be taken into account in your
high) in the transmission automatically when the power design.
take-off is engaged.
Please note that this function is active only when the
vehicle is at a standstill and the transmission is in the
neutral position.

W54.21-A127-01
Plug X1 (A 001 545 84 30)
Plugs X2 and X3 are not installed as standard at the factory. The plugs and
their corresponding pins must be retrofitted to enable connection to the
XMC.
W82.00-A004-01
Plug X2: A 168 545 08 28
W54.21-A128-01
Plug X3: A 013 545 65 26
Contact socket for plugs X1 and X2

Contact 0.50 ... 1.00 mm²: A 005 545 76 26
W54.21-A125-01
Contact socket for plugs X1 and X2
Contact socket for plug X3

Contact 0.50 ... 1.00 mm²: A 014 545 11 26
Contact 1.00 ... 2.50 mm²: A 014 545 13 26
W82.10-A029-01
Contact socket for plug X3
The functions that can be realized include:

• Engine start/engine stop
• Engine speed control (power take-off)
• Reverse gear lock and speed limiter
• Retarder without CAN interface
• Automatic transmission without CAN interface
Reverse gear lock and speed limiter
• Retarder without CAN interface
• Automatic transmission without CAN interface
XMC/PSM2 interfaces
1 Power supply from on-board electrical system of
vehicle
2 High-speed CAN interface to vehicle star point
3 Power take-off switch W54.00-A071-81
4 High-speed CAN interface for body electronics

5 Low-speed CAN interface to trailer
6 Digital outputs (relay drivers), e.g. D+ switched
7 Pulse-pause modulation (PPM) and pulse width
modulation (PWM) outputs, e.g. vehicle speed
signal
8 Digital inputs, e.g. engine start
9 Analog inputs, e.g. hand-throttle actuator
The functions that can be realized include: • Engine start/engine stop
• Engine speed control (power take-off) be retrieved from the Mercedes-Benz Bodybuilder Portal
• Reverse gear lock and speed limiter (http://bb-portal.mercedes-benz-trucks.com). It is not
possible to output the existing CAN output signals (for
• Retarder without CAN interface example, engine start, engine stop, buzzer) from the
• Automatic transmission without CAN interface ASAM/XMC through freely definable functions or logic
blocks.
Certain basic functions are assigned to the inputs. These
can be supplemented with additional functions or Body and trailer CAN
changed to other functions by means of
parameterization. The XMC is parameterized using The document entitled "Body CAN technical
XENTRY. These body/equipment mounting directives information", which belongs to the XMC manual,
cannot describe in full the wide variety of capabilities of describes the connection options and CAN messages
the XMC. A manual has therefore been produced for which can be accessed by the body and trailer CAN
parameterization, "Equations and parameters", that can and/or written to the vehicle CAN.

Contacting parts for plug X1, X2 & X3 on SAM with additional functions (XMC)
Designation Item number
Plug X1.40 0.50 – 1.00 mm² A 005 545 7626 (single item)
Contact socket MQS
Contact socket MQS
Contact socket MCP 2.8 1.00 – 2.50 mm² A 014 545 1326 (single item)
i
In combination with the Blind Spot Assist camera
system, sales code S1S, the fixed speeds 2 & 3, and
a starter lockout can only be requested over the
body CAN.
The digital inputs for these functions on the XMC are
already assigned at the factory, and parameterized
with Blind Spot Assist camera system functions.
---------------------------------------------------------------------------
CTT vehicles • 14 FF 00 38 hex
On vehicles with CTT sales code JCLM, CTT steering, • 10 FE CA 38 hex
electrohydraulic or JALG, relief control for rear loader, No CAN messages with the aforementioned IDs may be
the control units of the respective equipment are already sent by body control units to the vehicle CAN. This can
connected to the pins of the body CAN of the XMC. The result in malfunctions or component part failure on the
following CAN message ranges are, exceptionally, vehicle.
reserved for vehicle events:
• 18 EF xx EB hex
---------------------------------------------------------------------------
ISO 11898 requires adaptation of the resistance on the • With code combination JCLM and E4D, body
body CAN of the XMC control unit (code E3W) interface, behind cab, a resistor of 120 Ω is
(terminating resistor). connected to plug X227 (between pins 14 and 15).
This terminating resistor is already installed at the
factory as follows:
• With code combination JCLM and P0E, remote When the body manufacturer connects additional control
control for Meiller plant dumper, or P9H, pre- units, the existing resistor must be removed from plug
installation for Meiller dumper remote control, a X227 or X213, and installed again in accordance with
resistor of 120 Ω is connected to plug X213 (between the specifications (see document GF54.21-W-002-53-A
pins 7 and 16). Connecting control units for ISO 11898).
Connection of control units with ISO 11898
W54.21-A018-79
1 Terminating resistor 120 Ω B Variant 2
2 Terminating resistor 60 Ω ABH-SG Body manufacturer control unit
A22 SAM with additional functions (XMC) a 100 cm
CAN 8 Body manufacturer CAN b 10 cm
A Variant 1
CAN 8 Body manufacturer

CAN
ABH-SG Body manufacturer
control unit
C Wrong connection
D Correct connection
b 10 cm
W54.21-1624-75
Connection of several control units with ISO 11898 • The connection from the body manufacturer control
The following points must be observed when connecting unit (ABH-ECU) to the body manufacturer CAN must
two or more control units to the body manufacturer CAN: not exceed a length of 100 cm (a).
• A common CAN node may not be used to connect • Only one body manufacturer control unit (ABH-ECU)
two or more control units to the body manufacturer may communicate with the SAM control unit with
CAN . The CAN nodes must be a minimum distance additional functions. All other body manufacturer
of 10 cm (b) apart. control units (ABH-ECU) can communicate freely with
each other.
Connection of control units with ISO 11898
• The body manufacturer control unit (ABH-ECU), • Variant 2 (B): One terminating resistor 60 Ω each
which communicates directly with the SAM control to (2) CAN high and CAN low
unit with additional functions, must be equipped with • The addressee of a diagnosis message from the
a terminating resistor. Two options are possible: body manufacturer control unit (ABH-ECU) may not
• Variant 1 (A): One terminating resistor 120 Ω (1) be identical to a message already sent or received by
to CAN high the SAM with additional functions.
Trailer Control
Trailer Control
i The existing trailer sockets, 7‑pin to ISO 7638 and
Further information on the exact signals of the trailer 15‑pin to ISO 12098, extend communications between
CAN is provided in the document "Body the trailer and the vehicle.
manufacturer CAN, description for model 963, 964",
The signals from the EBS 22 , can be used to configure
available in the Bodybuilder Portal.
and display warning messages of trailer systems in the
integrated instrument cluster.

W54.21-A133-10
Indicator lamps and pop-ups in the instrument cluster
In the secondary display, signals from the EBS 23, can

be used to display the tire pressure values of trailers.
W54.21-A134-10
Tire pressure display in the secondary display
W31.00-A042-78
Since production month 12/2020, it has been possible to secondary display, including individual axle loads and
display trailer data for a maximum of 2 trailers in the the gross weight of the trailer – even without using code
Trailer Control
J3Z, Axle-load measuring system, and irrespective of

whether the base model vehicle is equipped with air
suspension or steel suspension.

W31.00-A043-78
Since production month 12/2020, it has been possible to

control the level control for a maximum of 2 trailers using
virtual switches in the secondary display.

W31.00-A044-78
Since production month 12/2020, further virtual switches

are available for controlling lifting and steering axles for
a maximum of 2 trailers in the secondary display.
Communications interfaces and fleet management system
i
Avoid potential dangers to people or property
damage due to lack of knowledge.
Before starting to install other make bodies or
equipment, please read the relevant chapters of
these Body/Equipment Mounting Directives, the
instructions and information from the equipment
supplier and the detailed operator's manual for the
base model vehicle.
---------------------------------------------------------------------------
Central gateway control unit (CGW) The sales codes described in the following sections are
The CGW provides an interface for telematics functions. available as pre-installations for these functions.

Pre-installation for FleetBoard, sales code J9C

This pre-installation comprises the technical
components for easy retrofitting of the FleetBoard
components along with all available services.
Components of pre-installation:
• GPS antenna base for vehicle position finding
• GSM antenna base for communication, installed on
the cab roof
• Communication module as interface to CAN bus, for
W82.85-A015-10
data querying, storage and fusion
Pre-installation for FleetBoard
• The entire wiring pre-installation with switches for the
FleetBoard hardware components and a 24 V/12 V
voltage converter
If FleetBoard is to be operated together with an FMS
interface, it is only possible to use the FMS interface in
FleetBoard.
Communications interface (COM), sales code E4A

The communications interface (COM) is a technical prerequisite for
connecting and operating an on-board computer (e.g. FleetBoard) via the
CAN bus of the vehicle. The interface is a component of the CGW.
W82.85-A016-01
Communications interface (KOM)
Standard interface for fleet management system

(FMS), sales code E4B
W82.85-A026-10
Interface for fleet management system (FMS), pushbutton switch
The standardized interface is an electronic

communication connection for the fleet management
systems of different manufacturers. It converts the on-
board CAN data into the standardized SAE J1939
format and forwards it to the respective system. The
data content of the interface is precisely defined and
coordinated between the manufacturers. As a result,
different fleet management systems can evaluate
vehicle data generated by equipment from the above-
named manufacturers without problem and irrespective
of the brand and make.
W82.85-A027-10
Since production month 10/2019, a modified installation Fleet Management System (FMS) interface, model series 963, 964
position of the interface is available for model series
963, 964, as shown in the pictures above.
i
On model series 967, the interface installation
position is next to the electrical compartment in the
front passenger footwell.
The equipment is not suitable for use with FleetBoard.

The FleetBoard pre-installation, sales code J9C, is
required for this purpose.
Installation of additional antennas When additional antennas are installed, ensure that the
safety and convenience features of the control units,
e.g. radio or fleetboard, are not impaired.
i The antennas must be at a minimum distance of
Risk of accident and injury to vehicle users due to 250 mm from each other so that no interference occurs.
malfunction/failure of the camera system: Of particular importance is the sensitivity of the GPS
For vehicles equipped with MirrorCam (only for antenna compared to the other antennas due to the
model series 963, 964), sales code F6T, a minimum necessity of ensuring a flawless connection with the
distance of 800 mm between antenna and camera satellites and avoiding interference.
lens must be maintained. Covering the antennas with shielding materials (usually
metallic components) is to be avoided.

1 Radio/telephone/GPS
2 FleetBoard GSM/GPS
3 Toll GSM/GPS
4 Tetra
W82.85-A018-01
Antenna installation diagram
German regulation concerning the transport of dangerous good...
i i
Risk of polarity reversal (positive and negative Stationary heater of GGVSEB/ADR-vehicles:
connections) When the power take-off is activated, the vehicle
The battery disconnect switch for the Actros/Arocs is changes from driving mode to the work mode. In this
not identical to the battery disconnect switch for the state, the stationary heater must be deactivated on
Atego. The BESO feed line on model 963, 964 is GGVSEB/ADR (hazardous goods) vehicles.
located on the upper side of the component part. On
model 967, the feed line is located on the underside
of the component part.
---------------------------------------------------------------------------
German regulation concerning the transport of supply depend on the vehicle equipment. Since these
dangerous goods by road, rail and inland waterways components should be installed as close as possible to
On vehicles subject to the German regulation concerning the battery, their installation location depends on the
the transport of dangerous goods by road, rail and inland main batteries.
waterways (GGVSEB/ADR), the ground connections of The GGVSEB/ADR and country-specific laws and
the electrical consumers must be routed to the battery regulations must be observed!
clamp or battery sensor. This switch for disconnecting
the battery is located in the cab. A second switch can be
ordered optionally and is located on the right behind the
i
cab. The battery disconnection is made at the positive Activation of the power take-off causes the vehicle to
side only (terminal 30). The pre-installation for twin-pole change from driving mode to working mode. In this
battery disconnect switch, sales code E9D, is available state, the stationary heater must be deactivated on
for disconnecting the positive and negative sides (tml. 30 GGVSEB/ADR (hazardous goods) vehicles.
and 31).
The installation location of the battery disconnect switch
control unit and the fuse for the tachograph power
Signal for backward rolling of vehicle
Detection signal for backward rolling of the vehicle • Via body CAN, GPM 1C1, byte 7, bits 0 ... 1
When the revised standard EN1501 for waste collection The relevant parameterization of the function is
vehicles comes into force in 2019, any backward rolling implemented through one of the available logic blocks in
of the vehicle must be detected when the step plate is equation 500 of the XMC.
occupied. Depending on the equipment installed in the vehicle, it
In combination with sales code S5I (Vmax 30 km/h, may be is necessary to check which usable pins are
engageable, reverse gear lock, refuse collector) the available. The updated pin assignment for the XMC can
drivetrain electronics monitor the vehicle's movement be found in the "Equations and parameters for Actros/
and assess whether the vehicle is driving or rolling Arocs, model 963/964, model generation 5" brochure.
backward, or whether it is stationary. Further information on the messages of the body CAN is
The rollback signal is made available by the vehicle in provided in the document "Body manufacturer CAN,
two different ways: description for model 963, 964", available in the
• Via digital pin (ex factory the pin X3-21/14 is Bodybuilder Portal.
parameterized)
Electronic parking brake, request via body
Parking brake, electronic, request via body • X1 40/19

The XMC enables a body system to send the following • X1 40/20
requests to the vehicle: • X1 40/28
• Apply parking brake • X1 40/38
• Suppress release of parking brake (inhibit function) The release can be inhibited either with or without
The parking brake can be engaged in two ways: confirmation by the driver.
• Via digital pin* The relevant parameterization of the function is
• Via body CAN, GPM 2A, byte 4, bits 2 ... 3 implemented through one of the available logic blocks in
equation 500 of the XMC.
There are also two ways to suppress the release of the
parking brake (inhibit function): Depending on the equipment installed in the vehicle, it
may be is necessary to check which usable pins are
• Via digital pin* available. The updated pin assignment for the XMC is
• Via body CAN, GPM 2A, byte 4, bits 4 ... 5 available in the "Equations and parameters for Actros/
Arocs, model 963/ 964, model generation 5" brochure.
* Depending on the equipment installed, one of the
following pins can be used: Further information on the messages of the body CAN is
provided in the document "Body manufacturer CAN,
• X1 40/08
description for model 963, 964", available in the
• X1 40/09 Bodybuilder Portal.
• X1 40/10
Reversing camera
diagrams
i
For further information on Mercedes-Benz
Accessories (see "Overview of documents/
catalogs/instructions/circuit diagrams →
Interface catalog" document).
---------------------------------------------------------------------------
Video function (TCC). With pre-installation for reversing camera, sales
With instrument cluster, 12.7 cm, with video function, code J9J, the wiring is installed up to the cab/chassis
sales code J1C, the instrument cluster has a video electrical connector. Display of the camera image via the
signal input and software which processes the signal coaxial video signal line can be realized via the
from a camera (e.g. reversing camera) and displays it in instrument cluster (ICUC) or via the TCC. The wiring
the multifunction display. If the Bluetooth® comfort radio/ required for the camera is available from Mercedes-Benz
navigation system, sales code J2D, is installed, the Accessories (see the table).
video function is realized by the Truck Control Center

N54.65-A000-01 N54.65-A001-01
Backup camera Multi cable
Backup camera

Reversing camera

The following parts are available for the reversing camera:
Item number Description
B6 753 0171 Reversing camera adapter cable (only in combination with pre-installation for
reversing camera, sales code J9J)
B6 782 1275 Backup camera
B6 782 1277 Multi cable 5000 mm
B6 782 1281 Helix cable incl. ABS socket, adapter cable and parking socket
B6 753 0173 Audio set (connection of audio devices)
B6 753 0174 Video set (Video-In and Video-Out/connection of video-capable devices)
B6 782 1276 Controller unit and monitor
ABS/EBS trailer socket, 7-pin, 24 V, in combination with sal...
Trailer socket ABS/EBS 7‑pin 24 V, in combination
with sales code B5A/B5B
The trailer socket fulfills the requirements of ISO 7638.

1 Terminal 30 (black/red)
2 Terminal 15 (black/red)
3 Ground connection for electric circuit contact 2 (brown)
4 Ground connection for electric circuit contact 1 (brown)
5 ABS recognition (green/yellow)
6 Trailer CAN High as per ISO 11992‑2 (blue)
7 Trailer CAN Low as per ISO 11992‑2 (blue)
W54.21-A131-01
Pin assignment of Mercedes-Benz trailer
socket (with corresponding cable colors)
(BR 963, 964)
The data of the trailer CAN are transferred via

connections 6 and 7. These and the associated lines are
available ex factory in combination with EBS.
This trailer CAN differs from the trailer CAN of the 15-pin
trailer socket described in the document "Body
manufacturer CAN, description for model 963, 964".
W54.21-A132-81
Trailer brake, sales code B5A, 2 lines, brake connections on left
(BR 963, 964)
Code E3B - Connecting point 12 V/15 A, for auxiliary consume...
E3B-Connecting point 12 V/15 A, for auxiliary

consumers
The electric line of the 12 V connecting point is routed
from the 24 V/12 V voltage converter to the FF interface
(cab/chassis interface) on plug X81.15 behind the front-
end flap.
With a maximum power consumption of 15 A, an
electrical device can be operated with a power
consumption of up to 180 W.
W54.10-A043-81
Pos. of body plug X81.15 on FF interface
Assignment of FF plug X81.15:

• Pin 10: 12 V + (12 V tml.30)
• Pin 11: 12 V - (12 V tml.31)
W54.10-A044-03
Extract from circuit diagram PE54.10-
W-2000FG
Code E4D - Body interface, behind cab
Body connector, sales code E4D quality of the overall vehicle and significantly reduces the
The optional body connector X226 and X227, sales effort that the body manufacturer would otherwise
code E4D, provides two sockets on the right in the expend on routing electric lines in the chassis.
longitudinal member immediately in front of the The pins of the body manufacturer interface on the
crossmember behind the transmission. The interface is chassis are connected directly to the body manufacturer
only available in combination with interface in the electrical compartment of the cab.
code E3W, PSM, 2nd generation. Pins are also provided for the power supply, for ground
The body connector eliminates the need for the body connection and for CAN lines which can be used for
manufacturer to route additional lines from the body into CAN signals transmitted by equipment installed by the
the vehicle frame, via the cab pivot point and to the body manufacturer.
electrical compartment in the cab. This improves the

W54.21-A137-11

Pin assignment of X226, body connector (15-pin) - BR 963, 964
Pin Signal Wire size range Technical information
1 Terminal 30 2.5 mm² Total of 6 mm², fused with 40 A at chassis power

distributor (A152)
2 Terminal 30 2.5 mm²
3 Terminal 30 1.5 mm² Fused with 25 A at cab power distributor (A8)
4 Terminal 31 1.5 mm² Connected to the interface at the frame ground point
8 Standing lamp 0.75 mm² Max. current draw 2 A at ASAM (A7) X2-52/8
9 Engine speed 0.75 mm² Max. current draw 1 A at XMC (A22) X2‑52/10,
parameterization must be observed!
10 Rotating beacon 0.75 mm² Fused with 10 A at beacon interface
11 Backup signal 0.75 mm² Max. current draw 2 A at ASAM (A7) X2‑52/52
12 Vehicle speed signal 0.75 mm² Max. current draw 0.05 A at ASAM (A7) X2‑52/51
(C3)
13 Step plate power 0.75 mm² Max. current draw 0.02 A at XMC (A22) X2‑52/51
supply
14 Step plate feedback 0.75 mm² Max. available current 0.02 A at XMC (A22) X2‑52/26
15 Power take-off 1 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/40
request

Pin assignment of X227, body connector (15-pin) - BR 963, 964
1 Work/surround lighting 0.75 mm² Fused with 10 A at cab power distributor (A8) in
conjunction with codes E7B, L3C or L9G
2 Fixed speed 1 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/28
3 Rpm + 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/10
4 Rpm – 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/08
5 (not used) 2.5 mm² Connected to cab/chassis interface, plug X61/12
6 Engine start request 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/27
7 Engine stop request 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/29
8 Travel distance signal 0.75 mm² Max. current draw 1 mA at TCO (P1) B8
(C4)
9 Brake light 0.75 mm² Max. current draw 2 A at ASAM (A7) X2‑52/04
10 Right turn signal lamp 0.75 mm² Max. current draw 1 A at ASAM (A7) X2‑52/11
11 Left turn signal lamp 0.75 mm² Max. current draw 1 A at ASAM (A7) X2‑52/10
12 Power take-off 0.75 mm² Max. available current 0.02 A at ASAM (A7) X10-52/20
feedback
13 Idling speed 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/09
14 Body CAN L 0.75 mm² Connected to XMC (A22) X1‑40/02
15 Body CAN H 0.75 mm² Connected to XMC (A22) X1‑40/03

Pin assignment of X226, body connector (15-pin) - BR 983
4 Terminal 31 1.5 mm² Connected to the interface at the frame ground point
8 Standing lamp 0.75 mm² Max. current draw 2 A at ASAM (A7) X2‑52/8
9 Vehicle active 0.75 mm² Max. current draw 1 A at XMC (A22) X2‑52/10,
Parameterization must be considered!
10 Rotating beacon 0.75 mm² Fused with 10 A at beacon interface
11 Backup signal 0.75 mm² Max. current draw 2 A at ASAM (A7) X2‑52/52
12 Vehicle speed signal 0.75 mm² Max. current draw 0.05 A at ASAM (A7) X2‑52/51
(C3)
13 Step plate power 0.75 mm² Max. current draw 0.02 A at XMC (A22) X2‑52/51
supply
14 Step plate feedback 0.75 mm² Max. available current 0.02 A at XMC (A22) X2‑52/26
15 Power take-off 1 0.75 mm² Max. available current 0.02 A at XMC (A22) X1‑40/40
request

Pin assignment of X227, body connector (15-pin) - BR 983
1 Work/surround lighting 0.75 mm² Fused with 10 A at cab power distributor (A8) in
conjunction with codes E7B, L3C or L9G
3 XR-Interlock weld 0.75 mm² Connected to cab/chassis interface, plug X81/04
4 XR-Interlock weld 0.75 mm² Connected to cab/chassis interface, plug X81/5
8 Travel distance signal 0.75 mm² Max. current draw 1 mA at TCO (P1) B8
(C4)
9 Brake light 0.75 mm² Max. current draw 2 A at ASAM (A7) X2‑52/04
10 Right turn signal lamp 0.75 mm² Max. current draw 1 A at ASAM (A7) X2‑52/11
11 Left turn signal lamp 0.75 mm² Max. current draw 1 A at ASAM (A7) X2‑52/10
12 Terminal 30c (12 V) 0.75 mm² Fused with 1 A at cab power distributor (A8)
13 Ground connection for 0.75 mm² Connected to the interface at the frame ground point 12 V
tml. 30c
14 Body CAN L 0.75 mm² Connected to XMC (A22) X1‑40/02
15 Body CAN H 0.75 mm² Connected to XMC (A22) X1‑40/03
Stecker X226: Part number: A 058 545 91 28

Hersteller AMP Bestellnummer: 1‑1564530‑1
Stecker X227: Part number: A 058 545 92 28
Hersteller AMP Bestellnummer: 2‑1564530‑1
W54.21-A138-01
Mating plug for the wiring harnesses of the
body
Kontakt 0,75 mm²: A 000 982 85 28 (tin-plated)

A 000 982 44 28 (silver-plated)
Dichtung: A 003 997 75 49
Hersteller AMP Bestellnummer 1703278‑2
Dichtung: A 000 997 10 45
Hersteller AMP Bestellnummer 2287497‑1
Blindstopfen: A 001 545 59 80
W54.21-A139-01
Contact socket for plug X226/X227

A 039 545 22 28 (tin-plated)
Dichtung: A 000 545 29 39
Blindstopfen: A 000 545 62 80
W54.21-A140-01
Contact socket for plug X226/X227
W54.21-A141-01
Dust cap 180°: A 003 545 06 83
W54.21-A142-01
Dust cap 90°: A 003 545 10 83
Code E4E - Engine start/stop for ABH, automatic
Engine start-stop for body manufacturer, automatic, If another wakeup-capable pin is to be used, this can be
sales code E4E changed at Mercedes-Benz Service using XENTRY
When equipped with the engine start-stop for body Diagnosis.
manufacturer, automatic, sales code E4E, the vehicle Other possible wakeup-capable pins are:
engine can be started and stopped while stationary by • X1 40/08
the body electronics. This function is useful for cooling
systems that are driven by the vehicle engine. The • X1 40/09
engine can be started and stopped independently of the • X1 40/10
cab lock status.
• X1 40/19
In order to be able to switch on the ignition of a parked
• X1 40/20
vehicle by means of a body control unit, the wakeup-
capable pin X1 40/37 on the XMC must be constantly • X1 40/28
energized. The ignition remains switched on as long as • X1 40/38
this pin is energized. After energizing the pin, a waiting
time of 5 seconds must be observed before an external Further switch-off times can be parameterized by means
engine start may be requested by the body control unit. of XENTRY Diagnosis in the EIS control unit:
When the engine is started by the body electronics, the • 14 hours
transmission remains locked in order to prevent theft. • No shutoff
The engine can be switched off at any time using the
The parameterization of the switch-off of terminal 30 in
start/stop button.
the EIS control unit is independent of sales code E4E.
Code E6A - Trailer socket, 24 V, 15-pin
i
Possible damage to the on-board electronics
through voltage peaks > 75 V:
Where inductances are retrofitted to the trailer
(e.g. in the brake light path) the freewheeling current
when switching off must be defined by a resistor.
Diodes are not permissible.
---------------------------------------------------------------------------
Trailer socket 15-pin 24 V, sales code E6A
The trailer socket fulfills the requirements of ISO 12098.

W54.21-A129-11
Trailer socket (15-pin)
1 Turn signal indicator, left (black/violet)

2 Turn signal indicator, right (black/green)
3 Rear fog lamp (yellow/white)
4 Ground connection (for electric circuit contact
1 ... 12) (brown)
5 Left tail lamp, clearance lamp, position lamp and
license plate lamp (gray/black)
6 Right tail lamp, clearance lamp, position lamp
and license plate lamp (gray/red)
7 Brake lamps (black/red)
8 Reversing lamp, reverse gear lock (white/red)
9 Power supply (+24 V) (red)
10 (free) (black/yellow)
11 (free) (black)
12 (free) (black/gray)
13 Ground connection (for electric circuit contact W54.21-A100-11
no. 14 and 15) (brown) Pin assignment of Mercedes-Benz trailer socket (with
corresponding cable colors)
14 Body and trailer CAN data communication,
ISO 11992‑3 (white/blue)
15 Body and trailer CAN data communication,
ISO 11992‑3 (white/red)
Code E6A - Trailer socket, 24 V, 15-pin
BR 963, 964, 983

Depending on the equipment installed, up to three
electric lines are available (pins 10, 11 and 12). These
can be used to supply voltage to or switch an electrical
consumer on the trailer/semitrailer from inside the cab.
The circuitry is the responsibility of the body
manufacturer. Alternatively, auxiliary consumers with a
maximum of 25 A at pin 9 (+24 V) can also be
connected to the trailer socket. Examples here are
rotating beacons or work lamps. It is not permitted to
connect auxiliary consumers to lighting pins 1 ... 8.
connections 14 and 15. These and the associated lines
are available from the factory in combination with XMC
(sales code E3W), switch no. 1 for external processing
(sales code E5A) or switch, lift axle, trailer/semitrailer
pre-installation (sales code E9I).
BR 963, 964, 983
X51.18 FF interface
X71.18 FF interface
X102.15 Trailer socket W54.21-A130-12
Connections between trailer socket, cab/chassis interface and
XMC, sales code E3W (BR 963, 964, 983)
BR 967
Depending on the vehicle equipment, up to three electric
lines are available for supplying electrical consumers of
the trailer/semitrailer with power from the cab, or for
switching them. Examples here are rotating beacons or
work lamps.
connections 14 and 15. These are only available from
the factory in combination with the XMC, sales
code E3W.
BR 967
X33.18 FF interface
X53.18 FF interface
X102.15 Trailer socket
W54.21-A190-11
Connections between trailer socket, cab/chassis interface and
XMC, sales code E3W (model series 967)
Code E9D - Pre-installation, double-pole battery circuit bre...
Installation of a mechanical battery disconnect switch Page 644
i
The specifications must be observed for installation
of a battery disconnect switch (see document
"Installation of a mechanical battery disconnect
switch").
---------------------------------------------------------------------------
Pre-installation for bipolar battery disconnect connector in the frame ex factory. It can thus be routed
switch, sales code E9D past the battery disconnect switch and connected to the
The equipment can be ordered for selected vehicles. ground connection of the battery.
Vehicles equipped with alarm system, with interior The pre-installation package detects the temperature in
monitoring, sales code F8Z, are excluded from these the AdBlue® injection valve and the run-on time of the
guidelines. AdBlue® system is calculated based on this.
The pre-installation facilitates the aftermarket installation After switching off the ignition and before actuating the
of a country-specific bipolar battery disconnect switch, retrofitted battery disconnect switch, the user must wait
such as is required for the Safe Loading Pass Scheme in for a certain period of time to elapse, on the one hand,
the UK, for example. this will ensure fault-free shutoff (sleep mode) of all
The package includes the interfaces and the associated control units and, on the other hand, it will ensure
electrical wiring harness to facilitate retrofit installation. cooling of the AdBlue® injection valve in the exhaust gas
The battery disconnect switch is not included. The aftertreatment unit.
corresponding circuit diagram PE54.10‑W‑2069F can be Various time periods must be observed depending on
found in the Mercedes-Benz Bodybuilder Portal. the vehicle equipment and temperature of the exhaust
(http://bb-portal.mercedes-benz-trucks.com) gas aftertreatment unit. These are displayed on the
instrument cluster in vehicles with sales code E9D. The
If a tachograph (TCO) is installed in the vehicle, this
waiting time between "Ignition off" and operation of the
must still be supplied with power even if the power
battery disconnect switch is shown on the instrument
supply is disconnected. A 1 A fuse including wiring to the
cluster for 60 s when the ignition is switched off.
cab/chassis interface is included in the pre-installation
package for the TCO supply. The following illustrations show the positioning of the
corresponding wiring harness for semitrailer trucks and
On vehicles with this equipment, the ground line of the
platform trucks:
digital tachograph (DTCO) is routed to an electrical

W54.21-A135-11
Semitrailer truck
Code E9D - Pre-installation, double-pole battery circuit bre...
W54.21-A136-11
Platform
Code E9E - Pre-installation for ADR, without chassis shieldi...
ADR pre-installation, without chassis shielding, be fulfilled with supplementary retrofitting by the body
sales code E9E manufacturer.
This pre-installation prepares the electrical system to The vehicle is sensibly pre-equipped with regard to the
satisfy type class FL for the transportation of highly entire electrics ex works, but without the B3-certification.
flammable liquids with a flash point of no higher than The body and the covers which, depending on the model
60 ℃ and combustible gases in tankers. The type class, may be required for special applications involving
classes EX/III, EX/II and AT are also catered for the transportation of hazardous goods can be retrofitted
electrically. Therefore the provisions of the European by the body manufacturer. The B3 certificate must be
Agreement Concerning the International Carriage of applied for later when the body modifications have been
Dangerous Goods by Road (ADR) and the German completed.
regulation concerning the transport of dangerous goods The pre-installation includes:
by road, rail and inland waterways (GGVSEB) can only

• Battery disconnect switch inside cab (standard),
W54.21-A120-11
Battery disconnect switch in cab
• If necessary, battery disconnect switch outside cab

(special equipment on frame, sales code E5G)
W54.21-A121-11
Battery disconnect switch on frame
Code E9E - Pre-installation for ADR, without chassis shieldi...
• Corrugated hose sheathing of wiring.
W54.21-A122-11
Corrugated hose sheathing of cables for battery disconnect switch
Code E9F Pre-installation, 2nd air suspension operating unit
i
Further information on activating the 2nd operating
unit and the function of the level control when the
ignition is off can be found in the operating
instructions of the vehicle!
W32.30-A000-81
Body plug X82 on cab-chassis interface
E9F Pre-installation for 2nd level control operating Mercedes-Benz replacement parts service. Depending
unit on the vehicle equipment, an operating unit for full-air or
The pre-installation is the basis for connecting a partial air suspension must be installed. The connected
2nd operating unit to control the air suspension outside additional operating unit must also be registered by the
the cab, e.g. in the box body. Mercedes-Benz service partner with the XENTRY
diagnostic system in the on-board electronics.
The scope of the pre-installation includes the LIN bus
wiring up to the cab/chassis connecting point at the plug As soon as the 2nd operating unit is activated, the
X82.40 pin 1‑3 behind the front-end flap. system works. An additional pushbutton switch in the
instrument panel is not required.
The 2nd operating unit is not included in the delivery
package. However, it can be obtained from the

Position of electr. signals on plug X82.40:

• Pin 1: LIN (+) 12 V
• Pin 2: LIN signal
• Pin 3: LIN (-) ground
W32.30-A001-71
Example: 2nd operating unit
Code E9F Pre-installation, 2nd air suspension operating unit
E9F Pre-installation for 2nd level

control operating unit
Circuit diagram of Actros 5

(BM 963.x)
PE54.25-W-2144F
Wiring diagram for

eActros (BM 983.x)
PE54.25-W-2144-97X
W54.25-A064-06
Code E9G - Pre-installation for electrical equipment
E9G Pre-installation for electrical equipment
The pre-installation for electrical equipment consists of
voltage pins for tml. 30 (+) & tml. 31 (-) in the cab, for
the power supply of additional 24 V consumers with
power consumptions up to 80 A. The pre-installation is
suitable for the retrofitting of additional electrical
consumers with a power consumption > 10 A in the cab.
W54.21-A146-81
Left-hand drive vehicle: Voltage stud M8 on inside of cab/chassis
supporting frame, above the cab power distributor control unit
The scope of supply of the equipment includes:

• Electrical fuse 80 A at connection X5 of cab power distributor
• Voltage stud M8 for terminal 30 and terminal 31 on inside cab/chassis
interface carrier over cab power distributor
• Electric line (line cross-section: 16 mm²) between the power distributors
on the chassis and the voltage pins on the cab/chassis interface
W54.18-A021-03
W-2164F
Code E9I - Pre-installation for switches, lift axle, semitra...
E9I-Pre-installation for switch, lift axle, semitrailer/

trailer
The pre-installation for operating a lift axle on a
semitrailer or trailer includes a locking push-button
switch, the electrical fuse with 20 A and the wiring from
the switch to pin 12 of the 15-pin trailer socket. The
locking push-button switch is located in the cockpit on
the driver's side next to the steering wheel and offers a
high degree of comfort when lifting/lowering the lift axle
of the semitrailer.
A switched 24 V voltage signal is output at pin 12 of the
15-pin trailer socket X102.15.
W35.50-A000-81
Lift axle switch (1)
If a pushbutton switch is required instead of the

standard locking push-button switch, the retrofit switch
"momentary" A 013 545 67 07 can be used. The
protective cap of the standard switch can be transferred.
W54.18-A022-12
Wiring diagram PE54.18-W-2200F
Code F8Z - Alarm system with interior sensing
German regulation concerning the transport of dangerous Page 678
goods by road, rail and inland waterways
Standard rpm and vehicle speed signal at plug X2 Page 650
i
Further information can be found in the circuit
diagram PE80.50‑W‑2002F in the Mercedes‑Benz
Bodybuilder Portal.
---------------------------------------------------------------------------
Alarm system with interior sensing, sales code F8Z For body manufacturers, the system provides an
The alarm system is a multifunctional monitoring system interface for connecting external motion detectors and
for the towing vehicle, the vehicle interior and the the contact switches at the doors. If necessary, also
semitrailer/trailer. The alarm system has three additional observe the GGVSEB/ADR regulations as well as
ultrasonic sensors in the cab, located at front right in the country-specific legislation and specifications (see
upper roof area, which are connected to the alarm document "German regulation concerning the
system over a data line. Every triggered alarm is transport of dangerous goods by road, rail and
recorded in the multifunction display with date and time inland waterways").
and displayed in the instrument cluster after ignition Connection options at control unit A6 (ATA, anti‑theft
"On". alarm system):

Pin Designation
16 Input for box body, ground switching (connection at cab-chassis connecting point X82.4, (see document
"Standard rpm and vehicle speed signal at plug X2"))
19 Spare output (not currently supported)
20 Input 1, spare, ground switching
21 Input 2, spare, ground switching
• All three inputs are separately configurable (with and • The inputs are fused so that parallel resistances
without monitoring), switches can be configured as greater than 5 kΩ or series resistances less than
normally open or normally closed. 100 Ω do not result in an alarm.
• Depending on the configuration, an alarm is triggered
either by connecting or disconnecting the ground.
Code J9P - Pre-installation and display for up to 4 cameras
Pre-installation and display for up to four cameras When reverse gear is engaged, camera 1 is
(sales code J9P) automatically activated.
The equipment J9P integrates a display wired into the
cab/chassis interface for up to four video cameras.

In the secondary display, up to four preview images are possible in real

time. The number of cameras and their designation, must be parameterized
in the Connect 5 control unit (ICC5) with XENTRY Diagnosis so that the
display is adapted to this number.
The plug corresponds to the number A 009 540 30 81 and the contact
sockets correspond to the number A 005 545 76 26.
N82.60-A000-01
Plug and contact socket

The following table shows the available pins in plug X43 for connecting the corresponding cameras:
Camera Video in Shield Power GND
1 4 14 10 20
2 13 3 9 19
3 2 12 8 18
4 11 1 7 17
It is possible to use PAL or NTSC cameras. • Connect video signal to "Video In" pin.
Fakra or video coaxial cables should be connected to • Gather shielding to "Shield" pin.
the corresponding pins.

The following table shows the available texts for the
camera designation:
Value in XENTRY Text
0 Camera 1
1 Camera 2
2 Camera 3
3 Camera 4
4 Camera 5
5 Left
6 Right
7 Front
8 Rear
Lighting systems according to UN directives and German vehic...
Lighting
At this point, we refer to valid regulations which must be As a standard reference work for the StVZO, we
observed: recommend:
• UN-R 48 in the latest valid version • "Lighting equipment for motor vehicles and trailers"
• StVZO for Germany or the respective country-specific ("Lichttechnische Einrichtungen an Kraftfahrzeugen
requirements in the latest valid version und Anhängern"), Kirschbaum publishing house
Contour marking
Lighting
General 2100 mm or a vehicle length of more than 6000 mm.

In accordance with the directives 2007/35/EC and UN- Retroreflective contour marking is not permitted on
R 48 or 76/756/EEC, complete commercial vehicles with vehicles of class M1 and O1.
a permissible gross mass of > 7.5 t must be equipped Exceptions are semitrailer trucks, chassis with cab and
with retroreflective contour markings. incomplete vehicles.
This applies to motor vehicles used for goods transport Application area
and for trailers with a vehicle width of more than

Motor vehicles for goods transport
Class Max. total mass Permissible
N1 ≤ 3.5 t Yes
N2 > 3.5 t ≤ 12 t Yes
N3 > 12 t Yes

Trailer
Class Max. total mass Permissible
O1 ≤ 750 kg No
O2 >750 kg ≤ 3.5 t Yes
O3 > 3.5 t ≤ 10 t Yes
O4 > 10 t Yes
With a vehicle width greater than 2.1 m, full contour • At rear area of vehicle: retroreflective film in red or
marking is required on the vehicle rear area. yellow
If the total vehicle length is greater than 6 m, full or Requirements/recommendations for attachment of
partial contour marking must be attached to the side of contour marking:
the vehicle.
Adhesive marking at the cab is permitted according to
If, owing to the special shape, structure or design of the guideline UN-R 48
vehicle body or owing to the vehicle use, it is not
possible to attach the prescribed full or partial contour The requirements that have to be met must be clarified
marking, it is permissible to use a line marking. with the technical service department and in compliance
with the directive.
If a so-called subtle reflective advertisement is attached
to the body, it must be positioned within the full contour The ECE mark must be visible in its entirety on every
marking. section of the contour marking.
According to guideline UN-R 104, class "C" films with a The legal requirements for contour marking must be
width of 50 mm (+10 mm/-0 mm) are to be used. taken into consideration.
Films with the following colors are permissible:
• On the side of the vehicle: retroreflective film in white
or yellow
---------------------------------------------------------------------------
General alignment of contour marking
The indicator markings must be attached as close as
possible to the edge of the vehicle horizontally and
vertically.

Contour marking
Lighting

Contour marking alignment
In width direction: The length to be attached must be min. 70% of the total width of the vehicle.
In longitudinal The marking must be attached as close to the ends of the vehicle as possible; max. 600 mm
direction: from each end of the vehicle.
The horizontal length 6 to be attached corresponds to min. 70% of the total length of the
vehicle (without cab).
Lmin. = 0.7 x (total length of vehicle - length of cab)
In height: Minimum: 250 mm

Maximum: 1500 mm
The uppermost installation dimension may be changed The distance of the marking to the upper edge of the
after consultation with the technical service department. vehicle must not exceed 400 mm.

Partial contour marking examples

In the case of partial contour
marking, each upper corner must be
made visible by means of two lines
which form an angle of 90° and each
measure min. 250 mm in length. If an
angle of 90° is not possible, the
marking must roughly follow the
structure of the body.
1 Min. 250 mm
2 Min. 250 mm
3 Max. 400 mm
4 Max. 600 mm
5 Min. 250 mm to max. 1500 m
m
6 Length W60.00-A052-05
7 Max. 600 mm Partial contour marking on side of vehicle
Conspicuous marking up to
2400 mm from the front end
of the vehicle also permitted
in the form of a row of Class
IV A reflectors according to
UN-R 3 or Class C according
to UN-R 104 (minimum
size 25 cm² each,
spacing ≥ 600 mm)
Contour marking
Lighting
W60.00-A053-10
The required 70% on the body is achieved. At the cab, only one
sticker is necessary within the first 600 mm.
W60.00-A054-10
To achieve the 70%, the cab must also be included.
Full contour marking examples

1 Max. 400 mm
2 Min. 200 mm
3 Min. 250 mm, max. 1500 mm
W60.00-A055-11
Full contour marking of the rear area of the vehicle
Contour marking
Lighting
Line contour marking
Instead of the prescribed partial contour marking, it is
permissible to attach a line marking if, owing to the
shape, body, design or operating conditions of the
vehicle, it is not possible to attach the prescribed partial
contour marking.
W60.00-A056-81
Examples of line contour marking on side of vehicle
Visibility
At least 80% of the marking must be visible from every
point on the area shown below.

1 Observation plane
2 25,000 mm
W60.00-A057-11
Rear
Contour marking
Lighting
1 Observation plane
2 25,000 mm
W60.00-A058-11
Long side
Height visibility
1 25,000 mm
2 3000 mm
3 1000 mm
W60.00-A059-06
Implementation examples

Contour marking
Lighting
W60.00-A060-71 W60.00-A061-71
Skip loader: line marking at rear underride Skip loader: line marking at sides of body
guard
W60.00-A062-71 W60.00-A063-71
Short-timber transporter: line marking on Roll-off dump truck: line marking at rear
side and rear underride guard
W60.00-A064-71 W60.00-A065-71
Fully enclosed swap body vehicle: line Bonding at cab: Select bonding position so
marking at rear twist lock carrier that sufficient advertising space remains.
Contour marking
Lighting
Left picture: It is not permissible to

integrate the company logo of the
body manufacturer in the contour
marking on the cab.
Right picture: Example of a sticker
that can be attached to the cab door
within the first 600 mm. The adhesive
label A 010 989 39 85 is available for
this purpose.
1 Company logo in contour
marking is not permissible. W60.00-A066-71 W60.00-A067-71
2 Company logo in contour Bonding at cab ECE mark on cab door: Sticker
marking is permissible.
Tail lamp installation
Lighting
Connection of electrical consumers Page 623
i
Possible loss of eligibility for registration:
If the lights are doubled, the light source control
function will only indicate failure once both
illuminants have failed, e.g. if the standard turn
signal indicator fails, but the retrofitted turn signal
indicator operates properly → no failure is detected.
Comply with the country-specific registration
regulations, e.g. UN-R 6.
The retrofitting of non-genuine Mercedes-Benz LED
tail lamps described here deactivates the failure
indicator for the lamps. No failure is detected. In
many countries, failure monitoring, e.g. of the turn
signal indicators, is mandatory (UN-R 6). This is no
longer guaranteed. The body manufacturer is
responsible for compliance with registration
regulations. Retrofitting LED lamps into the ex-
factory lamp housing is not permitted. The legally
prescribed values for beam angle, illumination and
light flux cannot be guaranteed. The certification of
the lamps is rendered invalid ("e" test symbol).
---------------------------------------------------------------------------
If parts of the lighting system can be covered by more to connect the side marker lamps and suitable reversing
than 50% when moving vehicle parts (e.g. cargo liftgate) lamps.
are in operation, the vehicle must be safeguarded The country-specific laws, directives and registration
accordingly. An appropriate notice must be attached at a regulations must be observed.
point where it can easily be seen by the driver of the
vehicle. The entire lighting system is monitored for individual bulb
failure. Additional power taps for the exterior lighting are
Vehicles with an overall length of over 6m must be available at the body manufacturer plug (see
equipped with side marker lamps as per UN-R48. There "Connection of electrical consumers" document).
are branch-off lines on the wiring harness of the chassis
---------------------------------------------------------------------------
Reversing lamps The logic of the installed illuminants must be applied to
The respective reversing lamp schematic can be found the respective additional lamp units, i.e.no mixed
in the wiring diagrams of function group 82.10. installation of bulbs and LED lamps and only use
illuminants with the same output/power consumption as
Connection of additional reversing lamps the standard illuminants already installed, e.g.21W+21W
and not 21W+10W. If special equipment sales code L1P,
The rear lights on the towing vehicle can be duplicated.
LED tail lamps, is installed ex-factory, note that not all
If further additional lamps are planned, e.g.through the
individual lamps of the rear lamp module can use LED
tripling of lights, please consult the relevant contact
technology.
person (see "Advice for body manufacturers"
document).

Lighting
1 Clearance lamp LED (light output same as

5 W bulb)
2 LED turn signal indicator (light output same as
21 W bulb)
3 Brake lamp LED (light output same as 21 W bulb)
4 Tail lamp LED (light output same as 10 W bulb)
5 Reversing light LED (light output same as
21 W bulb)
6 Rear fog lamp LED (light output same as
21 W bulb)
7 License plate lamp LED (light output same as
10 W bulb)
W82.10-A044-81
Location of tail lamp illuminants, code L1P(BR 963, 964, 967, 983)
Y-cable for additional reversing lamps according to the schematic shown and with the specified
Additional lamps at the rear area can be connected component parts. The line length must be matched to
directly to the existing tail lamps with a Y-cable. The the particular use case. The line cross-section must be
lines must be fabricated by the body manufacturer min. 1.5mm².

1 Plug A0545457028
2 Plug A0265451526
3 Plug A0265451526 (Mercedes‑Benztail lamps) or
specific plug if tail lamps from other
manufacturers are used
W82.10-A025-11
Wiring of additional tail lamps
Lighting
Pin assignment of Mercedes-Benz reversing lamps
1 Tail light and clearance lamp
2 Rear fog lamp
3 Ground
4 Turn signal lamp
5 Reversing lamps
6 Brake light
7 Reverse warning device/license plate lamp
W82.10-A026-01
Pin assignment of Mercedes-Benz tail
lamps
No other kinds of lamps (e.g. side marker lamps) are

permitted to be connected at these pins.

Protective caps
A0025456783, outlet 90°
A0025456883, outlet straight
W82.10-A028-10
Protective caps
Contact socket for plug A0265451526

A0009820026 (0.5‑1.0mm²)‑4pcs
A0135455426 (0.5‑1.0mm²)‑3pcs
W82.10-A029-01
Contact socket for plug A0265451526
Lighting
Contact pins for plug A0545457028

A0009828428 (0.5‑1.0mm²)‑4pcs
A0355458428 (0.5‑1.0mm²)‑3pcs
W82.10-A030-10
Contact pins for plug A0545457028
Individual seal for plug housing • Brake lamp

• A0039977549 (line ∅ 1.4‑1.9mm) gray The value for the minimum current in the ASAM is
• A0039977649 (line ∅ 1.9‑2.1mm) yellow 100 mA or 50 mA for turn signal and tail lights.
• A0039977749 (line ∅ 1.2‑1.6mm) red Full LED lamps to ISO13207 with

Hella Compatibility Solution (HCS) system may be used.
Retrofitting LED tail lamps In this case, the failure check functions without a
parameter modification.
The lamps are monitored based on the current level.
Normally, the current level of LED lamps is much lower The schematic circuit shown here permanently bridges
than that of filament bulbs. If the illuminants are replaced the failure indicator function so that no error message is
without further preparation, this can cause ongoing error displayed on the central instrument cluster if the LED
messages on the central instrument cluster and fault lamp fails. A resistor must be connected in parallel for
entries in the control unit. each lamp.
For the following lamps, the threshold values for the It is also possible to double the number of lights, as
failure check can be modified by parameterization: shown. If further additional lamps are planned, e.g.
through the tripling of lights, please consult the relevant
• Turn signal lamp
contact person (see "Advice for body manufacturers"
• Tail lamp document).
• Reversing lamp

1 LED module
2 If number of lights is doubled
W82.10-A027-02
Illustration of the principle of circuit for LED
lamp
Lighting on trailers/semitrailers side). Exception: A maximum of four reversing lamps

It is possible to triple the number of lamps on a trailer/ can be connected in total because these use a shared
semitrailer (up to three complete tail lamps per vehicle line for both sides of the vehicle.
Lighting
Out of all illuminants, only the connected turn signal All of the other reversing lamps connected for each
indicators are monitored for failure. These have to be function, e.g. brake lights, can be equipped with any type
identical on both sides of the vehicle, e.g.one Hella of illuminant (LED/filament bulb). It is also possible to
Compatibility Solution (HCS) and one bulb on the right install mixed variants. The connections are not equipped
necessitates one HCS and one bulb on the left, whereas with failure monitoring.
two bulbs on the right necessitates two bulbs on the left.
The lamps and lamp types for the turn signal indicators
(LED or bulbs) are automatically recognized by the on-
board electronics every time the ignition is switched on.
Pre-installations for installing lamps
Lighting
i
Risk of accident and injury for vehicle user through
malfunction/failure of camera system:
Beacons that are installed in combination with the
MirrorCam system (sales codeF6T) can impair its
function due to their design. In the case of an
improper retrofitting of beacons, function
impairments of the MirrorCam system can occur.
Install LED beacons without any infrared content
only.
---------------------------------------------------------------------------
Pre-installations for lamp mounting
Various pre-installations for lamp mounting are available i
ex factory. Descriptions and connection options for the
equipment items are available in the specified circuit
diagrams in the Mercedes-Benz Bodybuilder Portal.

BR 963, 964, 983
E7B Pre-installation for electrics/lamps, for swap PE82.10-W-2000-97FD

bodies
L9A Pre-installation for beacons PE82.10-W-2000-97FE
L9B Pre-installation for additional headlamps PE82.10-W-2000-97FE
L9C Pre-installation for additional headlamps, roof PE82.10-W-2000-97FD
L9G Pre-installation for work lamps, cab rear panel PE82.10-W-2000-97FD

Model series 983
E7B Pre-installation for electrics/lamps, for swap PE82.10-W-2000-97XA

bodies
L9A Pre-installation for beacons PE82.10-W-2000-97XB
L9C Pre-installation for additional headlamps, roof PE82.10-W-2000-97XA
L9G Pre-installation for work lamps, cab rear panel PE82.10-W-2000-97XA
Pre-installation for additional headlamps, roof, sales To guarantee proper functioning of the MirrorCam
code L9C: system, only beacons with LED technology may be
National legislation must be observed for the activation used.
of the headlamps. Conventional lamps with infrared components in the light
The sales code L9A, pre-installation for beacons, can be spectrum can cause the image displayed on the
configured at the factory in combination with the monitors of the MirrorCam system to be too bright.
MirrorCam system (F6T). Beacons with filament illuminants are therefore blocked
at the factory for sales code F6T.
Code E7B - Pre-installation for electrics/lamps, for swap bo...
Lighting
E7B-Electrics/lamp pre-installation, for swap bodies For retrofitting additional work lamps, an electrical wiring
In the case of chassis for swap body use, the code E7B harness is routed in the longitudinal frame member up to
is used to optimize the position of the work lamp the plug X155.2 (model series 963 only) on the tail lamp
(code L3A) on the cab rear panel and to pre-install an holder on the right.
electrical interface at the end of the frame for connecting The work lamps for the L3A & E7B equipment, are
further headlamps. operated by a common switch in the cab.
The work lamp (L3A) on the cab rear panel is lowered so The total power consumption for E7B in combination
that it illuminates the fully-enclosed swap body and no with L3A is 10 A. The headlamp code L3A is equipped at
shadows are cast in the area of the support feet. In the factory with a H3 24 V/70 W bulb.
addition, the work lamp is mounted offset to the side to
illuminate past the swap body connection.

1 Switch on instrument
panel
2 Work lamps under cab
X155 2-pin plug
W82.10-A035-76
W82.10-A036-09
Code E7B - Pre-installation for electrics/lamps, for swap bo...
Lighting
Circuit diagram PE82.10-W-2000FE - Actros 5 (model designation 963.x)
Code L9A - Pre-installation for rotating beacons
Lighting
i i
In this chapter, representations, code scopes and Risk of accident and injury for vehicle user through
pre-installations of other model designations and malfunction/failure of camera system:
model series are listed for reasons of Rotating beacons, which are installed in combination
standardization. The information that is applicable to with the MirrorCam system (sales codeF6T), can
your model designation/model series must impair its function due to their design. Improper
exclusively be used. retrofitting of rotating beacons can impair the
function of the MirrorCam system. Install LED
beacons without any infrared content only.
---------------------------------------------------------------------------
L9APre-installation for rotating beacons Rotating beacons can be mounted on the roof in the
The pre-installation enables the subsequent connection area to the left and right of the roof hatch, in the same
of up to two rotating beacons. It includes the complete place as the standard installation locations, with rivet
wiring as well as the corresponding switch in the nuts M5x12 according to MBN13024-A item number:
instrument panel. The wiring harness with the plugs X1.1 N 913024 005103. Deviating installation locations must
and X2.1 is routed up to the roof paneling next to the be clarified in advance with the relevant development
roof hatch in the area above the driver's seat and fused department!
with 10 A.
The installation location of the rotating beacon
connectors varies depending on cab and roof variant!

W82.25-A000-09
Installation locations of electr. connectors for beacons (model series 963, 964 and 983)
Lighting
Model series 967

Plug for beacon connections on front passenger side
W82.25-A002-81
Plug for beacon connections on long cab with roof
W82.25-A003-81
Plug for beacon connections on long cab with high roof on front passenger
side in area of roof cross bow
W82.25-A004-72
Lighting
L9APre-installation for rotating
beacons

Arocs 5 (model designation 963.x/
964.x)
W82.25-A001-06
PE82.10-W-2000-97FE
Circuit diagram of Atego (model

designation 967.x)
W82.10-A066-05
PE82.10-W-2000-97NHB
Code L9B - Pre-installation, additional headlamps
Lighting
i
In this chapter, representations, code scopes and
pre-installations of other model designations and
model series are listed for reasons of
standardization. The information that is applicable to
L9B-Pre-installation for additional headlamps

The pre-installation enables the simple connection of
additional headlamps at the front of the vehicle. It covers
the complete wiring up to the cab/chassis interface plug
X83.15 (on the Actros 963.x and Arocs 964.x), or plug
X62.18 (on the Atego 967.x), a relay module and a
switch in the instrument panel for switching over to the
additional headlamps.
Observe the country-specific laws and regulations when
fitting additional headlamps.
W82.10-A037-81
Installing additional headlamps
Lighting

Pin assigment cab/chassis X83.15 (model designation 963.x, 964.x)
1 Right turn signal lamp 1A Monitored
2 Left turn signal lamp 1A Monitored
3 Tml. 58, right Pin 3 + 4 together 2 A Non-monitored
4 Tml. 58, left
5 Tml. 31 Ground Monitored
6 Tml. 56a, right 3A Monitored
7 Tml. 56a, left 3A Monitored
8 Tml. 56b, right 3A Monitored
9 Tml. 56b, left 3A Monitored

Pin assigment cab/chassis X83.15 (model designation 963.x, 964.x)
7 Tml. 58, right Pin 7 + 8 together 2 A Non-monitored
8 Tml. 58, left
12 Right turn signal lamp 1A Monitored
13 Left turn signal lamp 1A Monitored
14 Tml. 31 Ground Monitored
15 Tml. 56b, left 3A Monitored
16 Tml. 56b, right 3A Monitored
17 Tml. 56a, left 3A Monitored
18 Tml. 56a, right 3A Monitored

Lighting
L9B-Pre-installation for additional

headlamps

Arocs 5 (model designation 963.x/
964.x)
W82.10-A038-06
PE82.10-W-2000FE
Circuit diagram of Atego (model designation 967.x)

W82.10-A065-09
PE82.10-W-2000-97NHA
Code L9C - Pre-installation, additional headlamps, roof
Lighting
L9C-Pre-installation for additional headlamps; roof
The pre-installation L9C allows up to four additional high beam headlamps
to be retrofitted on the cab roof. Standing lights and high beams can be
switched on in addition. The electrical connector X179.6 of the pre-
installation is installed on the roof paneling in the area of the interior lamp
on the front passenger side.
The current-carrying capacity is max. 5 A for the standing lights and
max. 15 A for the high beams.
For the connection of additional high beams at the front of the vehicle, the
electrical connector X109.21 in the driver's footwell can be disconnected
and used (part of the code L9C).
The total power consumption of all connected headlamps (standing lights
and high beams) may be 15 A. National legislation must be observed for
the mounting/activation of the headlamps.
For example, according to ECE R-48, a maximum of 4 high beam
headlamps may be active at the same time on the tractor vehicle. The
function of the additional roof lamps is only guaranteed via the "additional W82.10-A039-72
roof lamps" switch in the instrument panel. With this circuit, the two Installing additional headlamps
standard high beam headlamps are not functional. Actuating the switch
ensures that not all high beam headlamps are active at the same time. If
the switch is activated, only the 4 roof lights are activated when the driver
requests high beam. Even when the headlight flasher is activated, only the
4 roof lights are activated.
1 Terminal 58
2 Terminal 31
3 Terminal 56a
W82.10-A064-02
W2000FD
Code L9G - Pre-installation, work lamps, cab rear panel
Lighting
L9G-Pre-installation for work lamps, cab rear panel

The pre-installation includes a switch in the instrument panel, power supply
to the switch and switching relay and the electrical wiring harness from
switching relay to the interface X200.6 on the inner rear panel of the
driver's cab, in the area behind the driver's seat.
This allows the work lamp to be positioned freely on the cab rear panel and
it can be connected without difficulty.
If the vehicle is equipped ex works with the work lamp code L3A or
code L3C in addition to the pre-installation L9G, only one switch is installed
for both equipment items.
W82.10-A041-01
The total power consumption for L9G alone or together with L3A/L3C is
Work lamps switch (1) in instrument panel
max. 10 A (common fuse with 10 A for L9G + L3A/L3C).
Headlamps and fastening points on the rear panel of the cab are not
included in the scope of supply! The headlamp L3A is equipped ex works
with one bulb H3 24 V/70 W, the headlamp L3C with two bulbs H3 24 V/
70 W.
W82.10-A042-01
Installation location of plug X200.6 for work
lamp
Circuit diagram of Actros 5 & Arocs 5 (BM 963/964)

Code L9G - Pre-installation, work lamps, cab rear panel
Lighting
W82.10-A043-09
PE82.10-W-2000FD
Overview of documents/catalogs/instructions/circuit diagrams
Additional information
Product and vehicle information for body manufacturers Page 33
Explanatory documents/catalogs/instructions/wiring may be required to reach the correct information due to

diagrams the high level of detail involved. The corresponding
The following information facilitates searching in the pathway is included below the link. Registration and
Bodybuilder Portal. The specified links generally link to login at the Bodybuilder Portal using your user name is
the correct area of the portal. However, further inputs necessary before you can open the link.
---------------------------------------------------------------------------
Interface parts catalog Bodybuilder Portal → Technology → Trucks → "Select
You can find information about the Mercedes-Benz vehicle model designation" → Interface parts catalog
interface parts catalog on the Internet at the home page:
https://bb-portal.mercedes-benz-trucks.com/de/
GLOBAL
---------------------------------------------------------------------------
Body manufacturer information https://bb-portal.mercedes-benz-trucks.com/de/
You can find information about current topics such as GLOBAL
new developments, new equipment packages, technical Bodybuilder Portal → Information → Bodybuilder
modifications, law changes and other current issues on Information Bulletin
the Internet at the following home page:
---------------------------------------------------------------------------
(Preliminary) Body/Equipment Mounting Directives/ https://bb-portal.mercedes-benz-trucks.com/de/
calculation guidelines GLOBAL
You can find information on the Body/Equipment Bodybuilder Portal → Technology → Trucks → "Select
Mounting Directives, additional information (Body/ vehicle model designation" → Body/Equipment Mounting
Equipment Mounting Directives Book II: Calculation) and Directives
preliminary information on all truck model series on the
Internet at the following home page:
---------------------------------------------------------------------------
Wiring diagrams (Catalog only shared when the vehicle model
Information on wiring diagrams for all truck model series designation, engine code and Euro standard have been
can be found on the Internet at the home page: specified.) Bodybuilder Portal → Technology → Trucks →
"Select vehicle model designation" (observe note) →
https://bb-portal.mercedes-benz-trucks.com/de/ Wiring diagrams
GLOBAL
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Operating instructions Bodybuilder Portal → Information → Product information
You can find information on operator's manuals for all → Operator's manuals
truck model series at the following home page:
GLOBAL
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Overview of sales codes MBIS home screen → Trucks → "Select vehicle model
Information on the code overview for various vehicle designation" → Code overview
model designations can be found on the home screen:
GLOBAL/mbis?id=52&L=de
---------------------------------------------------------------------------
Overview of documents/catalogs/instructions/circuit diagrams
Complete genuine accessories catalog Mercedes‑Benz Trucks - Home screen → Services &
Information on Mercedes-Benz genuine accessories can Parts → Mercedes-Benz GenuineParts, accessories &
be found on the Internet at: tires
https://www.mercedes-benz-trucks.com/en_GB/
home.html
---------------------------------------------------------------------------
Country-specific contact persons https://bb-portal.mercedes-benz-trucks.com/ portal/
You can find information about country-specific contact apps/ansprechpartner_db/
persons on the Internet at the following home page: Bodybuilder Portal → Help → Contact persons
---------------------------------------------------------------------------
Tip-over limit calculation https://bb-portal.mercedes-benz-trucks.com/de/
You can find information on tilt threshold calculations for GLOBAL
all truck model series on the Internet at the following Bodybuilder Portal → Technology → Trucks → "Select
home page: vehicle model designation" → Tilt threshold calculations
---------------------------------------------------------------------------
Electrics/electronics https://bb-portal.mercedes-benz-trucks.com/de/
Here, you can find documents about electrical interfaces, GLOBAL
about the parameterizable special module (PSM), about Bodybuilder Portal → Technology → Trucks → "Select
the SAM with additional functions (XMC), about pin vehicle model designation" -> Electrics & electronics
assignment along with much other information from the
field of electrics/electronics:
---------------------------------------------------------------------------
Power take-offs https://bb-portal.mercedes-benz-trucks.com/de/
You can find information about installation positions and GLOBAL
performance data of power take-offs on the Internet at Bodybuilder Portal → Technology → Trucks → "Select
the following home page: vehicle model designation" → Power take-offs
---------------------------------------------------------------------------
Workshop Information System (WIS) modalities (see document "Product and vehicle
Use of the Workshop Information System is subject to a information for body manufacturers → Information
charge and requires prior registration. The process for for non-MB body manufacturers").
this may differ from country to country. For the further
Calculations
Connecting device Trailer coupling (without tongue weight)

The required size of the trailer coupling and fifth-wheel The following drawbar ratio formula applies for
coupling is determined using the drawbar ratio. mechanical connecting devices that are not suitable for
The drawbar ratio is defined as the theoretical transferring tongue weights:
comparative force for the force between the towing
vehicle and the trailer/semitrailer.

D Drawbar ratio [kN]

g Normal g force 9.81 m/s²
T Permissible gross mass of towing vehicle in [t]
R Permissible gross mass of trailer with vertically free-moving towing
device in [t]
W31.00-A011-01
Trailer coupling (with tongue weight) defines the equivalent vertical acceleration at the
For mechanical connecting devices that are suitable for coupling point depending on the type of rear-axle
rigid drawbar trailers (SDAH) or center axle trailers suspension system of the towing vehicle and a constant
(ZAA), the Dc value and V value apply. The V value factor.

DC Drawbar ratio [kN]

T Permissible gross mass of towing vehicle including tongue weight
in [t]
C Permissible gross mass of rigid drawbar trailer or center axle trailer
without tongue weight in [t]
W31.00-A012-01
Calculations
For rigid drawbar trailers with a permissible tongue
weight at the coupling point of more than 10% of the
trailer mass or more than 1000 kg:
V V-value [kN]
a 1.8 m/s² (acceleration for towing vehicles with
air suspension or comparable suspension)
a 2.4 m/s² (acceleration for towing vehicles with
other suspensions, e.g. leaf spring
suspension)
X¹⁾ Length of cargo area of rigid drawbar trailer
W31.10-A020-10
or center axle trailer in [m]
I¹⁾ Theoretical drawbar length, measured from
the center of the axle assembly to the center
of the towing eye in [m]
C Permissible weight of rigid drawbar trailer or
center axle trailer without tongue weight in [t]
S Permissible tongue weight at coupling point
in kg
For center axle trailers in general and for rigid drawbar trailers with a
permissible tongue weight at the coupling point of max. 10 % of the trailer
mass and no more than 1000 kg:
V V-value [kN]
a 1.8 m/s² (acceleration for towing vehicles with air suspension or
comparable suspension)
a 2.4 m/s² (acceleration for towing vehicles with other suspensions,
e.g. leaf spring suspension)
X ¹⁾ Length of cargo area of rigid drawbar trailer or center axle trailer in
[m]
I ¹⁾ Theoretical drawbar length, measured from the center of the axle W31.00-A010-01
assembly to the center of the towing eye in [m]
C Permissible weight of rigid drawbar trailer or center axle trailer
without tongue weight in [t]
¹⁾ For values calculated as X²/l²< 1, 1.0 must be used.

Fifth-wheel coupling
The drawbar ratio formula applies for mechanical
connecting devices that are suitable for semitrailers/
trailers:
D Drawbar ratio [kN]
T Permissible gross mass of semitrailer truck
including the fifth wheel load in [t]
R Permissible gross mass of semitrailer including
fifth wheel load in [t] W31.00-A013-10
U Fifth wheel load in [t]
Axle load calculation before any work on the body is carried out. The weights
An axle load calculation is required to optimize the measured by weighing form the basis of the axle load
overall vehicle (vehicle and body). It is only possible to calculation.
match the body to the truck if the vehicle is weighed
Calculations
The moment theorem is used to distribute the weight of - (minus) is everything that relieves the load on the
the equipment on the front and rear axles. All distances vehicle
are to be referred to the center of the front axle
(theoretical center). Mark the weight with mathematically Axle distance
correct signs and enter them in the table. The result will + (plus) means everything behind the center of the front
assist you in choosing the optimum positioning of the axle
body.
- (minus) means everything in front of the center of the
The following definitions have proved useful for the axle front axle
load calculation:
Calculate the load distribution on the front and rear axle
Weight using the following formulae:
+ (plus) means everything that places a load on the
vehicle

Δ GHA Weight change for rear

axle in [kg]
GComponent part Component weight in [kg]
a Axle distance to theoretical
center of front axle in [mm]
R Theoretical wheelbase
[mm]
Δ GVA Weight change for front
axle in [kg]
W31.00-A014-10
Technical wheelbase
Technical wheelbase determination on 3-axle

vehicles

To calculate the technical wheelbase

Ri, the following formula and the
following values apply:
R Vehicle wheelbase
measured from center of
axle 1 to center of axle 2
HA Rear axle base
G2 Permissible axle load of 2nd
axle according to weight
code
W00.10-A027-04
G3 Permissible axle load of 3rd
If G2 is equal to G3, then formula (1) simplifies to formula (2).
code
Calculations
W00.00-A043-10
3-axle vehicle
Technical wheelbase determination on 4-axle

vehicles
Axle configuration 8x6/4 or 8x8/4 with axle load

compensation on both front axles

To calculate the technical wheelbase

Ri, the following formula and the
following values apply:
R Vehicle wheelbase
VA Front axle base
HA Rear axle base
G1 Permissible axle load of 1st
code
G2 Permissible axle load of 2nd
code
G3 Permissible axle load of 3rd
W00.10-A028-05
code
If G1 is equal to G2, then formula (3) simplifies to formula (4); if G3 is equal to G4, then
G4 Permissible axle load of 4th formula (4) simplifies to formula (5).
code
W00.00-A044-10
4-axle vehicle
Calculations
Axle configuration 8x4/4 without axle load Advice for Body Manufacturers or via the Mercedes-
compensation on both front axles Benz customer consulting system for commercial
4-axle vehicles with the 8x4/4 axle configuration do not vehicles (MBKS).
have axle load compensation on the two front axles. The The following information is required for the calculation:
two front axles have independent suspension. This • Order number (if available)
results in a statically "overdetermined" bearing.
• Vehicle model designation
On these vehicles, therefore, the axle loads cannot be
determined as before by calculating a "substitute • Vehicle equipment
wheelbase" (as on vehicles with axle load compensation • Individual axle loads in unloaded state
and 8x6/4 and 8x8/4 axle configurations).
• Additional weights and their center of gravity
A corresponding axle load calculation tool is available on (e.g. crane, hydraulic oil reservoir, etc.)
the Mercedes‑Benz Bodybuilder Portal at:
Contact:
Technical Consulting for Body Manufacturers:
in the "Technical data sheet" area.
Tel.: +49 7271 71 2506
Alternatively, calculations for determining the actual axle
Email: sosbb@daimler.com
loads/payload range can be obtained via Technical
---------------------------------------------------------------------------
4-axle vehicles with triple axle

W00.00-A045-10
4-axle vehicle with triple axle
To calculate the technical wheelbase Ri, the following

formula and the following values apply:

R Vehicle wheelbase
VLA Front axle base
HA Rear axle base
G1 Permissible axle load of
1st axle according to
weight code
2nd axle according to
weight code W00.10-A029-04
3rd axle according to
weight code
4th axle according to
weight code
Code JALG - Relief control for rear loader
Calculation of minimum front axle load on rear

loaders with sales code JALG i
The CTT code JALG provides a load relief control For a more detailed description of code JALG, see
system for 4-axle Econic vehicles with leading axle and PIT Trucks (Product Information Tool).
rear loader body that operates as follows:
• When the vehicle is unladen, the 1st rear axle
(leading axle) is relieved of load. The example calculation below is intended as a guide for
the theoretical calculation.
• When the vehicle is loaded, the 1st rear axle remains
relieved of load as long as the sum of the rear axle
loads of the 2nd and 3rd rear axles is < 19,000 kg
(regardless of the weight variant). i
The calculation is to be carried out in suitable
• Even when the 1st rear axle is relieved of load, there loading steps.
is assumed to be an axle load of approx. 800 kg due
to its dead weight.
• When the rear axle loads 2 + 3 = 19,000 kg, the Vehicle: 8x2/6 (with leading and trailing axle) weight
1st rear axle is increasingly loaded. variant 32 t (8.0/7.5/11.5/7.5)
i
The body manufacturer must ensure that the
minimum front axle load is maintained in all load
conditions.
---------------------------------------------------------------------------
Example: 1. Initial situation (without JALG)

Chassis weight as weighed: Front axle: 4570 kg
Rear axle HA1: 1060 kg
GG: 8610 kg
Ri technical wheelbase: 5100 mm
VA Front axle
HA Rear axle
GG Gross weight
W00.00-A107-75
2. Vehicle with sales code JALG

Axle load HA2 + HA3: < 19,000 kg
Rear axle HA1: relieved
New technical wheelbase Ri2: 5633 mm (only HA2 + rear axle HA2 + HA3 according to the new technical
HA3 considered) wheelbase.
800 kg of rear axle 1 stays at the 3750 mm position; the
remaining 260 kg is distributed to the front axle and to

New axle load distribution of chassis Front axle: 4657 kg

weight:
Rear axle HA2 + 3: 3153 kg
GG: 8610 kg
Calculation of the axle load
distribution of the desired body +
payload (L) with the new technical
wheelbase Ri2.
W00.00-A108-75
From the axle load distribution of the chassis and the

body + payload (L), calculation of the front axle load in
%.

L Weight of body + payload

s Distance from center of gravity
to front axle
W00.00-A109-75
3. Vehicle with JALG

Axle load HA2 + HA3: 19,000 kg
Rear axle HA1: is increasingly loaded
To calculate the axle loads, the calculation is performed Using the known distance from the center of gravity to
in two parts: the front axle, the weight of the body + payload [La] that
a) Only considering HA2 + HA3: is borne by HA2 + HA3 is calculated.
These together carry a maximum of 19,000 kg. Some of This also gives us the front axle load share of [La].
this is required by the chassis (in our example, 3153 kg)
Thus, in our example, for the body + payload, 15,847 kg
is left over, which is borne by HA2 + HA3.
La Weight share of body +

payload, which is borne by
HA2 + HA3
s Distance from center of
gravity to front axle
W00.00-A110-75
b) Only considering HA1: To calculate the total front axle load, we take the sum of:
The rest of the weight of the body + payload must be Front axle load of chassis + front axle load proportion of
borne by rear axle HA1 and the front axle: Lb = L – La La + front axle load proportion of Lb
To calculate the axle load distribution of Lb, the to determine the value.
wheelbase between the front axle and HA1 is used.

W00.00-A111-75
List of abbreviations

Abbreviation Explanation
ABE General operating permit
ASAM Advanced Signal Actuator Module
CTT Custom Tailored Trucks
DIN Deutsches Institut für Normung/"Deutsche Industrie-Norm" (German Standards

Institute/"German Industry Standard")
EC European Community
EPC Electronic Parts Catalog
ESP® Electronic Stability Program
ETG European Type Approval
ICUC Instrument Cluster Unit Common
ISO International Organization for Standardization
PIT Product Information Tool
PSM Parameterizable Special Module
QPL Qualified Partner List
SZF Semitrailer truck
UBB Certificate of non-objection (CNO)
VDA German Association of the Automotive Industry
VLA Leading axle
WIS Workshop Information System
XMC SAM with additional functions
ZFZR Central Vehicle Register
Risk of accident from vehicle starting off by itself when en...
Attachment
aWarning
Potential risks • It is not permitted for persons to be in the danger

zone in front of or behind the vehicle while tests are
Risk of accident being performed.
Caused by the vehicle starting off by itself during the • Shift the gearshift lever to neutral on vehicles with
starting procedure manual transmission.
(e.g. during compression test) due to engaged gear or • On vehicles with automatic transmission, move
with the engine running and vehicles with automatic selector lever into position "P" or "N" (except for
transmission due to selector lever position "P" or vehicles that do not have selector lever position "P").
"N" not being engaged (except for vehicles that do not • On vehicles that do not have selector lever position
have selector lever position "P"). "P", the selector lever is to be secured against
Risk of injury
• Wear closed and close-fitting work clothes.
Severe injuries can be caused by freely rotating parts in
the area of the running engine. • Remove all jewelry such as necklaces, chains, rings,
etc.
Because the engine heats up when operating, serious
burns can be caused by touching unshielded parts. • Persons with long hair must put on a suitable head
covering.
Safety instructions/precautions
• Before commencing any work on the running engine,
• In general, only work on a running engine when it is familiarize yourself with the location of potentially hot
absolutely necessary. parts.
• Apply parking brake before starting the engine. • When carrying out work when starting the engine or
• The vehicle is to be secured against moving forwards when the engine is running, do not touch any hot or
or backwards. rotating parts.
• The person performing tests on a vehicle with the • Use the exhaust extraction system.
engine running must sit in the driver's seat to be able
to prevent the vehicle from moving.
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First aid measures in the event of burns • Consult a physician immediately.
• Do not rub the skin areas affected; rinse with plenty
of cold water and cover skin with sterile dressings.
The high voltage used for electric welding presents a lethal...
Attachment
aDanger
poisoning from inhalin
Potential risks Risk of injury from welding splatter and UV light

when welding as well as from flying sparks when
Risk of death from high voltages used for electric grinding
welding
Severe burns can be caused if hot chips (flying sparks)
If electric welding work is performed in a humid from grinding work or welding sparks or splatter from
environment or on a wet surface, there is a risk of death liquid welding material come into contact with
due to voltage being conducted through the human unprotected body parts.
body. This can result in severe burns, heart fibrillation or
cardiac arrest. Normal work clothing (consisting of cotton or synthetic
fiber) can ignite from weld sparks and splatter from liquid
Danger! welding material or from flying sparks when grinding,
Persons with cardiac pacemakers should not and cause severe burns.
perform electric welding work. The UV light emitted during electric welding can lead to
eye damage and burns on unprotected skin.
Risk of explosion
Welding in the area of highly flammable substances can
cause explosions.
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Risk of poisoning from inhaling welding fumes • Wear appropriate protective clothing (leather, Kevlar),
Inhaling vapors that are caused by material burning headgear (welding shield or helmet with suitable
during welding can lead to headache, nausea, dizziness glasses), welding apron and protective gloves
and unconsciousness. • Perform welding work in well ventilated rooms only.
Safety instructions/precautions • Wear respiratory protective mask or use air extraction

system.
• Wear safety shoes (with rubber soles) and use
insulating mats. First aid measures
• Ensure that a good connection to ground is made. • Rinse affected skin with large quantities of cold water
• Persons with cardiac pacemakers should not perform and cover with sterile dressings.
electric welding work. • Move unconscious person into the fresh air
• Remove highly flammable or combustible materials immediately and provide artificial respiration, if
and fluids from the hazard area. necessary.
• Consult a physician immediately.
Risk of accident caused by vehicle starting off on its own w...
Attachment
aDanger
parts.
Potential risks • The vehicle must be securely positioned on the

saddles; place a non-slip base on the saddle if
Risk of accident necessary.
Caused by vehicle driving off on its own when in • Wear closed and close-fitting work clothes.
operation (e.g. during measurements) with engine
running and gear engaged. Danger caused by vehicle • Remove all jewelry such as necklaces, chains, rings,
slipping off the jack stands. etc.
• Persons with long hair must put on a suitable head
Risk of injury covering.
Severe injuries can be caused by freely rotating parts in • Before commencing any work on the running engine,
the area of the running engine and drivetrain. familiarize yourself with the location of potentially hot
Because the engine heats up when operating, serious parts.
burns can be caused by touching unshielded parts. • When carrying out work on the running enginedo not
touch any hot and rotating parts.
• The danger zone of the vehicle may only be entered First aid measures in the event of burns
by persons required to conduct the work. • Rinse the area of skin affected with plenty of cold
• To perform the work, climb into cab. water and cover skin with sterile burn dressings. Do
not apply the dressings tightly, but rather loosely over
• Lift the vehicle high enough that the wheels do not
the affected area of skin. Do not use fraying
touch the ground when in operation.
dressings (e.g. absorbent gauze). Do not rub the
• The person sitting in the driver's seat must be familiar affected area of skin.
with the operation of the vehicle and be able to
• Consult a physician immediately.
initiate appropriate measures.
• When setting up the jack stands, make sure they are
positioned on solid ground and that they are standing
firmly.
Risk of injury to skin or eyes from hydraulic fluid spraying...
Attachment
aWarning
Risk of injury to skin or eyes from hydraulic fluid spraying Depressurize hydraulic system completely before starting
out under pressure.Risk of poisoning from swallowing any work on it. Wear protective clothing and safety
hydraulic fluid. glasses.
Potential risks • Immediately close off disconnected lines and hoses

and connections to the major assemblies using blind
Risk of injury plugs.
If hydraulic lines are detached without having • Wear protective gloves, protective clothing and safety
depressurized the system beforehand, dangerous glasses.
injuries can occur to the skin or eyes due to the very
high pressures involved (greater than 200 bar). Skin The following points should be observed if protective
damage can occur if hydraulic fluid, particularly central gloves cannot be worn:
hydraulics fluid (a particularly serious health hazard) • Keep contact of skin with hydraulic fluid to a
comes into contact with unprotected skin. minimum; clean affected part of skin with water and
soap.
Risk of poisoning
• Change moistened clothing as quickly as possible.
Swallowing hydraulic fluid may produce symptoms of
poisoning such as headaches, dizziness, stomach First aid measures
aches, vomiting, diarrhea, cramps and unconsciousness. • Have the person affected drink plenty of water with
Safety precautions/instructions activated charcoal additive.
• Depressurize the hydraulic systems before beginning • If large amounts are swallowed, consult a physician.
work on them, and it may even be necessary to • If hydraulic fluid gets into the eyes, rinse eyes
empty the system. immediately with copious amounts of clean water/eye
• Do not pour hydraulic fluid into beverage containers. rinse.
• It is particularly important to have good ventilation • Consult a physician immediately in cases of injury to
when working with central hydraulics fluid. the skin or eyes from an hydraulic fluid jet.
• Ensure accessibility to hydraulic fluid only for

authorized persons.
Risk of explosion due to escaping combustible gas or overhea...
Attachment
aDanger
Risk of explosion due to escaping combustible gas or Remove any sources of ignition.
overheating of gas cylinders.Risk of injury caused by Protective clothing, safety gloves and safety glasses must
burns to skin and eyes. Risk of frostbite to body parts always be worn.
caused by escaping gas and by touching components
near the valves when empty Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over
60 °C, all gas cylinders must be removed.
Potential risks frostbite when coming into contact with components

close to the valves.
Risk of explosion
There is a risk of explosion when gas escapes (e.g. due Risk of poisoning and asphyxiation
to a leakage) or in case of overheating of the gas There is a risk of poisoning and asphyxiation if gas is
cylinders. inhaled when high gas concentrations are present in the
surrounding air. Particular attention must be paid in this
Risk of injury respect to the potential accumulation of gas in closed
Accidental ignition of the escaping gas may pose the risk environments.
of burns to skin and eyes.
Risk of frostbite
When filled gas cylinders are emptied, the expanding
gas cools down to such an extent that there is a risk of
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Safety precautions/instructions
No smoking, fire, open flames or mobile phones: i
The gas lines are sufficiently emptied when the
• in the vicinity of the refueling point,
engine switches to gasoline operation or stops by
• in the vicinity of the engine compartment, itself after running at idle speed for several minutes.
• in the vicinity of the gas cylinders,
• in the vehicle parking hall or the workshop.
In workshops, adequate ventilation openings must be i
provided in the roofs of the shops to ensure that any Model 956, 963 with two pressure unloading valves
escaping gas is able to rise up and escape into the at gas cylinder
atmosphere without risk. It must be taken into account that the line to the
Before commencing work, ensure that all sources of pressure unloading valve remains pressurized at the
ignition have been removed. Ensure adequate gas pressure of the associated gas cylinder, even
ventilation of the immediate area around the vehicle. with a closed gas shutoff valve. This as-built
configuration is pointed out in the document
AH00.10-N-1000-06A.
i
Adequate ventilation means an exchange of air at
least 3 times an hour at a distance of 3 meters from Vehicles fitted with gas systems on which the gas shutoff
the gas shutoff valve. valves remain closed and the gas lines have been
emptied can be handled in the same way as vehicles
that operate with spark-ignition engine fuel, provided that
Close the gas shutoff valves on the gas cylinders before • the gas shutoff valves remain closed,
commencing repair work. • the gas lines have been emptied and
After closing the gas shutoff valves, empty the gas lines • the gas cylinder is not allowed to reach a temperature
by running the engine.
in excess of 60 °C.
Work that involves any risk of ignition is only permissible
on vehicles with natural gas systems after special safety
precautions, e.g. closing gas shutoff valves, have been
taken to prevent gas from escaping and to prevent the
heat from increasing the pressure in the gas cylinder or
Risk of explosion due to escaping combustible gas or overhea...
Attachment
in the gas lines. If applicable, the gas lines must be
emptied and the gas cylinders removed.
---------------------------------------------------------------------------
Maintenance and repair work may only be carried out by vehicles fitted with a natural gas system on which the
specially trained personnel. gas shutoff valves are not closed and the gas lines are
Any vehicle fitted with a natural gas system and present not emptied may only be parked at places
on the premises of the workshop must be provided with • at which an exchange of air takes place at least 3
an easily visible warning of the presence of a natural gas times an hour.
system. is present.
Natural gas is lighter than air and may under certain
conditions accumulate in the air. For this reason,
---------------------------------------------------------------------------
If there is a risk that gas cylinders filled with natural gas
may reach a temperature of more than 60 ℃ when i
placed in driers for coating material (e.g. when painting), Leak detectors that can also perform gas
they must be removed prior to drying. measurements far below the explosion threshold are
After performing work on the components or gas lines of especially suited as gas measurement and warning
the natural gas system, a leak test must be carried out. devices. A leak detecting spray is used for precise
The specifications regarding the leak test vary between location of leaks.
countries. Please refer to the national legislation for the
specific regulations.
The procedure for detecting leaks in a natural gas Natural gas can cause frostbite injuries. Protective
system must avoid any risk of igniting gas that may leather gloves should be used if necessary.
escape.

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Discharge area: Alternatively, it can be stated in the service instructions
You should avoid discharging the gas of the gas system that pressure relief of the gas system is not to be carried
to the atmosphere - if possible - because natural gas is a out when there is the risk of a thunderstorm. The
greenhouse gas. Furthermore, discharging may also discharge area should have a way to ground the vehicle,
disturb the neighborhood. If discharging cannot be e.g. by using a steel rod hammered into the ground.
avoided, the specifications from the vehicle or system
manufacturer must always be observed.
Pressure relief of gas systems by means of discharging i
may only be performed outside. A marked area of Special considerations for CNG:
approx. 10×10 m is required for pressure relief of the gas
system. No other vehicles may be located in this area
during the pressure relief process and no other work If the discharge area is partially or completely roofed
may be performed. over, you must ensure that the escaping gas can flow
freely upwards.
The discharge area should preferably be equipped with
a lightning protection system (lightning rod).
---------------------------------------------------------------------------
Storage area for removed and non-inerted gas cylinders: area must be marked and access to the cylinders can be
Removed and non-inerted gas cylinders should not be restricted, e.g. by means of a tightly-worked chain link
stored in the general maintenance and repair area. The fence. In any event, make sure that the gas can mix
storage area can also be located outside. The storage freely with the ambient air.
Risk of injury from engine start by remote start function
Attachment
aWarning
clothes
Risk of injury • Wear closed and close-fitting work clothes.

The engine can start running suddenly through the • Remove all jewelry such as necklaces, chains, rings,
remote start function. Persons working in the area of etc.
freely rotating parts may be injured by this. • Persons with long hair must wear a suitable head
Safety instructions/precautions covering.
• Do not reach into the rotation area or danger zone of • Prior to starting work, deactivate the remote start
freely rotating parts. function and secure against reactivation.
Risk of death caused by vehicle slipping or toppling off dur...
Attachment
aDanger
Risk of accident and injury

The vehicle may only be lifted at the vehicle lift or vehicle i
jack support points as specified by the vehicle As a matter of principle, the safety regulations of the
manufacturer. Ensure that the vehicle is ideally aligned respective country are applicable. The user is
and secured against tilting according to the general personally responsible for complying with these.
safety specifications and regulations.
Non-observance of the safety specifications can cause
the vehicle to slip off the lifting device and thereby result
in life threatening or fatal injuries.
Risk of death when working on component parts and systems wi...
Attachment
aDanger
Risk of death when working on component parts and Do not touch damaged or defective live component parts
systems with U >= 30 V alternating voltage (AC) or U >= and lines or non-insulated electrical connections and
60 V direct voltage (DC) lines.
Voltage • On DC generators with a defective rectifier diode.

Alternating voltages (AC) of U >= 30 V and/or direct • On illuminated door sill moldings, DC/AC converters,
voltages (DC) of U >= 60 V occur on the following and their supply lines
systems and component parts in vehicles and bodies:
Potential risks caused by alternating voltages (AC)
• On the high-voltage on-board electrical system and of U >= 30 V and/or direct voltages (DC) of U >= 60 V
high-voltage component parts of HYBRID vehicles,
electric vehicles, and fuel cell vehicles The flow of electric current through the body can
lead to involuntary muscle contractions, heart rhythm
• On the lithium-ion battery of HYBRID vehicles, disturbances, fibrillation of the heart, cardiac arrest,
electric vehicles, and fuel cell vehicles respiratory arrest, burns, or other cellular damage. The
• On fuel cells severity of the injury depends on the current strength,
• On solenoid and piezo injectors and their control current type, the frequency of the current, the exposure
units and supply lines of gasoline and diesel engines time, and the route through the human body.
• On spark plugs, ignition coils, their control units, and Electric arcing can lead first-degree to fourth-degree
supply lines of the ignition system on gasoline and burns, flash burns to the eyes because of the strong UV
natural gas engines light (similar to that caused by welding), blast trauma
and injury from moving parts.
• On electrical ballasts, xenon bulbs, and their supply
lines of xenon headlamps Secondary accidents occur as a result of startle
responses that are caused by contact with voltages or
• On the MAGIC SKY CONTROL, DC/AC converters, electric arcs. Secondary accidents include, for example,
and their supply lines falling from a raised workstation or a person's head
• On voltage converters from 12 or 24 V to 230 or making contact with an engine hood.
110 V Each of these harmful effects can cause serious
• On spark generators and electrodes, and their supply human injury or death.
lines of stationary heaters Effects can occur up to 24 hours after the time of the
• On systems that are supplied with alternating accident. Therefore, it is essential to have a medical
voltages (AC) of U >= 30 V and/or direct voltages examination immediately after an accident involving
(DC) of U >= 60 V via engine-driven alternators or via alternating voltages (AC) of U ≥ 30 V and/or direct
external connections. voltages (DC) of U ≥ 60 V.
---------------------------------------------------------------------------
Safety precautions/instructions voltages (AC) of U ≥ 30 and/or direct voltages (DC)
• People who have electronic implants (e.g. cardiac of U ≥ 60 V or which personal protective equipment
pacemakers) must not perform work on component (PPE) is required can be found in the respective
parts and systems with alternating voltages (AC) of documentation concerning the topic in the WIS,
U ≥ 30 V and/or direct voltages (DC) of U ≥ 60 V. Xentry TIPS, EVA and, if applicable, country-specific
sources before starting work.
• For work on component parts and systems with
alternating voltages (AC) of U ≥ 30 and/or direct • Only tools that have been tested and have the
voltages (DC) of U ≥ 60 V, the necessary safety corresponding approval may be used for work on
precautions according to the country-specific component parts and systems with alternating
directives and legislation must be taken with the voltages (AC) of U ≥ 30 V and/or direct voltages (DC)
corresponding qualification measures/briefings in of U ≥ 60 V.
accordance with the respective documentation • No damaged or defective live component parts and
concerning the topic in the WIS, Xentry TIPS, EVA, lines and no non-insulated electrical connections and
and, if applicable, country-specific sources before lines may be installed on component parts and
starting work and during work. systems with alternating voltages (AC) of U ≥ 30 V
Information as to which safety precautions for work and/or direct voltages (DC) of U ≥ 60 V.
on component parts and systems with alternating
Risk of injury caused by burns to skin and eyes. Risk of poi...
Attachment
aCaution
Risk of injury caused by burns to skin and eyes. Risk of Work in well ventilated rooms only. Wear safety glasses
poisoning caused by inhaling fumes when working with with side protection and protective gloves.
heat-shrinkable tubing.
Potential risks Safety precautions/instructions
Risk of injury • Work only in well-ventilated rooms.
When working with heat-shrinkable tubes, the high • Avoid overheating the heat-shrinkable tube.
temperatures involved may cause burns to skin and • Stop heat-shrinking immediately if the heat-
eyes. shrinkable tubes become blistered or charred or
show other signs of damage.
Risk of poisoning
• Do not inhale the vapors that might be released.
When working with heat-shrinkable tubes, vapors may
be produced which lead to symptoms of poisoning such • Avoid contact with melted material.
as coughing, headaches, dizziness and nausea. • Wear safety glasses with side protection and
Moreover, irritation may occur to the respiratory paths protective gloves.
and eyes.
---------------------------------------------------------------------------
First-aid measures • Contact a physician or medical service.
When melted shrink tubing comes into contact with skin Fire protection measures
or eyes:
Suitable extinguishing agents
• Rinse the affected area immediately with plenty of
water for approx. 15 minutes. • Water mist, general-purpose foam, powder, carbon
dioxide
• Treat affected area like a burn wound. Do not remove
any burned portions yourself. • Protective equipment for firefighters (compressed air
equipment, oxygen apparatus, chemical-resistant
• Contact a physician or medical service. protective clothing)
If vapor is inhaled:
• Take the person into the fresh air.
• Keep the person calm and cover with a blanket.
Risk of death from lowering vehicle when working between whe...
Attachment
aDanger
Risk of death from lowering vehicle when working Testing and repair work between the wheel and wheel
between wheels and body. Risk of injury from pinching or arch or in the wheel well should only be performed if the
crushing when working on the air suspension. vehicle is secured using suitable support fixtures to
prevent it from lowering.
Adjustment operations should only be performed from
underneath the vehicle.
Use only suitable support fixtures to secure the vehicle
frame or vehicle axles in order to prevent them from
lowering.
If necessary, additionally use suitable support fixtures in
order to prevent other moving vehicle parts that are in the
working area from lowering, or use suitable retaining
devices to prevent these parts from moving suddenly and
without warning.
Secure areas with moving vehicle parts against
Risk of death performed if the vehicle is secured using suitable

If the air suspension system is defective, sudden support fixtures to prevent it from lowering
pressure loss may cause the vehicle to lower quickly on • Adjustment operations should only be performed
its own. This can result in life-threatening injuries caused from underneath the vehicle
by trapping and crushing. • Adjustment operations should, to the extent possible,
Adjustment operations to the air suspension system may be performed with switched off ignition and/or fully
result in an aeration or ventilation of the air suspension depressurized compressed-air system
bellows or lift bellows and thus in a lifting or lowering of • Use only suitable support fixtures to secure the
the vehicle or individual axles. This can create an vehicle frame or vehicle axles in order to prevent
unclearly defined danger area. them from lowering
Risk of injury • If necessary, additionally use suitable support fixtures
Reaching into the area of the axle suspension or level in order to prevent other moving vehicle parts that are
control system during adjustment operations or with a in the working area from lowering, or use suitable
defective compressed air system can result in serious retaining devices to prevent these parts from moving
injuries. suddenly and without warning
During adjustment operations or in the case of a • Secure blind hazard areas against unauthorized
defective compressed-air system, serious injuries can access using appropriate shielding (e.g. barriers,
occur to persons located in the immediate vicinity of the safety guards)
air suspension bellows or lift bellows.
• Testing and repair work between the wheel and
wheel arch or in the wheel well should only be
Risk of death when loosening nuts of axle for attaching auto...
Attachment
aDanger
Risk of death when loosening nuts of axle for attaching Do not loosen nuts of axle assembly simultaneously!
automatic tire chains
Replace nuts of spring U-bolts successively by double or slip off the lifting device, and in doing so, cause life-
nuts for attaching the assembly plate for the snow threatening or fatal injuries. As a matter of principle, the
blower chains! Otherwise, the entire axle assembly will safety regulations of the respective country are
come loose. applicable. The user is personally responsible for
Risk of accident and injury complying with these.
If the safety regulations are not observed, the axle

assembly may move or fall off, the lifted vehicle may tip
Risk of injury from cutting pressurized compressed air lines
Attachment
aWarning
lines
Risk of injury When disconnecting the pressurized line, the

When disconnecting pressurized compressed air line. pressurized air remaining in the line escapes suddenly
and stirs up dust and dirt from the surroundings, which
When disconnecting the pressurized line, the line may then ends up in one's eyes, nose, mouth and ears.
detach suddenly due to the existing pressure in the
system, get out of control and thereby cause severe Safety instructions/precautions
injuries due to the detached end of the compressed air • Wear protective gloves and safety glasses.
line whipping about
• When disconnecting the line, close compressed air
When disconnecting the pressurized line, the outlet.
pressurized air remaining in the line escapes suddenly
and can penetrate orifices of the body
Risk of injury from being trapped in the swivel range of ste...
Attachment
aWarning
Risk of injury from being trapped in the swivel range of Ensure that no persons or objects are in the swivel range
steered axles of all steered axles when turning the steering wheel. Do
not stand in the swivel range of the additional steering
axle when the engine is running.
Risk of injury steering axle may start steering autonomously, which in

If persons are standing in the swivel range of steered turn can pinch objects and persons located in the swivel
axles, they can be pinched when the steering wheel is range.
turned and sustain serious injuries as a result of the high In addition, the front axle steering system must not be
mechanical forces present in this area. operated whenever work is carried out on the auxiliary
Objects that are in the swivel range of steered axles can steering. Unless individual work activities require such
be damaged when the steering wheel is turned. There is movement while taking the necessary precautions. Here,
also the danger of parts from damaged objects flying too, there is the danger of becoming pinched as well as
around and injuring persons. a high risk of injury due to the resulting forces and
pressures in this area.
If a faulty steering movement occurs on vehicles with
additional steering axles while the vehicle is at a Safety precautions/instructions
standstill and the engine is running, the control unit for • Ensure that no persons or objects are in the swivel
the additional steering axle (ASA) or electrohydraulic range of all steered axles when turning the steering
auxiliary steering may not detect this. In this scenario, it wheel.
is possible that the control unit cannot initiate a fault
response that e.g. would result in the additional steering • Do not stand in the swivel range of the additional
axle being deactivated. The wheels on the additional steering axle when the engine is running.
Risk of burn injuries, suffocation and poisoning when workin...
Attachment
aWarning
the exhaust. Risk of
Risk of burn injuries! • Avoid inhalation of exhaust gases; wear respiratory

The exhaust system and all component parts connected protection.
to it are very hot during operation and remain so after • Use the exhaust extraction system.
the engine is switched off. Do not touch hot parts. • To prevent skin contact on hands, wear nitrile gloves.

First aid measures
Risk of suffocation and poisoning! In the event of inhalation:
Exhaust gases may cause cancer. Move victim from the danger zone to fresh air without
At higher concentrations, irritation of mucous endangering yourself and consult a physician
membranes and headaches may occur. Carbon immediately.
monoxide may cause damage to unborn children. After contact with skin:
Risk of injury! Immediately wash affected areas of the body with plenty
Risk of injury to the eyes, skin, and respiratory paths due of soap and water. Employees who have experienced
to contact with exhaust residues such as diesel skin contact must consult a physician immediately.
particulates and diesel soot.
Safety instructions/precautions After contact with eyes:
• Allow component parts to cool down before starting Rinse eyes thoroughly with running water for at least
work. 10 minutes with the eyelids wide open and contact an
eye doctor immediately.
• Do not touch hot parts. Transport hot or glowing
objects only using suitable aids.
Risk of burn injuries and scalding when working on AdBlue(R)...
Attachment
aWarning
AdBlue(R)
Potential risks On vehicles with a compressed air system, individual

lines are flushed with compressed air after the engine
Risk of burn injuries and scalding is switched off. For this reason, work on the exhaust
The AdBlue® lines and all components attached to them gas aftertreatment system may not be started until at
are under pressure during operation and remain so after least 5 minutes have elapsed after the engine is
the engine is switched off; they may be hot. There is a switched off.
risk of burn injuries. There is a risk of scalding caused by • Open connections and plugs on the system
escaping hot AdBlue® when the line system is opened. components slowly. Cover the connecting point with
rags when opening.
Risk of injury
• Pour AdBlue® only into marked containers specially
There is a risk of skin irritation and eye damage on intended for the purpose. Do not pour AdBlue® into
contact with AdBlue®. drinking containers.
Risk of poisoning • Wipe up any AdBlue® spills immediately because
there is a high risk of someone slipping.
There is a risk of poisoning if AdBlue® is swallowed.
Rules of conduct
• In vehicles with an electric delivery pump, the
AdBlue® is pumped back from the line into the
AdBlue® tank after the engine is switched off.
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Safety precautions for handling removed parts and Ingestion: Rinse mouth with clean water and drink large
working under the vehicle quantities of water. Immediately seek medical
• Wear suitable protective gloves. assistance.
• Wear protective clothing. Firefighting measures

• Wear safety glasses. AdBlue® is not combustible. NH3 (ammonia) can be
released in the event of fire, causing a risk of poisoning.
First aid measures Firefighting measures must therefore be suited to the
Contact with skin: Wash the affected skin areas with surroundings.
plenty of clean water. Change moistened clothing as
quickly as possible.
Contact with eyes: In the event of contact with eyes,
immediately rinse eyes thoroughly with plenty of clear
water; contact an eye doctor if necessary.
Risk of fire/risk of explosion due to short circuit and esca...
Attachment
aDanger
of poisoning c
Potential risks such as tools or jewelry (watch strap or ring) become hot
The flow of electric current through the body can in seconds, and red hot/liquid metal sprays are released.
lead to involuntary muscle contractions, heart rhythm Do not expose batteries to mechanical pressure. There
disturbances, fibrillation of the heart, cardiac arrest, is a risk of short circuits and leakage of battery
respiratory arrest, burns, or other cellular damage. electrolyte/mist.
The severity of the injury depends on the current Detaching battery clamps or connector couplings under
strength, current type, the frequency of the current, the load or a short circuit can cause electric arcs. Electrical
exposure time, and the route through the human body. arcing can result in first-degree to fourth-degree burns,
flash burns to the eyes caused by strong UV light
Risk of fire/explosion (similar to that caused by welding), blast trauma and
When charging a lead-acid battery, a highly explosive injuries from moving parts.
oxyhydrogen gas mixture is created. This gas mixture
ignites by means of fire, sparks, open flames, and Risk of poisoning
smoking. Swallowing battery electrolyte can result in symptoms
In the event of a short circuit from the positive battery of poisoning such as headache, dizziness, stomach
terminal to the negative battery terminal, the battery ache, respiratory paralysis, unconsciousness, vomiting,
terminals and conductive objects causing a short circuit, caustic burns, and cramps.
such as tools or jewelry (watch strap or ring), as well as Absorption of lead from acid batteries into the body
the battery, become hot in seconds. There is a risk of through contact with component parts containing lead
fire/explosion. (battery terminals, lead plates in damaged batteries)
In the event of an internal short circuit of the battery damages the blood, nerves, and kidneys; lead
cells, there is a risk of fire/explosion. compounds are also toxic for reproduction.
In the event of improperly sealed degassing/electrolyte The risks of poisoning listed above also apply to lead-
leakage openings, there is a risk of fire/explosion as a antimony batteries.
result of overpressure in the battery housing. Risk of death
Do not expose batteries to mechanical pressure. There Risk of death due to an alternating voltage (AC) of
is a risk of fire/explosion. U >= 30 V and/or a direct voltage (DC) of U >= 60 V.
Risk of injury/burn injuries Secondary accidents
Contact with the battery electrolyte/mist results in severe Secondary accidents occur as a result of startle
chemical burns to the skin, eyes, and mucous responses that are caused by contact with voltages from
membranes. This results in deep tissue damage. high-voltage batteries and electric arcs. Secondary
In the event of a short circuit from the positive battery accidents include, for example, falling from a raised
terminal to the negative battery terminal, the battery workstation or a person's head making contact with an
terminals and conductive objects causing a short circuit, engine hood.
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Safety precautions/instructions briefings. The corresponding training/safety
• If there is an acute risk to a lithium-ion battery as a precautions/briefings must be carried out in
result of smoke, fire, heat development, electrolyte accordance with the documentation concerning the
leakage (visible/smellable), immediately make an topic in WIS, TIPS, EVA, and if applicable, country-
emergency call to the respective location-specific and specific sources before starting work and during
country-specific emergency number. Do not touch the work.
lithium-ion batteries, and vacate the danger zone. • Keep batteries and battery electrolyte out of reach of
• Training is required in order to handle lithium-ion unauthorized persons.
batteries. You can obtain the required training from • No fire, sparks, naked flames and smoking.
various places, including Mercedes-Benz Global • Do not expose batteries to mechanical pressure.
Training. You can find out from your respective MPC
as to whether additional country-specific directives • Do not charge or reinstall batteries with a damaged
and legislation require additional special training/ housing.
Risk of fire/risk of explosion due to short circuit and esca...
Attachment
• Charge 12 V batteries only in well ventilated rooms • Always store, transport, and install batteries with
with the correct voltage and correct current with liquid battery electrolyte horizontally; otherwise,
approved chargers, taking into account the battery electrolyte may leak out of the degassing
instructions of the battery and charger manufacturers. holes.
• Do not switch on the charger for 12 V batteries until • For vehicles with a 48 V on-board electrical system,
after connecting to the terminals; switch off before wait for at least 10 s before releasing the 12 V
disconnecting. positive line to ensure that the recharging function is
• It must be ensured that the degassing/electrolyte deactivated.
leakage openings are not improperly sealed and that • Do not charge the 48 V battery directly; instead,
the corresponding devices for dissipating the gases/ charge it via the 12 V on-board electrical system with
electrolyte are connected correctly. the existing/approved 12 V chargers.
• Ensure the degassing line does not have any kinks • Do not place any tools or other conductive objects on
and is not blocked at any point. top of the battery. This creates the risk of a short
• Always disconnect the negative terminal first; always circuit!
connect the positive terminal first. Otherwise, there is • In the event of opened and damaged batteries. Wear
possibly a risk of a short circuit between the positive acid-resistant clothing and safety glasses with side
battery terminal and the body ground caused by the guards.
tool. • Observe the instructions for use that are delivered
• Pour leaked battery electrolyte only into suitable and together with the batteries.
appropriately marked containers.
Risk of death. There is a risk of death to persons located w...
Attachment
aDanger
body is lowered.
Potential risks Safety precautions/instructions
Risk of death • Apply parking brake before tilting.
Death may result if a load falls off the dump body while it • Make sure the vehicle is securely parked in a level
is being raised, or if the vehicle topples over when it is position before tilting.
parked at or on an incline or on unsurfaced ground. • Ensure that the wheels under load when tilting are
Death may result if the dump body drops while someone standing on solid ground.
is working underneath the raised dump body. • Ensure that no person is located within the swivel
range of the dropside or within the tilting range.
Risk of injury
• When working under the raised dump body
Severe injuries may be caused if the dropside suddenly (e.g when removing the spare wheel), secure the
swings open while the dump body is being lifted. dump body with the dump body support.
Body parts may be crushed or jammed when the dump • Observe the safety regulations and operator's
body is lowered. manual of the dumper manufacturer.
Risk of explosion caused by paint vapors igniting. Risk of p...
Attachment
aDanger
Risk of explosion caused by paint vapors igniting. Risk of No smoking! No open fire! Use respiratory protection,
poisoning caused by inhaling paint vapors. protective clothing, gloves, safety glasses and protective
skin cream. Ensure that the area is well ventilated.
Potential risks • Always use protective clothing, gloves, safety glasses

and protective skin cream.
Risk of explosion: When working on paints, vapors
are created that explode when ignited • Paint in a spraying booth. Ensure adequate
ventilation and always wear a protective respiratory
Risk of poisoning mask.
Inhaling paint vapors and spray mist can pose a health • Paints require special identification. Poisonous and
hazard! Contact with paint vapors can cause irritation to cancer causing substances (marked with a T, skull
skin and eyes. and crossbones) may only be handled in the
presence of specially qualified personnel.
Paint may contain hazardous substances such as:
• When handling these materials, please observe the
• Cancer causing substances (e.g. benzene, zinc
pertinent safety regulations of the UVV-VBG 23, the
chromate),
Directive on Dangerous Substances and the
• Poisonous substances (e.g. zinc chromate, phenol), environmental protection regulations (according to
• Genetically hazardous substances (e.g. ethyl glycol the hazardous substance ID on the container and the
acetate/ethyl acetate) safety data sheets from the supplier).
• In export countries, please observe your country-
Rules of conduct and protective measures specific accident prevention and protection
• No smoking! No open fire! regulations.
---------------------------------------------------------------------------
First-aid measures Skin
Eyes • Splashes on the skin must be immediately and

carefully washed off with plenty of soap and water. If
• Rinse the eye thoroughly for several minutes with necessary, clean skin again with a suitable skin
lukewarm water while protecting the non-affected cleaning agent.
eye. Eyelid must be wide open. Request victim to
move the eye in all directions as it is being rinsed out.
Consult an eye doctor and be sure to state measures
already taken.
Respiratory paths
• Fresh air; perform mouth to mouth respiration if the
victim is no longer breathing, if necessary administer
oxygen, keep warm, keep calm. Consult a physician.
Risk of explosion caused by paint vapors igniting. Risk of p...
Attachment
Daimler Truck AG - TE/PEX
Order no. Germany

ARL LKW Actros Arocs AeJ2022 2a 202207 en

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Actros/Arocs Model

Actros/Arocs Model Series 963x/

Daimler Truck AG - TE/PEX

@ 2022 Daimler Truck AG

Body manufacturer consulting 19

Display without fault message 66

Technical threshold values for planning 111

Vehicle overhang and technical wheelbases 111

Damage prevention 123

Electrical system 123

Modifications at frame 150

Vehicle frame material 150

Detachable parts at frame 167

Mounting on vehicle frame 167

Modifications to basic vehicle 241

Leading/trailing axle 241

Modifications at cab 255

Exhaust gas aftertreatment system 263

Exhaust gas aftertreatment system for Euro III Standard 263

Power take-off 360

Power take-off, general information and exhaust gas aft... 360

Driver assistance systems 422

Front sensors 422

Compressed-air system 455

Repair and extension of plastic compressed-air lines of... 455

Subframe, general 487

Design of bodies 516

Design of bodies, general 516

Electrics/electronics - General, wiring diagrams, inter... 579

Connection of electrical consumers 623

Lighting systems according to UN directives and German ... 705

Additional information 730

Overview of documents/catalogs/instructions/circuit dia... 730

System for quality assurance Page 43

Contact person: Stephan Folk Team Manager

Contact person: Martin Glaser Team Manager

Contact person: Carsten Hirt Technical Weights, Tire Change, ESP®

Marius Marxer Certificates of Non-Objection

Peter Neffle Certificates of Non-Objection

Rafael Scandelari Certificates of Non-Objection

Süleyman Özyer Certificates of Non-Objection

Postal address: Daimler Truck AG

Contact person: Rainer Thomas Team Manager

Contact person: Sascha Pompejus Econic (model series 956.0/.4)

Thomas Wagenblatt Econic (model series 956.5), Zetros (model

Tel.: +49 7271 71 8479

Volker Jungmann U216 – U530 (UGN and UGE)

Andreas Rödler U4000 - U5023 (UHN and UHE)

Stefan Tauras Offer Drawings, 3D Models

Mario Messina Marketing, Processes and Contracts

Fax: +49 7271 71 8086

Postal address: Daimler Truck AG

Point of Contact for Weight Mercedes‑Benz Sales Germany

Postal address: Department: VDS, in-house post code:

Point of Contact for Vehicle Technical Advice for Body Manufacturers

Point of Contact for Weight Daimler Truck AG

Point of Contact for Vehicle Technical Advice MBS

Roll-off container vehicle Page 537

• The retroactive issue of a certificate of non-objection • Operating and road safety

Additional specifications of sectional changes in • Specification of actual maximum effective vertical

Specification of the following

• Skip loader subframe dimensions, material thickness • Dc value

General information • Distances from contact points of dump body on