Body Equipment Mounting Directives For Trucks - Accelo

Body/Equipment Mounting Directives for
Trucks
Accelo 979.0XX Euro 3/5
Mechanic
11.26.2020
Body/Equipment Mounting Directives for Trucks
These guidelines provide instructions for the References to laws, standard, guidelines, etc. are given
manufacturing and assembly of additional structures, just for information. The valid version of all the laws,
bodies, equipment and accessories by third parties. standards, guidelines mentioned in this manual, always
is the current one, except if otherwise indicated by
In order to keep the operation safety and to preserve
technical specifications issued by Mercedes-Benz do
the rights from the warranty, the indications herein
Brasil Ltda..
contained must be strictly observed.
The right to carry out alterations without previous notice
Mercedes-Benz do Brasil Ltda. does not assume any
is reserved.
liability if the current guidelines are not observed.
As the vehicle operation mode can vary according to the
The schematic figure and drawings are only examples
optionals required, discrepancies may appear in the
and explain the texts and tables. They can not represent
illustrations.
all the details of the vehicles with accuracy.
For special versions not covered by these
To carry out installations, buildings or assembly of
guidelines, the Implementer shall contact
implements, parts of equipment or accessories in our
Mercedes-Benz do Brasil Ltda. at “Technical
vehicles it is important to have knowledge of these
Consulting and Contacts”  page 17.
guidelines, and some works may only be carried out by
qualified staff. The copy, translation, total or partial reproduction
without previous authorization is not permitted.
Due to the great diversity of manufacturers and
different types of bodies and pieces of equipment, Accelo - Mechanic
Mercedes-Benz do Brasil Ltda. cannot anticipate the
BMD-BR020003BE3
dynamic behavior, stability, weight distribution, center
of gravity among other things, resulting from changes to Edition: 11/2020
the chassis due to the installation and construction of Mercedes-Benz do Brasil Ltda.
implements. For that reason, Mercedes-Benz do Brasil
Ltda. will not be liable for accidents or damages
resulting from these changes, which might interfere,
negatively, in the operational behavior of its vehicles.
The manufacturer of road implements is obliged to
warrant that his equipment are free from defects, do not
cause faults in the complete vehicle and do not put it in
a risky situation. In the case this obligation is not
complied with, the manufacturer of road equipment is
liable to the product.
i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

1
! Observe the indications related to the changes! Always print complete chapters in the updated version.
Table of Contents
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Manual Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Presentation Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Vehicle Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Note About Copyright Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Implements Assembly Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.1 Required Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.2 Lawsuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Product Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.1 Traceability Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.2 Warranty Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.8 Relevant Features for the Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8.1 Accidents Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.9 Body Builders Information Portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.10 Technical Consulting and Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Body and Equipment Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.1 Vehicle Identification/Proposal Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Changes in the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Dimensions and Weight Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.1 Hydraulic Steering Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.7 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7.1 Exhaust Gas Aftertreatment System (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.8 Optional/Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.8.1 Wind Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8.2 Auxiliary and Signaling Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.9 Additional Pneumatic Consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Limit technical values during the planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1 Vehicle Frame Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Subframe Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2.1 Dimensions of the Profile for the Subframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3 Extension of the Rear Overhang and Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4 Weight Distribution and Height of the Gravity Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.1 Load Distribution on the Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5 Driveability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.6 Free Space for the Major Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.7 Clearance for the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2
Table of Contents
3.7.1 Cab Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.7.2 Additional Structure on the Cab Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.8 Telligent® Stability Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.9 Semitrailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.10 Dimensioning of the Trailer Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.11 Total Technical Weight of the Vehicle and Loads on the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12 Power Take-off Technical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.12.1 Power Calculation for the Coupled Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.13 Technical Data Concerning the Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.14 Tightening Torque for the Fastening of the Vehicle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Damages prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1 Fuel and Brake System Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2 Welding Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3 Painting Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.5 Leaf Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.6 Cab Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.7 Start by Towing and Vehicle Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.9 Vehicle Storage and Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5 Basic Vehicle Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Drilling in the Vehicle Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 Frame Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.4 Chassis Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.4.1 Vehicle Alignment Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.5 Change of the Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.5.1 Alteration of the Wheelbase Distance Due to the Displacement of the Rear Axle Block . . . . . . . . . . . . 69
5.5.2 Alteration of the Wheelbase by Means of Cutting the Longitudinal Members . . . . . . . . . . . . . . . . . . . . 70
5.5.3 Reinforcements in the Longitudinal Member Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.5.4 Repositioning the Crossmembers in the Vehicle Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.6 Rear Overhang Alterations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.6.1 Rear Overhang Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.6.2 Shortening the Rear Overhang. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.6.3 Propeller Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.6.4 Arrangement and Angle of the Propeller Shafts Flanges Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.7 Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7.1 Air Reservoirs Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.7.2 Compressed-air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.8 Additional Components and Major Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.8.1 Assembly/Repositioning the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3
Table of Contents
5.8.2 Repositioning of the Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.9 Subframes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.9.1 Subframe Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.9.2 Subframe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.9.3 Regions Appropriate for the Subframe Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.9.4 Regions Inadequate for the Fastening of the Subframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.10 Fenders and Wheel Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.11 Spare Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.12 Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.13 Side Protector for Cargo Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.14 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.14.1 Cab Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.14.2 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.15 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.16 Auxiliary Axle or Trailing Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.16.1 Instructions to Adapt the Rear Auxiliary Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.17 Retrofitting of an Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.18 Auxiliary Power Take-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.19 Auxiliary Power Take-off Coupled to the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.19.1 Assembly of the Propeller Shafts for the Power Take-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.20 Power Take-off Actuated by the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.20.1 Power Take-off in the Engine, Front Part, Actuated by Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.20.2 Power Take-off in the Engine, Back Part, Actuated by the Engine Flywheel . . . . . . . . . . . . . . . . . . . . . 112
5.21 Coupling or Engagement for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.21.1 Use of the Vehicle with the Center Axle Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.22 Tractor Trucks for Semitrailers (“Tractor Truck”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.23 Alterations in the Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4
1 Preface
1.1 Manual Structure
1.1 Manual Structure The following figures illustrate the separation between
the basic vehicle and the implement.
To enable the quick finding of the desired information
the document “Guidelines for the Assembly of Road
Implements and Equipment” is divided in
interconnected chapters:
i Browsing
To make easier to browse through the manual,
activate the Adobe Reader® browsing bar under
View/Tool bar/Browsing Basic vehicle
1 Introduction.
2 Body building process.
3 Body and equipment planning.
4 Limit technical values during the planning.
5 Damages prevention.
6 Basic vehicle changes.
In some parts of the text the terms “additional Implement
structures, bodies, equipment, major assemblies and
accessories” can be referred to simply by “implements”.

5
1 Preface
1.2 Presentation Forms
1.2 Presentation Forms
These “Instructions for the Production and Assembly of
Implements and Equipment” include the following
presentation types.
G Risk of Accident
A warning signal will call your attention to possible
risks of accidents and injuries.
H Environment Protection Related Indication

An indication related to the environment protection
will provide suggestions on how to preserve and
protect the environment.
! Material Damage
This indication will call your attention to possible
risks of damages to the vehicle.
i Other Information
This indication will provide you with
recommendations or any other kind of information.
page This symbol will indicate the page where

you can find further information on the
theme, it contains a “hyperlink” in PDF
format.

6
1 Preface
1.3 Vehicle Safety
1.3 Vehicle Safety Mercedes-Benz Dealers or Qualified Workshops can
provide more information.
G Risk of Accident and Injury

i Information
Before performing the installation work for
Always observe the standards and legal requirements
implements, bodies, equipment or accessories in the
for each region and/or country, since the type of
basic vehicle or in major assemblies, it is necessary
vehicle classification can be changed in terms of
to read the vehicle operator's manual chapter that
approval and traffic license depending on the
brings instructions for these installations, as well as
installation, equipment assembly and/or implement,
instructions for the operation and assembly provided
and it can also be terminated.
by the equipment and accessories manufacturers.
Otherwise, it may be impossible to foresee possible The replacement or alteration of parts/characteristics
risks to the driver and others. of the vehicle in which:
The acceptance by the inspection and public control • the type of vehicle approved/homologated in the
services or the authorizations granted by official traffic license is changed.
agencies does not exclude the safety risks.
• places a risk for street and road users, or that
Indications Related to the Vehicle Safety reduces the quality of vehicle emission levels, such
as exhaust system gases and noises, being subject to
We recommend:
the suspension of the traffic license.
• Only use Mercedes-Benz genuine parts, as well as
equipment and accessories expressly approved by
Mercedes-Benz for each vehicle version. The safety,
reliability and adequacy of these parts were proven in ! Attention
special tests. Relevant for the vehicle safety: After the assembly of
We are not responsible for reliability, safety and the implement, all the vehicles mus be inspected in a
adequacy when: Mercedes-Benz Dealer or Qualified Workshop before
the delivery to the customer.
• genuine parts or parts of authorized equipment and
accessories are replaced by other commercial parts Safety related items that must be considered in a
and/or other changes are performed later in the delivery inspection:
vehicle; • Brake system inspection.
• implements are not manufactured and assembled in • Steering system inspection.
compliance with the guidelines established in this
manual, or in case of differences, the approval is not • Integrity of assembled chassis.
required to Mercedes-Benz do Brasil Ltda. • Integrity of vehicle components.
• Damages to the vehicle electrical systems.
• Vehicle interface with the implement.
• Etc.

7
1 Preface
1.4 Operational Safety
1.4 Operational Safety
G Risk of Accident and Injury

Before performing the installation work for
implements, pieces of equipment in the basic vehicle
or in major assemblies, it is necessary to read the
vehicle "Operator's manual" chapter that brings
instructions for these installations, as well as
instructions for the operation and assembly provided
by the manufacturers of equipment and accessories
employed. Otherwise, it may be impossible to
foresee possible risks to the driver and others.
In the case of any inadequate intervention/alteration
in the vehicle electronic system, the electronic
components and their software may present faults
and/or stop operating. Furthermore, due to the
network connections IES-CAN (Integrated Electronic
System - Controller Area Network), the systems that
have not been directly altered may also have been
affected. The electronic system components
operation problems may also compromise the
operational safety of your vehicle.
The works or alterations in electronic systems and
components must be carried out only by Mercedes-
Benz Dealer or Qualified Workshop.
For systems related to safety, the work must be
performed by Mercedes-Benz Dealer or Qualified
Workshop.
Some safety systems only work with the engine
operating in normal regimen. Therefore, do not
switch the engine off while driving the vehicle.
Before tilting the cab, see the vehicle “Operator's
manual”.

8
1 Preface
1.5 Note About Copyright Protection
1.5 Note About Copyright Protection
The texts, figures and data contained in these
Guidelines for the Assembly of Road Implements and
Equipment are protected by copyright, or any technical
instruction that supplements these Guidelines.
This applies also to the digital media editions and other
data support systems.
If doubts arise, please contact Mercedes-Benz do Brasil
Ltda. Customer Center
Telephone: +55 0800 970 90 90

9
1 Preface
1.6 Implements Assembly Approval
Mercedes-Benz do Brasil Ltda. does not grant approvals
for implements produced by other manufacturers. It ! Attention
only makes available for the implements manufacturers A Mercedes-Benz do Brasil Ltda. voluntarily grants an
the important information and instructions concerning implement assembly approval according to the
the technical interface between the "vehicle" and the following criteria:
"implement" contained in these Guidelines.
• The approval for the implement assembly on the
All the alterations of the vehicle and the assembly of vehicle chassis refers only to their interface.
implements must be carried out according the Mercedes-Benz do Brasil Ltda. will base its
guidelines established in this “Instructions Manual”. decision on the technical documentation produced
Mercedes-Benz do Brasil Ltda. does not recommend the by the implement manufacturer who will perform
implements assembly when: the modifications.
• They have not been manufactured or assembles • Requests for on site assessment and technical
according to the guidelines defined in the support have to be formally made to
“Instructions Manual” and/or expressly authorized Mercedes-Benz do Brasil Ltda commercial
by Mercedes-Benz do Brasil Ltda. Product areas (Sales and After-Sales).
Engineering. • Technical assessments by Mercedes-Benz do
• The electro-electronic interface is not compatible Brasil Ltda. Implementer support will only be
with the vehicle to be implemented. performed for cases in which the vehicle
implementation meets its application.
• The permitted loads for the axles have been
exceeded. • When Mercedes-Benz do Brasil Ltda is
responsible for selling the complete vehicle to
• The Gross Vehicle Weight Rating (GVWR) has been the customer, the Implementer support team
exceeded. will perform a technical assessment of the
interface project as well as technical
inspection visits for the 1st unit produced by
! Attention the Implementer.
The approval for the implement assembly does not

refer to the project/design of the implement as a
whole, its functions or its planned application. G Product Liability and Civil Liability
The implement assembly approval is valid only when The implement assembly test does not exempt the
the project/design of the implement, its production implement manufacturer, who carries out alterations
and assembly are carried out by the manufacturer of in the vehicle, from his responsibility for the product
the implement, according to the requirements and his civil liability.
established in the valid Guidelines for the Assembly
of Road Implements and Equipment issued by The implement manufacturer must carry out
Mercedes-Benz do Brasil Ltda.. appropriate calculations, tests and verifications of
the overall vehicle, in order to ensure its operational
and driving safety and correct steering behavior.
Considering this, it is the manufacturer's
! Attention responsibility to ensure the compatibility of his
implements, the assembly of accessories and
The specific laws, the license obtainment guidelines
devices and/or adaptations/modifications carried
and requirements of each country must be observed
out in the basic vehicle, as well as the operational
for the implement project!
completeness and safety of the transformed vehicle.

10
1 Preface
1.6.1 Required Documents 1.6.2 Lawsuits
For approval purposes, Mercedes-Benz do Brasil Ltda. No lawsuits are applicable in relation to the granting of
shall receive the respective documentation, in an assembly approval.
electronic format, including project specifications and
Due the technical improvements and obtained
technical drawings with all dimensions, views and
knowledge Mercedes-Benz do Brasil Ltda. may deny an
details required.
assembly approval even if a "similar" approval has been
The drawings must contain the following indications: previously granted.
• All deviations from the Guidelines for the Assembly of The assembly approval may be limited to the individual
Road Implements and Equipment. vehicle.
• All the indications relative to dimensions, calculation The assembly approval may be denied for vehicles
of load distribution on the axles and gravity center for already implemented, built or delivered.
the modified vehicle in the laden and empty
The implements manufacturer is responsible for:
condition.
• The operation, compatibility and safety of its
• Details about the implement fastening points or
implements, pieces of equipment, accessories,
those of the equipment attached to the vehicle
adaptations or modifications to the basic vehicle.
frame.
• The operation and installation of products
• Dimensions and technical specifications of the
manufactured by them
subframe material.
• All modifications and parts installed and that are not
• Eventual changes in the vehicle components location.
specified, or that have been omitted from the
For example: crossmembers, air reservoirs, fuel tank
documentation produced for approval
etc.
• The warranty that covers the services performed to
If calculations, function and durability tests are
change the vehicle original characteristics, even
necessary to be carried out with the vehicle, as well as
when approved by Mercedes-Benz do Brasil Ltda. for
second certifications/approvals to meet the
assembly; being also responsible for complying with
requirements of the laws, the costs incurred in will be
the country current legislation.
for the body builder's account. In case the product has
to be inspected by Mercedes-Benz, the Implementer
shall formally request it as described in “Implements
Assembly Approval”  page 10.

11
1 Preface
1.7 Product Liability
1.7 Product Liability The manufacturer of the implements disclaims
Mercedes-Benz do Brasil Ltda. from the
For product liability (according to the civil law) it is responsibility when damages are due to non-
meant the responsibility of a manufacturer for the compliance with the “Guidelines for the Assembly
damages caused during its use, to a driver or third of Road Implements and Equipment”.
parties, by the single fact that the product does not
provide the safety for the expected use. 1.7.1 Traceability Warranty
In the scope of product liability we want to call the The faults that have been detected in his equipment/
attention to the following points: implement only after its delivery may require the later
adoption of measures in the market (information and
• Every manufacturer is responsible for his product. notices to the customers, recalls). For these measures
• Mercedes-Benz do Brasil Ltda. WILL NOT undertake to be created as efficiently as possible, it is necessary
any liability for damages due to interference or faults to track the product after the delivery.
of the products caused by products manufactured by Therefore, in order to make possible to find the affected
other manufacturers assembled later in the original owners, we recommend to register immediately in the
vehicle. data base the series and identification numbers of the
Therefore, the implements manufacturer (additional equipment/implement linked to the vehicle
structures, bodies, equipment and/or accessories) will identification number (VIN - Vehicle Identification
be solely responsible for: Number).
• Implements operation and application safety.
• Operation and application safety regarding parts that
are not specified in the documentation produced for
approval.
• Vehicle operation and application safety (gear
shifting, braking and directional behaviors shall not
be hindered by the implement).
• The influence of implements subsequently installed
on the chassis.
• Malfunctions and damages resulting from the
implements, installations or modifications.
• Malfunctions and damages resulting from the
subsequent installation of electrical or electronic
systems.
• Keeping operation safety and free motion of all
chassis moving parts, even in case of diagonal
torsion in relation to the implements.
The services or changes performed in the chassis and/
or implement must be recorded in the Maintenance
Manual.

12
1 Preface
1.7 Product Liability
1.7.2 Warranty Rights
The warranty claims can only be applied in the scope of
the purchase and sale agreement between the parties,
later the respective product seller will be required to
provide assurance to the purchaser.
Mercedes-Benz do Brasil Ltda. will not undertake any
liability resulting from the warranty when
• The recommendations estated in these “Guidelines
for the Assembly of Road Implements and
Equipment” fail to be observed.
• The vehicle specific performance fails to match the
technical/legal requirements for the country where it
will be used.
• The specific performance of the vehicle used fails to
match the application and/or type of
implementation.
• Damages to the chassis are caused by the
implements or their inappropriate assembly.
• The vehicle basic parameterization is tampered with
by the Implementer.
• Damages to the chassis are caused by asymmetric
distribution of loads.
! Attention
Mercedes-Benz do Brasil Ltda. will not provide any
statements regarding the vehicle gear shifting,
braking and directional behavior in case of excessive
changes to the wheelbase and to the bodies, for
loads with unfavorable center of gravity. The
implements manufacturer is responsible for the
vehicle safety after their assembly.

13
1 Preface
1.8 Relevant Features for the Safety
1.8 Relevant Features for the Safety Documentation
The components or systems which if faulty or defective If safety relevant issues are identified according with
may directly put at risk the life and the physical integrity the ten safety aspects, they must be informed in writing
of the road users are safety relevant items. correspondingly as being relevant for the safety and the
information must be filed in databases, documenting
Mercedes-Benz do Brasil Ltda. recommends that the the functions and corresponding characteristics.
vehicle safety relevance of the components or functions
is assessed:
• General modifications to the chassis.
• Installation of additional equipment to the vehicle.
• Interface between the vehicle and the implement
(mechanical components, electrical/electronic
systems, power take-off and hydraulic and pneumatic
components).
A component or a function must be considered safety
relevant if it can cause at least one of the following
risks:
• Temporary loss of road visibility.
• Driveability malfunction.
• Loss or partial malfunction of braking functions.
• Driving malfunction.
• Uncontrolled wheel drive.
• Sudden driving force malfunction.
• Fuel leak/risk of fire.
• Separation of load/trailer/parts.
• Injuries during vehicle operation or other type of
vehicle operation.
• Passenger protection in case of accidents.
When assessing the relevance safety, pay attention to
the following influences associated to the customers:
• Extreme utilization conditions.
• Improper use by people with no appropriate training.
• Improper use in case of response time malfunction.
• Wear and tear.

14
1 Preface
1.8 Relevant Features for the Safety
1.8.1 Accidents Prevention
The implements manufacturer will be liable for
damages:
• Caused by incorrect operation or lack of operational
safety regarding implements manufactured and/or
installed by the manufacturer.
• Caused by insufficient or incorrect “Operation
Instructions” for implements manufactured and/or
installed by the manufacturer.
The pieces of equipment, major assemblies, bodies and
accessories assembled or installed shall meet the
“Legal requirements” applicable, as well as the
workplace protection standards or accident prevention
standards, safety regulations and provisions from
insurance companies.
All the possible techniques must be applied to prevent
the lack of operational safety.
The laws, prescriptions and guidelines specific for each
country must be observed.
The implements manufacturer will be responsible for
observing and complying with the laws and regulations
in force.

15
1 Preface
1.9 Body Builders Information Portal
1.9 Body Builders Information Portal
i Note
In preparation phase!

16
1 Preface
1.10 Technical Consulting and Contacts
1.10Technical Consulting and Contacts
Collaborators from the Truck Development Department
in charge of technical support for Implementers are
responsible only for technical and constructive
questions regarding the end product interface.
Contact
BBMgt - Body Builders Management Team.
Telephone: +55 11 4173-8095/8919/8071, or through
Mercedes-Benz do Brasil Customer Relationship Center.
Telephone: +55 0800 970 90 90
Mercedes-Benz do Brasil Ltda.,
Address: Av. Alfred Jurzykowski, 562
São Bernardo do Campo - SP
CEP 09680-900
CIP (internal mail code): B 122 2C

17
2 Body and Equipment Planning
2.1 Vehicle Identification/Proposal Drawings
2.1 Vehicle Identification/Proposal Drawings Vehicle identification
These chassis have been developed to meet the various Tab 1: FIN - Manufacturer Identification Number
implementation conditions, making possible better 9BM 979 048 1 D XXX XXX
relations between the weight and dimensions of the
implement; in the case the wheelbase dimension has to 6 digits production sequence
number
be altered, a previous technical consultation and the
approval from Mercedes-Benz do Brasil Ltda. are Producing plant of the vehicle
required Steering: (1) Left side (2) Right side
Vehicle model version
Vehicle model
i Information
International manufacturer identification
For bodies and pieces of equipment planning it is
possible to request technical information to the D/ Tab 2: VIN - Vehicle Identification Number
VC Department (Implementer Support and Vehicle 9BM 979 048 7 B XXX XXX
Customization) refer to chapter “Technical
6 digits production sequence
number
Before starting the bodies and pieces of equipment Producing plant of the vehicle
assembly, check: Manufacturing year
• If the chassis is appropriate for the planned body Vehicle model version
and/or equipment.
Vehicle model
• If the type of chassis and equipment are suitable for International manufacturer identification
the utilization intended.
For the safe use of the vehicle in the desired application
area, the correct choice of the chassis is required.
Therefore, it must be mainly considered:
• Wheelbase.
• Engine (torque/power).
• Transmission (type/ratio).
• Axle transmission ratio.
• Total technical Gross Weight permitted.
• Center of gravity.
• Legal signaling (for example: lower bumper) in the
plan step and if they are proper to the corresponding
application.

18
Vehicle Identification Plate
Information contained in the vehicle identification plate.
• Vehicle model.
• Vehicle Identification Number (VIN).
• Technical and legal maximum allowed weight per
axle.
• Total Gross Vehicle Weight Rating (GVWR), technical
and legal.
• Combined Gross Vehicle Weight Rating (CGVWR).
• Maximum hauling capacity.
• Manufacturing year.
Tab 3: Vehicle Model Designation (example)
13 16 Engine output in CV (= x 10)
Allowed gross weight in tons
Offer Drawings
i Note
The application suggestions described below refer to
those to which the vehicle model has been developed
and/or which are more appropriate, taking into
account the product and implement technical
characteristics, for other possible applications
1 Vehicle model contact the D/VC (Implementer Support and Vehicle
2 Technical and legal maximum allowed weight per axle
Customization) Department “Technical Consulting
and Contacts”  page 17.
i Information
The technical weight capacity 2 of the vehicle are i Note
established by its manufacturing plant and the weight The vehicle frame crossmembers arrangement is
limits established by the laws of the country where inserted in the respective Offer Drawings of each
the vehicle is going to operate must be observed. The vehicle model.
smaller number indication must always prevail.
For the approval of the implement/body dimensioning
(length, wheelbase and overhangs), it is necessary that
the technical and legal limits of total and per axle load
capacity of the chassis are not exceeded, considering
all operation and loading conditions (dynamic and
static). Refer to chapter “Limit technical values during
the planning”  page 30.

19
Tab 4: Accelo Design number 979.0XX - Designation / Application
Offer Drawing Nº
Wheelbase Constructio Engine
Models Traction Suggested Application
(mm) n Nº (Code)
Normal Short Spring
156 CV (MN5 +
3.700 979026 A9790020597 -
MS3)
156 CV (MN5 +
4.400 979028 A9790020697 -
MS3)
156 CV (MW6 +
3.100 979023 A9790020497 -
MS5)
Dry cargo, Box, Sider, Refrigerated, 156 CV (MW6 +
815 4x2 3.700 979026 A9790020597 -
Flatbed, auto platform MS5)
156 CV (MW6 +
3.900 979026 in operation -
MS5)
156 CV (MW6 +
4.400 979028 A9790020697 -
MS5)
156 CV (MW6 +
MS5)
156 CV (MN5 +
3.700 979046 A9790020597 -
915C Dry cargo, Box, Sider, Refrigerated, MS3)
4x2
MENA Flatbed, auto platform 156 CV (MN5 +
4.400 979048 A9790020697 -
MS3)
156 CV (MN5 +
3.700 979046 A9790020297 -
Dry cargo, Box, Sider, Refrigerated, MS3)
915C LA 4x2
Flatbed, auto platform 156 CV (MN5 +
4.400 979048 A9790020397 -
MS3)
156 CV (MW6 +
3.100 979073 A9790020797 -
MS5)
156 CV (MW6 +
3.700 979076 A9790020897 -
MS5)
Dry cargo, Box, Sider, Refrigerated,
Flatbed, Beverages, Tanks, Tow Truck, 156 CV (MW6 +
1016 4x2 3.900 979076 in operation -
Garbage Truck, Dumo Truck, Crane, Car MS5)
carrier trailer
156 CV (MW6 +
4.400 979078 A9790020997 -
MS5)
156 CV (MW6 +
MS5)
156 CV (MW6 +
3.700 979078 A9790000496 -
MS5)
Dry cargo, Box, Sider, Refrigerated, 156 CV (MW6 +

Flatbed, Beverages, Tanks, Tow Truck, MS5)
1316 6x2
Garbage Truck, Dumo Truck, Crane, Car 156 CV (MW6 +
carrier trailer 4.400 979098 A9790000199 -
MS5)
156 CV (MW6 +
MS5)

20
2.2 Changes in the Vehicle
2.2 Changes in the Vehicle
G Risk of accident
Do not change the steering and braking system,
since these changes may interfere with the proper
operation and cause malfunctions. This way, the
driver may lose control of the vehicle and cause an
accident.
The characteristics of the original suspension cannot
be altered.
No alterations are allowed in the steering, brake,
cooling, engine air feed systems, acoustic protective
coating, and data communications lines (Bus-CAN)
etc.
It is only permitted to make changes to the basic
vehicle within the scope of the extensions described
in these “Bodies and Equipment Installation
Instructions”.
The modifications necessary in the vehicle due to

alterations in the vehicle frame must not affect the:
• Load distribution on axles.
• Structural resistance.
• Turning circle.
• Maintenance Access.
• Driving and operation.
The vehicle that has its original basic characteristics or
structures altered, such as the modification of the
wheelbase distance (lengthening or shortening), will
only be registered, licensed or will only have its annual
license renewed when the alteration has been
previously authorized by the transit authorities and the
vehicle safety is evidenced by a local “OFFICIAL
TECHNICAL INSTITUTION”. Observe the respective
“Legal requirements” valid in each country.
! Attention
In the absence of the regulations and laws valid in the
country, the technical guidelines and
recommendations issued by Mercedes-Benz do Brasil
Ltda. will prevail

21
2.3 Dimensions and Weight Indications
2.3 Dimensions and Weight Indications The wheelbase available for each vehicle model can be
checked on the respective tables “Table of dimensions
and weights”  page 44.
G Risk of accident and injury

The tire load capacity must not be exceeded. Its
loading cannot be higher than the total gross weight
defined for the vehicle. Otherwise, the tires can
overheat and deform. Therefore, vehicle control may
be lost, causing accidents or injuries to the driver
and/or third parties.
The vehicle identification plate brings information on
permissible loads on axles, refer to “Vehicle
Identification Plate”  page 19.
The allowed loads on the axles and the allowed total

gross weight (PBT) indicated in the technical date must
not be exceeded under no hypothesis.
! Attention
The weight indications in our informative materials
refer to standard basic version vehicles.
In case of installing special or optional pieces of

equipment, the chassis weight will change.
We recommend to check the vehicle actual weight by
weighting it.
Chapter “Total Technical Weight of the Vehicle and Loads
on the Axles”  page 44 informs the chassis weights
according to the gear, total gross weights permissible
per axle and the vehicle center of gravity position.
i Information
It is important to note that an implement with very
long rear overhang may cause overload the rear axle
and cause the front wheels loose the grip.
Refer to the chapter “Extension of the Rear Overhang
and Wheelbase”  page 33.
On the other hand, a very short implement may cause

the overloading of the front axle, causing the steering
wheel to seem heavy and the maneuvers more difficult,
particularly in urban operations. Refer to chapter “Load
Distribution on the Wheels”  page 35.

22
2.4 Steering System
2.4 Steering System
Special care with the steering system during the
body assembly process:
• The steering components must be adequately
protected during the welding and painting process.
• The use of steering system components to carry out
tests of welding electrodes, and or to connect to
ground the welding equipment.
• During cutting or drilling works, be careful not to
damage the hydraulic line.
When finishing the body assembly check the hydraulic
power steering system for leakages, mainly around the
fittings.
! Attention
Alterations in the hydraulic lines of the steering
system are not allowed.
The Implementer is responsible for all modifications
and the consequences resulting for such
modifications.
2.4.1 Hydraulic Steering Reservoir
G Risk of accident
The hydraulic steering oil reservoir must not be
repositioned. The reservoir is installed in its final
position, and it is not permitted to change its position
and fastening.
In case the Body Builder needs to change the reservoir

positioning and/or its support, the Implementer shall
contact Mercedes-Benz do Brasil Ltda. at “Technical

23
2.5 Cooling System
2.5 Cooling System 2.6 Intake System
The air cooler must be properly protected before During the body assembly process, the whole intake air
performing any services in the cab front area in order system must be protected from impacts or paint
not to damage the fins. It mas not be painted. residues. It is extremely important that the engine
receives air free of dust, water and impurities.
In order to ensure that sufficient opening for the air flow
for the coolers, do not put labels, plates or other
ornament parts on the front grill of the vehicle.
Engine intake
i Information
Should it be necessary to remove the air filter, the
connecting hose, between the air filter and the
turbocharger, will have to be sealed immediately
after removing the air filter and maintained this way
during the whole body building process. The
protection may only be removed during the air filter
assembly.
! Attention
Modifications in the air filter position and the air
intake lines are not allowed by Mercedes-Benz do
Brasil Ltda.
Compressed air jets are not to be utilized for the
cleaning of the filtering element in order not to
damage it.

24
2.7 Exhaust System
2.7 Exhaust System
If the exhaust pipe is extended, provide for radii and
diameters higher than those specified in the respective
chapter “Alterations in the Exhaust System”  page 117.
The plastic ducts or lines, electrical cables and spare
wheel shall be at least 200 mm distant from the exhaust
system. If this is not possible, the thermal protection of
such components to high temperatures must be
provided.
2.7.1 Exhaust Gas Aftertreatment System (SCR)
i Information
For modifications to the exhaust gas aftertreatment
system “SCR” system, refer to chapter “Alterations in
the Exhaust System”  page 117.
H "AdBlue®"
In Brazil the chemical product (urea diluted in water)
is called ARLA 32 (Agente Redutor Líquido
Automotivo). For further information, refer to the
Equipment - "General Manual".
! Attention
All connections lines, "AdBlue®" reservoir and pump,
when disassembled must be protected in order not to
suffer damages and contaminations.

25
2.8 Optional/Special Equipment
Optional and/or special equipment, as well as
installation instructions, may be acquired using their
sales code at the Mercedes-Benz Dealers or Qualified
Workshops.
Not all optional or special equipment are compatible
with the various vehicle models, mainly in the case of
later assemblage.
The optional and/or special equipment installed later by
third parties must be in accordance with the technical
recommendations described in the Guidelines for the
Assembly of Road Implements and Equipment.
In case the technical information in the Guidelines for
the Assembly of Road Implements and Equipment do
not meet the needs, Mercedes-Benz Dealers or
Qualified Workshops can provide more information.

The use of parts, equipment and accessories not
approved by Mercedes-Benz do Brasil Ltda. may
affect the safety of the vehicle. Refer to chapter
“Operational Safety”  page 8.
i Information
Information on optional/special equipment weights
and sales codes are available at Mercedes-Benz
Dealers or Qualified Workshops.

26
2.8.1 Wind Deflectors
i Information
For modifications and installations in the cab,
contact Mercedes-Benz do Brasil Ltda. at “Technical

27
2.8.2 Auxiliary and Signaling Lights
In case it is necessary to install auxiliary and/or
signaling lights in the cab roof, avoid drilling it since it
may result in water ingress and/or corrosion.
i Information
For the installation of the electric interface of the
auxiliary lights and signalization, please refer to the
"Guidelines for the Assembly of Road Implements and
Equipment - Specific electro-electronic part".

28
2.9 Additional Pneumatic Consumers
2.9 Additional Pneumatic Consumers Vehicles without air drier filter
G Risk of accident
It is not allowed to the connection and/or
shunting of the APU valve ports 21 and 22, as
well as the lines and connections thereof to feed
auxiliary equipment.
The ports 21 and 22 are exclusively aimed at
feeding the vehicle brake systems.
Vehicles equipped with air drier filter (Code B66)
Tab 6: APU valve - Air feeding ports
21 Brakes circuit I (rear)
22 Brake circuit II (front)
23 Parking brake, trailer (Optional)

Clutch actuation, engine brake, ancillaries and leading axle
24 lift
In the case of auxiliary equipment assembly, it must be

observed that:
Tab 5: APU valve - Air feeding ports • The auxiliary equipment, with high or continuous air
consumption, must have an auxiliary compressor of
21 Brakes circuit I (rear) higher capacity.
• The auxiliary equipment of low air consumption may
22 Brake circuit II (front)
be directly linked to the four way protective valve
23 Parking brake, trailer (Optional) “APU”, port “24” or “26”, if they are protected by a
retaining valve (opening pressure from 7.3 to 7.5 bar).
Clutch actuation, engine brake, ancillaries and leading axle
24 lift the compressed air circuits are protected together by 4
discharge valves, with limited reflux inside the APU
valve.
The consumer auxiliary equipment only must be
connected to the ports “24” or “26” of the APU valve,
with maximum pressure of 8.5 bar.

29
3 Limit technical values during the planning
3.1 Vehicle Frame Material
3.1 Vehicle Frame Material
In the case of extending the rear overhang and
wheelbase, the material of the extension piece and the
reinforcement must correspond to the quality and
dimension of the standard vehicle frame. For more
Information, refer to chapters “Change of the
Wheelbase”  page 68 e “Rear Overhang Alterations” 
page 75.
Tab 7: Longitudinal members dimensions and material
Accelo Dimensions (mm)

Material
model A B C r
815/31/37;
915C/37 185 65 5 8 LNE 50
1016/31/37/39
815/44;
915C/44 185 65 7 8 LNE 50
1016/44/46
1316/37/39;
185 65 5+5(*) 8 LNE 50
1316/44/46
i Information
(*) For 13-ton. models, there is a double frame
longitudinal member (“U” profile) (5 + 5 mm).

30
3.2 Subframe Material
The material of the auxiliary units may not have lower
quality than the longitudinal members material. Use
bent “U” profiles; do not use general purpose laminated
profiles.
Subframes in aluminum must not have quality lower
than Almg SIL F 31 - DIN 1747, it is recommended to
apply protection between this and the vehicle frame, in
order to reduce the electrolytic corrosion (zinc
chromate base primer paint).
In hardwood bodies, it is possible to use auxiliary
wooden longitudinal members of equal quality, which,
however, have to be properly reinforced using steel
longitudinal tie rods to ensure the required structural
resistance.
Quality of the material for subframes in steel:
• For subframes with fastening by consoles (adhesion
bonding), the quality of the material must be E 380
TM or St 52.
• Subframes with fastening resistant to the thrust
(positive joint), using screwed plates the material
quality has to match the E 500 TM vehicle frame.
• The assembly structures with very resistant steels
must have at least the resistance of the assembly
structures made of steel. Secure by adherence
junction.
Tab 8: Material mechanical properties
Resistance to
Elasticity limit
Material traction
(N/mm²)
(N/mm²)
LNE 38
> 450 380
E 380 TM
St 52 > 490 355
LNE 50
> 560 500
E 500 TM

31
3.2.1 Dimensions of the Profile for the Subframe For the case of loads not evenly distributed or special
With the aid of the diagram, the dimensions of the equipment where located efforts occur (Example: tilting,
auxiliary longitudinal members dimensions can be cranes, lifting platforms, concrete pumps, etc.), the
obtained, with the profile in “U” due to the sectional subframe longitudinal members must be sized due to
modules (Wx). the acting loads, as well as a chassis with wheelbase
proper for this use should be adopted.
The subframe and the vehicle frame must have the
same thickness and both with the same thickness. For vehicles used in the sugar cane transportation, in
the wood extraction, in the civil construction, and
The resistance sectional modules and profile minim, the sectional module or resistance module (Wx)
dimensions informed in the diagram refer to auxiliary of the subframe must be sized so that, being the
longitudinal members designed for distributing the load longitudinal member sectional module composed, in the
evenly on the body. critical points (maximum bending moments), the
If more than one equipment is assembled to the frame, material stress has a safety coefficient at least equal to
the highest amount among the indicated resistance 3, in relation to its rupture limit.
modules must be considered as basis for the calculation
of the subframe.
Open profile, a = profile height in mm
Resistance modules (Wx)

32
3.3 Extension of the Rear Overhang and Wheelbase
G Risk of accident
When designing the bodies, avoid possible loading on
the rear part.
The following points must be observed, otherwise the
transfer of driving and braking power required for a
safe driving will not be possible.
• The rear axle overhang determination must be

performed, based on standard, considering the
allowed loads over the axles and the minimum load
over the front axle.
• Observe the minimum load on the front axle “Load
Distribution on the Wheels”  page 35.
• When making the calculation, consider the optional
equipment weight.
Maximum length of the rear overhang (Ü):
• Two axle vehicles, 60% of the extreme axles distance
(R).
• Three-axle vehicles, 60% of wheelbase (Ri).
i Information
In Brazil, the rear overhand is 60% of the extreme
wheelbase, limited to 3,500 mm, however, for the 1 - 4 x 2 vehicles with metallic suspension
2 - 6 x 2 vehicles with rear air suspension
proper calculation, it is necessary to consider the
3 - 6 x 2 vehicles with metallic suspension (rocker arms)
number of axles, type of suspension, center of gravity 4 - 8 x 2 vehicles with metallic suspension (rocker arms)
and minimum load on the front axle. Observe the
legislation applicable in the respective country.
R - Technical wheelbase
Ü - Rear overhang

33
Determining the technical wheelbase distance for 3 Determining the technical wheelbase distance for 4
axle vehicles axle vehicles
i Note
Not applicable!
3 axle vehicles
For the technical wheelbase (Ri), it is applied the

formula:
( HA ⋅ G3 )
Ri = R + -------------------------
( G2 + G3 )
To calculate the technical wheelbase (Ri), the following values are
required:
R = Wheelbase of the vehicle measured from the center of axle 1 to
the center of axle 2
HA = Rear wheelbase
G2 = Allowed load on the 2nd axle according to the weight code
G3 = Allowed load on the 3rd axle according to the weight code
If G2 is equal G3, the formula is simplified:
( HA )
Ri = R + ------------
(2)
To calculate the technical wheelbase (Ri), the following values are
required:
R = Wheelbase of the vehicle measured from the center of axle 1 to
the center of axle 2
HA = Rear wheelbase
G2 = Allowed load on the 2nd axle according to the weight code
G3 = Allowed load on the 3rd axle according to the weight code

34
3.4 Weight Distribution and Height of the Gravity Center
3.4 Weight Distribution and Height of the Gravity It was proved that it makes sense to specify the
Center following to calculate the load on the axle:
Weight
+ (more) means everything that is loaded on the vehicle
G Risk of accident
- (less) means everything that removes load from the
When designing the bodies, avoid possible loading on vehicle (weights)
the rear part. Wheelbase
The following points must be observed, otherwise the + (more) means everything that is behind the front axle
transfer of driving and braking power required for a center
safe driving will not be possible.
- (less) means everything that is in front of the front axle
3.4.1 Load Distribution on the Wheels center
When designing bodies and pieces of equipment, avoid Calculation of the weight distribution in the front and
single side weight distribution. rear axles with the formula:
The load on the wheel (1/2 of the allowed load on the
axle) allows a maximum tolerance of 4%.
Observe the tires load capacity. G componente × a
Example: G = ------------------------------------------------- ⋅ [ kg ]
Δ HA R
• Permissible load on axle 10,000 kg.
• Load on each wheel 10,000/2 = 5,000 kg (ideal load
on each wheel). ΔGHA = Weight change — rear axle in [kg]
• Tolerance 5,000 X 4% = 200 kg (maximum load G Component = Component weight in [kg]

exceeded for the wheel).
a = Wheelbase for the theoretical front axle center in [mm]
• Load distribution permitted on wheels 5,200 kg and R = Theoretical distance between wheels [mm]
4,800 kg.
The static load in the front axle, under any loading
conditions, must be a minimum of 25% of the respective
total gross weight (PBT) to provide a good driveability to
the vehicle.
ΔGVA = G componente – G HA [ kg ]
For 3-axle vehicles, a minimum value of 20% is allowed.
Refer to chapter “Driveability”  page 36.
Calculation of the load on the axle Δ GVA = Weight change — front axle in [kg]
For an excellent complete vehicle (vehicle and body), it GComponent = Component weight in [kg]
is necessary to calculate the load on the axle. Adjusting
the body with the truck is only possible if prior to any ΔGHA = Weight change — rear axle in [kg]
work in the body, the vehicle is weighted. The weights
determined in the weighting are the base for the
calculation of the load on the axle.
The principle of the angular moment serves to distribute
the assembly weight by the front and rear axles. All the
distances are in relation to the center of the front axle
(theoretical center). Write down the weight with the
 correct mathematic signals and record them on a table.

The result will contribute to the ideal positioning of the
body.

35
3.5 Driveability
3.5 Driveability
To ensure good drive ability of the vehicle, the minimum
load on the front axle must be kept the same whatever
the loading situation is.
G Notice
When designing the bodies, avoid possible loading on
the rear part. The following points must be observed,
otherwise the transfer of driving and braking power
required for a safe driving will not be possible.
The load in the vehicle rear part has a negative
influence on the shifting behavior, requiring more
attention when driving.
i Information
The allowed load on the front axle must not be
exceeded.
Tab 9: Minimum load on the front axle

Minimum load on the front axle
(% of the vehicle total weight)
% of the
Vehicles
minimum
Application, axle version and tires
load
Version 4x2 25%

Accelo
Version 6x2 20%
with load platform or crane on
the rear part or application
2 axles 30%
with a single axle trailer, with
center axle or with rigid boom
without implements in the rear
2, 3 and 4 axles part of the vehicle, without
operation without application with center axle 22%
trailer trailer, not at the center point
of gravity of the lifted load

36
3.6 Free Space for the Major Assemblies
3.6 Free Space for the Major Assemblies Transmission device (shifting).
In order to ensure the operation, maintenance and • Sufficient distance for the implement, even with the
operational safety of major assemblies (engine, axles, cab tilted.
transmission, retarder etc), the clearances specified Rear axle brake combined cylinder.
must be preserved.
• In vehicles with drum brake, observe the free space,
and easy access for the brake emergency unlocking,
releasing the accumulator spring bolt from the
i Information combined cylinder.
Carefully observe the measures informed in the Engine, transmission, APU valve and retarder.
respective proposal drawings and the indications in
this manual, refer to chapter “Vehicle Identification/ • Minimum distance for bodies and equipment is
Proposal Drawings”  page 18. 30 mm, in order to allow replacing the air drier
element.
Free space for transmission.
Automated manual transmission.
• As far as possible, avoid implement crossmembers
on the upper part of the transmission.
• Particularly for vehicles with automated manual
transmission, the subframe must have a height “h”
enough to avoid interference of the implement
crossmembers with the module and sensors that are
arranged in the upper part of the transmission,
allowing simultaneously free access for maintenance,
diagnosis and repair.
• In the event of a subframe with a long “h” height is
not possible, due to height limitations of the
implement, an inspection window over the
transmission must be provided to allow maintenance,
Fuel float and float tube set
diagnosis, and repair.
In the fuel tank area, at the fuel float and float tube set,
there should be an inspection window or enough space
to clean or repair the filter.
1 Sensor a Play ≥ 30 mm

2 Module h Subframe height

37
3.6 Free Space for the Major Assemblies
1 Fuel float and float tube set
Front and rear axle lift
! Attention
There must be no crossmembers/diagonal bars of
the subframe in the region of the front and/or rear
axle lift.
In the front and/or rear axle lift region the subframe
height must exceed the lift clips ends by at least by
30 mm.
h = subframe height

38
3.7 Clearance for the Cab
3.7 Clearance for the Cab 3.7.1 Cab Extension
• Pay attention to the allowed gravity center point and
load on the front axle.
• There must be free space enough for the tilting.
Clearance for tilting the cab.
Tab 10: Clearance with Atego cab

Minimum distance in (mm)
Front
Cab overhang “C”, from the
“B”, from the axle
“A” (mm) cab Conformity certificate according to the legal
center to the body
to the body
provisions
Standard 1.300 420 50
In case it is necessary to extend the vehicle original cab,
Extended 1.300 600 50 it is theoretically possible after the formal
“Acknowledge and agreed” and a technical assessment
In vehicles with standard cab, the subframe minimum of the project and execution by Mercedes-Benz do
height, “D” measure, should be 150 mm, taking into Brasil Ltda. Product Engineering. For more information,
account the “B” distance informed in the table. see “Technical Consulting and Contacts”  page 17.
The distance between the cab and the implement or For the verifications, documentary evidences are
exhaust piping directed upwards, “C” measure, has to required concerning:
be at least 50 mm.
• Dimensions, structures (profiles, materials).
• Mass, including additional mass with center of gravity
point.
• Cab support adaptation.
• Information on internal top coat, utilization etc.

39
3.7 Clearance for the Cab
3.7.2 Additional Structure on the Cab Roof
For the fastening of structures with weight over 50 kg,
Mercedes-Benz do Brasil Ltda. must be consulted.
i Information
For “Implements Assembly Approval”  page 10 see
“Required Documents”  page 11.
i Information
For the air deflectors assembly, see “Wind
Deflectors”  page 27.

40
3.8 Telligent® Stability Control System
3.8 Telligent® Stability Control System
i Note
Not applicable!

41
3.9 Semitrailer
3.9 Semitrailer
i Information
Not applicable.

42
3.10 Dimensioning of the Trailer Coupling
3.10Dimensioning of the Trailer Coupling
Coupling system (Without vertical load) 2
x ⋅C
The necessary size of the trailer and semitrailer V = a ⋅ ------------
2
⋅ [ kN ]
coupling is determined by the D value. I
The D value is defined as theoretical comparison force

for the tractor truck and the trailer/semitrailer force.
Where:
Coupling or engagement for towing V = Value V [kN].
a = 1.8 m/s (for traction vehicles with pneumatic suspension or
The coupling dimensions for tows will be established comparable suspension)
according to “D”. a = 2.4 m/s (for traction vehicles with other suspensions, e.g., leaf
spring suspension)
X*= Length of the load surface of the center axle trailer in [m]
I*= Theoretical length of the traction town bar, measures from the
axle group center to the trailer eyelet center in (m)
T⋅R C= Allowed weight from the center axle trailer without vertical load
D = g ⋅ ------------ ⋅ [ kN ]
T+R in [t]
*In case of X²/l² < 1 values calculated, it should be applied 1.0.
Where:
D = Value [kN].
g = Acceleration due to the gravity 9.81 m / s2
T = Total weight allowed for the traction vehicle in [t]
R = Total weight allowed for town in [t]
Coupling to towing (with vertical load)

For devices of mechanical junction indicated for center
axle/rigid tow bar towing, the values DC and V are
applied. The value V defines the vertical acceleration
factor in the coupling point due to the traction vehicle
rear axle suspension and of a constant value.
T⋅C
D c = g ⋅ ------------- ⋅ [ kN ]
T+C
Where:
Dc = Value D [kN].
g = Acceleration due to the gravity 9.81 m/s2.
T = Total weight allowed for the traction vehicle including vertical
load in [t].
C = Total weight allowed for the center axle trailer without vertical
load in [t].

43
3.11 Total Technical Weight of the Vehicle and Loads on the Axles
3.11Total Technical Weight of the Vehicle and Loads
on the Axles
i Information
In order to obtain the theoretical values of the gravity
G Risk of accident centers, the vehicle focused is a basic standard
version. The center of gravity may vary according to
During the designing of the implements, the the cab version, pieces of equipment and/or optional
calculation of thee load distribution must be made items installed in the vehicle.
avoiding possible loading at points on the chassis.
The points below must be observed, otherwise the
transference of necessary/adequate steering and
braking forces will not be possible to achieve a safe
driving.
Table of dimensions and weights
i Note
Before referring to the weight tables and vehicle load
center, check the notes below.
• For the implements and other pieces of equipment
assembly project, it should be considered the
center of gravity for the whole vehicle (vehicle +
implements/equipment + load + occupants) to
achieve a good load distribution.
• Under any load condition, the maximum gross
weights specified for the front and rear axle shall
not be exceeded, and, to ensure adequate
driveability, refer to chapter “Driveability”  page
36.
• The indicated weights refer to the series version.
• The maximum gross weight indicated for the front
and rear axles, under any load conditions, must
not be exceeded, to ensure an adequate drive-
ability. Observe the minimum load on the front
axle in chapter “Load Distribution on the Wheels”
 page 35.
• The supplementation of the chassis must meet
the technical instructions issued by Mercedes-
Benz do Brasil Ltda.

44
Tab 11: Weight and theoretical gravity center for the vehicle
R - Distance between axles (wheelbase) (mm)
CG - Center of gravity for the vehicle without the body
h - Relative position to “z” axle (without load and with the
cab)
X - Position relative to the “x” axis
X’ = R - X
R - Distance between axles
ED - Front axle
ET - Rear axle
* IN OPERATION Theoretical weight (kg)
Chassis with cab Total Gross Weight

X ± 100 h ± 50
Vehicle Traction R (mm) Type of cab
(mm) (mm)
ED ET T ED ET T
Euro 5 3.100 Standard 2.190 1.100 3.290 3.000 5.300 8.300 1.040 360
Euro 5 2.220 1.140 3.360 3.000 5.300 8.300 1.220 360

3.700 Standard
Euro 3 2.100 1.020 3.120 3.000 5.490 8.490 1.438 377
815 Euro 5 4x2 3.900 Extended 2.276 1.134 3.410 3.000 5.300 8.300 1.200 360
Euro 5 2.280 1.150 3.430 3.000 5.300 8.300 1.475 360

4.400 Standard
Euro 3 2.202 1.098 3.300 3.000 5.490 8.490 1.464 370
Euro 5 4.600 Extended 2.348 1.200 3.548 3.000 5.300 8.300 1.450 360
3.700 Standard 2.100 1.020 3.120 3.000 5.490 8.490 1.438 377
915C Euro 3 4x2
4.400 Standard 2.202 1.098 3.300 3.000 5.490 8.490 1.464 370
3.100 Standard 2.200 1.120 3.320 3.200 6.400 9.600 1.045 350
3.700 Standard 2.230 1.180 3.410 3.200 6.400 9.600 1.280 350
3.700 Extended 2.254 1.194 3.448 3.200 6.400 9.600 1.280 350
1016 Euro 5 4x2
3.900 Extended 2.314 1.190 3.504 3.200 6.400 9.600 1.280 350
4.400 Standard 2.290 1.180 3.470 3.200 6.400 9.600 1.450 350
4.600 Extended 2.356 1.204 3.560 3.200 6.400 9.600 1.450 350

45
Tab 11: Weight and theoretical gravity center for the vehicle
R - Distance between axles (wheelbase) (mm)
CG - Center of gravity for the vehicle without the body
h - Relative position to “z” axle (without load and with the
cab)
X - Position relative to the “x” axis
X’ = R - X
R - Distance between axles
ED - Front axle
ET - Rear axle
* IN OPERATION Theoretical weight (kg)
Chassis with cab Total Gross Weight

X ± 100 h ± 50
Vehicle Traction R (mm) Type of cab
(mm) (mm)
ED ET T ED ET T
3.700 Standard 2.300 1.980 (1º+2º) 4.280 3.200 10.000 13.200 1.940 350
3.700 Extended 2.324 1.994 (1º+2º) 4.318 3.200 10.000 13.200 1.940 350
3.900 Standard * * * * * * * *
1316 Euro 5 6x2 3.900 Extended * * * * * * * *
4.400 Standard 2.320 2.060(1º+2º) 4.380 3.200 10.000 13.200 2.300 350
4.400 Extended 2.344 2.074 (1º+2º) 4.418 3.200 10.000 13.200 2.300 350
4.600 Extended * * * * * * * *
i Weighing condition
Vehicle with tools, such as emergency spare wheel,
reservoirs supplied (diesel, "AdBlue®" and water),
without the driver.

46
3.12 Power Take-off Technical Characteristics
3.12Power Take-off Technical Characteristics
The allowed power for the auxiliary power take-off can
be calculated through the following formula:
M×n×i
P = ----------------------
9550
Where;
P - Allowed power of the auxiliary power take-o
M - Allowed tightening torque (Nm)
n - Actuation rpm
i - Power take-off transmission ratio
• To turn ON and OFF the power take-off, see the

“Operation Manual”.
• The auxiliary power take-off and the countershaft
gear have a combined oil circuit.
• The temperature of 120° C of the transmission oil
and the temperature of 100° C of the coolant must
not be exceeded.
A1 - Distance up to the front axle center line

B1 - Distance up to the upper rim of the longitudinal member
C1 - Distance up to the center of the outlet flange

47
Tab 12: Power take-off coupled to the transmission

Arrangement
Continuous Direction
Transmission Torque (2) (mm)
Transmission Model PTO Drive type Type of output power (1) of
ratio Nm
kW/rpm revolution
A1 B1 C1
MB Pump
G56-6
Chelsea 442
Flange
1,000 271 * * *
Pneumatic Cardan 28,3/1000

NS42/2 c
Twisted axle Ø 1.25"
* * *
ZF
1,020 265
S5-580 TO Pump
NS42/2 b
Flange SAE B/13 splines
* * *
Pump
3003678
* * *
Eaton
0,980
FSO-4405A Cardan
3003718
Twisted axle Ø 1"
* * *
24,3/1000 237
Cardan
3004052
Twisted axle Ø 1"
* * *
0,990
Pump
3004053
* * *
Eaton Pump Inverse

FSO-4505A
3005252
* * *
to the
engine
Cardan
3005254
Twisted axle Ø 1"
0,805 349 (Clockwise) * * *
Pneumatic Pump
3005255
3003661 Flange DIN 5462/8 splines
* * *
Pump
3005244
* * *
0,750 374
Cardan
3005246
Twisted axle Ø 1"
29,4/1000 * * *
Eaton
FSO-4505HDA Cardan
3005247
Twisted axle Ø 1"
0,925 303 * * *
Pump
3005248
Flange DIN 5462/8 splines
0,750 374 * * *
Eaton Pump
EAO - 6106 Flange SAE B/13 splines
* * *
3003661 0,800 351
Eaton Cardan
EAO - 6206 Twisted axle Ø 1"
* * *
The values of Moment of maximum force for continuous operation are equivalent to 70% of the peak values mentioned in the table.
PTO output speed = engine speed X gear ratio
(1) from engine speed (rpm).
(2) the power rotation is available at the socket.

48
3.12.1Power Calculation for the Coupled Pump
The actuation tightening torque (required torque in the
auxiliary power take-off) can be calculated through the
formula.
9550 × P
M = ---------------------
n×η
When the flow is known.
15 ,9 × Q × p
M = ------------------------------
n×η
Where,
M = Tightening torque (Nm)
n = Revolutions
P = Power (kw)
p = Pressure (bar)
Q = Flow (l /min)
η = Efficiency
The tilting pump power can be calculated through the
formula:
Q×P
P = ------------------
600 × η
Where,
P = Power (kw)
p = Pressure (bar)
Q = Flow (l /min)
η = Efficiency

49
3.13 Technical Data Concerning the Rear Axle
3.13Technical Data Concerning the Rear Axle
i Note
The dimensions of the axles may vary according to
the vehicle model and type of suspension, therefore,
it will require a more technical analysis of the desired
alteration, to be carried out by the Mercedes-Benz do
Brasil Ltda. Product Engineering area
i Information
Contact Mercedes-Benz to get more information on
the rear axle dimensions, according to “Technical

50
3.14 Tightening Torque for the Fastening of the Vehicle Components
3.14Tightening Torque for the Fastening of the Tab 14: Torque for the fastening of the frame
Vehicle Components components
We recommend the use of self-locking bolts and nuts Components
Bolts Torque
with flange according to the Mercedes-Benz standard (mm) (Nm)
and material quality class 10.9. Support M14 x 1.5 150 ± 30
Air reservoir
Straps M8 x 1.25 20 ± 2
M14 x 1.5 150 ± 30
"AdBlue®" reservoir Support
M12 x 1.5 90 ± 10
Support M14 x 1.5 150 ± 30
Fuel tanks
Straps M12 x 1.5 90 ± 10
Propeller shaft intermediate Support M10 x 1.5 50 ± 10

bearing Bearing M14 x 1.5 150 ± 30
Tab 15: Axle components tightening torque

Torque
Components Screws/nuts
(Nm)
Brake support M16 x 1.5 mm 94

M18 x 1.5 mm 350
Wheels
M22 x 1.5 mm 600
Tab 13: Torque for the fastening of the frame bolts
inner nut 300
Bolts Torque Cube play - 140°
Thread MB Standard M62 x 1.5 mm
(mm) (Nm) (0.02 - 0.04 mm)
M8 x 1.25 25 outer nut 300 - 350
Thick Wheel hub
M10 x 1.5 51 inner nut 350
M12 x 1.5 92 MBN 10105 Cube play - 110°
MBN 13023 M80 x 1.5 mm
M14 x 1.5 150 (0.02 - 0.04 mm)
MBN 10112
M16 x 1.5 225 Thin MBN 10142 outer nut 350 - 400
M18 x 1.5 330

M20 x 1.5 760 Tab 16: Propeller shaft bolts torque
M20 x 2.5 520 Thick
EN ISO 4014 Transmission Rear axle
M22 x 1.5 590 EN ISO 8674 Model
EN ISO 8676 Coupling/ Torque Coupling/ Torque
M24 x 2 690 Thin type Nm type Nm
EN ISO 8765
M27 x 2 900
815/31 Yoke/SPL 70 70±10 Yoke/SPL 70 70±10
815/37 Yoke/SPL 70 70±10 Yoke/SPL 70 70±10
Tab 14: Torque for the fastening of the frame 815/44 Yoke/SPL 70 70±10 Yoke/SPL 70 70±10
components 1016/31 Yoke/SPL 90 70±10 Yoke/SPL 90 70±10
Bolts Torque 1016/37 Yoke/SPL 100 70±10 Yoke/SPL 100 70±10
Components
(mm) (Nm)
1016/44 Yoke/SPL 100 70±10 Yoke/SPL 100 70±10
 Batteries case
“SCR” catalytic converter
Support
Support
M14 x 1.5
M14 x 1.5
150 ± 30
150 ± 30
1316/37
1316/44
Yoke/SPL 100
Yoke/SPL 100
70±10
70±10
Yoke/SPL 100
Yoke/SPL 100
70±10
70±10

51
4 Damages prevention
4.1 Fuel and Brake System Lines
G Risk of accident
Other lines, shunts and/or mends must not be
fastened to the brake system lines.
G Risk of accident
If works are performed improperly in the brake, fuel
system lines and electric cables, its operation can be
affected and cause failure of the components or
parts related to the safety.
• Before you carry out welding works, drilling, trimming

or cutting with abrasion discs, the synthetic material
lines must be protected (brake system and fuel
system lines, as well as the wiring harnesses, in order
not to damage them. If necessary, disassemble them.
i Information
In order to protect the synthetic material lines and
wiring harness we recommend the use of covers with
leather scraps.

52
i Note
To obtain further information about the removal of
components and wiring harness, refer to the
Equipment Guidelines for the Assembly of Road
Implements and Equipment - "Specific electro-
electronic part" of the respective vehicle model.
• After disassembly and assembly the lines, check the

installation for pressure loss (tightness).
• In the installation of other lines next to the brake
system lines, use spacers to prevent friction between
the lines.
! Attention
It is not permitted to heat brake and fuel systems
lines to assemble the connections. Do not use a
heat gun.
i Information
For the assembly of pneumatic and fuel connections,
refer to chapter “Compressed-air Line”  page 82.

53
4.2 Welding Works
4.2 Welding Works
The welding works in the vehicle frame must only be
performed by specialized personnel.
To ensure that the electronic components are protected
against over voltage during the welding services, it is
necessary to adopt some safety measures.
i Note
To obtain further information about the removal of
components and wiring harness, refer to the
Equipment Guidelines for the Assembly of Road
Implements and Equipment - "Specific electro-
electronic part" of the respective vehicle model.
! Attention
The ground cable terminal of the welding machine
must not be hold to the major assemblies (engine,
transmission, axles, etc). In welding works in the
vehicle, the ground cable terminal of the welding
machine must not be hold to the transmission. If it
occurs, the electrical current induction in the support
or contact points inside the major assembly can
generate voltaic arcs (sparks), which can generate
structural changes in the surfaces, causing their
hardening. These damages above lead to early failure
in the transmission. Welding works must not be
performed:
• in major assemblies such as engine, transmission,
axles etc.
• in the vehicle frame (except for alteration to the
wheelbase and frame);
• in the frame tab.
i Note
To obtain more information about the welding works
in the vehicle frame, refer to Guidelines for the
Assembly of Road Implements and Equipment -
"General Manual".

54
4.3 Painting Works
4.3 Painting Works
H Indication related to the environment

protection
In the case of improper handling, paints and
varnishes are harmful to the environment and health.
Remove the paints and varnishes observing the
protective measures for the environment.
Before performing the paint works, protect or cover the

following areas:
• Contact surfaces between the wheel hub and brake
drums.
• Contact surface of the wheels nuts.
• Coupling flanges of the drive axles, propeller shaft
and auxiliary actuations.
• Hydraulic cylinder piston rods (hydraulic system to
tilt the cab etc.).
• All the pneumatic system control valves (compressed
air).
• Transmission breathers, axles, etc.
• Disc brakes.
! Attention
The temperature to dry the paint shall not exceed 80
°C.
i Information
For more information about the painting, refer to the

55
4.4 Engine
4.4 Engine
There is a warning alarm audible to the driver. This
i Information
sound alarm will be used as warning or information
when; In case it is necessary an auxiliary cooling circuit, a
modification or utilization of the engine cooling
• The maximum permitted temperature was exceeded
system circuit, contact Mercedes-Benz do Brasil
for the coolant.
Ltda. a the D/VC - BBM (Implementer Support)
• The coolant level is too low. department “Technical Consulting and Contacts” 
page 17.
• The engine oil pressure is too low.
• The engine oil level is too low. Engine intake system
• The engine maximum speed was exceeded. If it is necessary to change the engine air intake system,
it should be observed that:
• The engine air filter is saturated.
• In order to assure the operation, the series parts
For devices used outside the cab (For instance: vehicles supplied, such as air filter, water deflectors, lines,
with loading platform, hoist for cars and firefighting cushions (vibration dampening) etc, must be
vehicles) must be additionally installed, in the area of assembled the same way as the series version.
the equipment control panel, a visual warning device
(warning light). This warning device must be controlled • The flow speed in the air intake, before the manifold
by an engine diagnosis system additional to the system and in the air intake manifold, must not be increased.
already existent. Do not reduce the free cross section.
• After the air filter, the lines, hoses, manifolds and
connections of the air filter saturation indications
i Information must not be changed.
For more information, contact Mercedes-Benz do • The connections, lines, hoses and manifolds after the
Brasil Ltda. at the D/VC - BBM (Implementer air filter must have the tightness (sealing) of 100%.
Support) department “Technical Consulting and • The connections, lines, hoses of the external air
Contacts”  page 17. intake before the filter must be performed in order to
Observe the indications in the “Operation Manual” seal (prevent) dust and water from entering.
and the additional use instructions. • In the air intake area (engine intake), no changes are
allowed.
Engine cooling system
• Do not install an air intake outlet in a swirl area,
The engine cooling system (cooler, after-cooler (air/air
caused by the air flow in the cab or body.
cooler), air inlet front grill, air inlet channels, coolant
circuit, etc.) must not be altered. A proper line for the • Install the air intake air manifold in areas distant from
cooling air must be provided. dust, splash or water vapor.
• Always keep the cooler and post-cooler air inlet • Use appropriate measures to protect the air intake
opening free (vehicle front grille). outlet from rain and water splash, as well as against
water that falls from the cab trough. If necessary,
• Do not attach warning papers, plates, hoist or other
foresee measures to separate and deviate water.
decorative parts in the cooler and post-cooler area
preventing air flow.

56
4.4 Engine
Fuel system
! Attention
Use only Diesel S50.
The refueling with any other type of fuel, or diesel
with a sulfur concentration higher than 50 mg/kg will
cause damages to the engine and to the
aftertreatment system.

57
4.5 Leaf Spring
4.5 Leaf Spring
parabolic springs
• The damaged parabolic springs must be replaced.
• The parabolic springs blades must not be replaced
individually.
• Use only genuine Mercedes-Benz springs.
Reinforcements are not allowed though the blades
additionally assembled.
• During the assembly work, do not damage the
springs blades surface and anti-corrosive protection.
• Before the welding works, cover the springs against
welding drops. Do not touch the electrodes and the
terminal (“alligator” clamp) for electrodes on the
springs.

58
4.6 Cab Tilting
4.6 Cab Tilting

Before tilting the cab, see the vehicle “Operator's
manual”.
Otherwise, it might not be possible to recognize
certain risks causing injuries to you and other people.
i Note
For further information, refer to the Guidelines for the
"General Manual".

59
4.7 Start by Towing and Vehicle Towing
4.7 Start by Towing and Vehicle Towing

Before perform the vehicle towing, see the
“Operation Manual”.
Otherwise, it might not be possible to recognize
certain risks, cause an accident and cause injuries to
you and other people.
! Attention
If the information in the Operation Manual is not
observed, it can cause damages to the transmission.

60
4.8 Gas System
4.8 Gas System
i Note
Not applicable!

61
4.9 Vehicle Storage and Delivery
4.9 Vehicle Storage and Delivery
Storage
To avoid damages during the storage of the vehicles,
Mercedes-Benz recommends the maintenance and the
storage of such vehicles according to the indications
described in the Guidelines for the Assembly of Road
Implements and Equipment - "General Manual".
Delivery of the vehicle
To avoid and eliminate eventual faults existing in the
vehicles and implements, Mercedes-Benz do Brasil
Ltda. recommends that a vehicle and implement
delivery review is carried out in order to ensure its
correct functioning and perfect condition.
i Note
For further information, refer to the Guidelines for the
"General Manual".

62
5 Basic Vehicle Changes
5.1 General
5.1 General
i Information
The approval of eventual modifications to the chassis
frame can only be granted by Mercedes-Benz do
Brasil Ltda. as described in chapter “Technical
i Note
We emphasize also that any alterations eventually
processed in the vehicle frame, even if previously
approved by Mercedes-Benz do Brasil Ltda., will be
for the responsibility of the implements
manufacturer, as described in the Guidelines for the
"General Manual".
i Note
Changes to the vehicle basic characteristics and
original structure, for example, changes to the
wheelbase, must be recorded, licensed and have its
operation authorized by the local traffic regulation
authority, see chapter “Changes in the Vehicle” 
page 21.

63
5.2 Drilling in the Vehicle Frame
5.2 Drilling in the Vehicle Frame it, a full surface support must be provided on both sides
of the core, avoiding the "membrane" effect.
Use preferably the already existing longitudinal
members bores.
i
i Note. For more information, contact Mercedes-Benz do
Brasil Ltda. at the D/VC - BBM (Implementer
To obtain further information about the frame drilling, Support) department “Technical Consulting and
refer to Guidelines for the Assembly of Road Contacts”  page 17.
Holes will not be allowed:

• In the vehicle frame upper and lower tabs, except
holes at the longitudinal member rear end. The plant
produced bores, existing in the rims must no be
widened or used for the fastening of components.
• In the points of load incidence (for example, together
with spring supports).
• In the front area of the vehicle frame (“Z” profile).
If it is not possible to use the bores already existing in
the longitudinal member, new bores may be drilled in
the longitudinal member core, since they are in the
same track (center line of the bores) as indicated in the
figure below, keeping the same minimum distance
between the holes.
a - 45 mm from the end c - 125 mm

b - 100 mm Ø - maximum diameter 15 mm
 Do not apply force to the central region of the

longitudinal member (core), if it is not possible to avoid

64
5.3 Frame Welding
5.3 Frame Welding
i Note
performed by specialized personnel. To obtain more
information about the welding works in the frame,
refer to Guidelines for the Assembly of Road
! Attention
In order to prevent damage to vehicle components,
before performing welding work on the frame, refer
to chapter “Damages prevention”  page 52.
G Risk of fire and explosion

In case of welding work near the fuel tank, the tank
must be removed and properly protected.

65
5.4 Chassis Leveling
The vehicle must be parked on a flat surface, duly
choked and supported on racks as shown in the figure
below. The chassis must be relieved from tensions and
strains due to the weight of components and major
assemblies in such a manner that the suspension is
defeated. The tires must not be supported on the
ground.
The number and arrangement of racks must be defined
by the Implementer. During the leveling process, take
into account the tires installed in the chassis so that the
chassis height is controlled according to the definition
in “Vehicle Identification/Proposal Drawings”  page
18.
The stands must support the vehicle frame longitudinal
member only. The use of mechanic components is not
allowed (engine, transmission, axles, articulation, etc.)
and crossmembers as support points.

66
5.4.1 Vehicle Alignment Confirmation Confirmation of the vehicle frame axles alignment
Vehicle frame alignment confirmation The check of the axles alignment must be carried out by
The confirmation of the chassis alignment must be comparing the values obtained at both sides. The
carried out at least at 5 points (a, b, c, d, e...). The check difference between the measurements must not be
points must be established, preferably, by the greater than the indicated values
positioning of the vehicle frame crossmembers. The
difference between the values obtained in the
measurements must not be greater than the indicated
values.
a - Distance between the 1st front axle and the 2nd front axle
b - Distance between the 1st front axle and the 1st rear axle
c - Distance between the 1st front axle and the 2nd rear axle
d - Distance between the 1st rear axle and the 2nd rear axle
a,b,c,d,e - Measurement points 2 Line Tab 18: Axles check values

1 Terminal strip 3 Measuring tape
a (mm) b (mm) c (mm) d (mm)
Tab 17: Chassis confirmation values
<5 < 10 < 10 <5
a (mm) b (mm) c (mm) d (mm) e (mm)
<5 <5 <5 <5 <5

67
5.5 Change of the Wheelbase
5.5 Change of the Wheelbase Recommended distances for the alteration of the
wheelbase "R" distance.
The recommended distances for the wheelbase
i Information alteration have as starting point the largest factory
produced wheelbase distance.
Eventual approval of wheelbase changes can only be
granted by Mercedes-Benz do Brasil Ltda. as
described in chapter “Technical Consulting and
Contacts”  page 17.
In the alteration of the wheelbase distance, use

preferably a chassis in which the distance between the
axles of a standard vehicle is as close as possible of the
desirable wheelbase.
For any modification to the wheelbase, the resulting
gross weights on the axles and total gross weight shall
R - wheelbase
not exceed the maximum values permitted, and it is also
necessary to observe the vehicle turning circle
influence according to local legislation and/or
recommendation of Mercedes-Benz do Brasil Ltda.,
refer to chapter “Total Technical Weight of the Vehicle i Note
and Loads on the Axles”  page 44. For wheelbase shorter than 3,100 mm and larger
For alterations to the wheelbase dimensions, it is than 4,400 mm contact Mercedes-Benz do Brasil
necessary to adjust the propeller shafts to the new Ltda. at the D/VC - BBM (Implementer Support)
conditions, observing the procedure under chapter department “Technical Consulting and Contacts” 
“Propeller Shafts.”  page 77. page 17.
i Information ! Attention
Inquiries shall be sent to Mercedes-Benz do Brasil Wheelbase changes above the values recommended
Ltda. at the D/VC - BBM (Implementer Support) by Mercedes-Benz do Brasil Ltda. may result in
department “Technical Consulting and Contacts”  driveability malfunction and/early break and wear of
page 17. vehicle components.
After performing the changes in the wheelbase,
reinforce the chassis with a continuous subframe.
i Note
For other information, refer to chapter “Subframe
Attachment”  page 91.

68
5.5.1 Alteration of the Wheelbase Distance Due to the
Displacement of the Rear Axle Block
i Note
For Accelo vehicles, it is recommended to change the
wheelbase moving the rear suspension set with the
rear axle in the frame longitudinal member. In the
cases of chassis extension, this will be the best
option as we will not have this way the cutting and
mending in the wheelbase, transferring the frame
extension to the rear overhang.

69
5.5.2 Alteration of the Wheelbase by Means of Cutting
the Longitudinal Members
The chassis has to be supported on its ends on both
sides and where the sectioning will be performed,
according to chapter “Chassis Leveling”  page 66.
Foresee the cut lines so that no hole existing in the
frame longitudinal member is cut.
After having been cut, the longitudinal members of the

vehicle frame, as well as the sections to be added to the
wheelbase distance in the extension cases, must be
beveled according to the standard DIN 1912.
1 Added section 3 Intermediate layer
The filling of the "V" seam must not be made a single 2 Inner layer 4 External layer
time, the filling must be made in layers, as shown in the
figure. After the welding, it is necessary to pay attention
to enable a slow and homogeneous cooling. In order to make possible the adequate fastening of the
reinforcements to the longitudinal members surface,
the mends weld surplus must be ground.
After checking the chassis alignment, the cuts/
i Note
junctions areas must be reinforced in order to assure
To obtain more information about the welding works the resistance, without impairing the frame elasticity.
in the frame, refer to Guidelines for the Assembly of
Road Implements and Equipment - "General Manual".

70
Regions appropriate for the frame sectioning
Cut the frame preferably between the frame
crossmembers, avoid as much as possible to displace
the crossmembers.
When the vehicle has more than one propeller shaft, it is
necessary, preferably, to section the longitudinal
member so that the vehicle intermediary bearing and
original propeller shafts are preserved.
Inadequate regions to cut the frame
It will not be allowed to cut the frame in the following
areas:
• On areas where load is applied.
• Between the front and rear suspension spring
supports.
• In the suspension area near the spring supports.
• In the transmission and transfer case regions.

71
5.5.3 Reinforcements in the Longitudinal Member Fastening of the reinforcement element to reduce
Splice the wheelbase distance
After the alteration of the wheelbase distance, and the
frame alignment check, the cut and mend regions must
be reinforced to ensure their resistance without
compromising the elasticity of the vehicle frame.
The vehicle frame original reinforcements must be
considered in the new wheelbase distance.
i Information
For the arrangement of original reinforcements, see
“Vehicle Identification/Proposal Drawings”  page
18. For the extension and assembly of the brake
system lines, see chapter “Brake System”  page 80.
! Attention
It is not permitted to set fastening points on the Fastening of the reinforcement element to increase
longitudinal member flanges. The reinforcements the wheelbase distance
must not negatively affect the elasticity of the vehicle
frame.
The reinforcements must be fastened to the longitudinal

member cores by bolts with flange and self-locking
nuts, using as much as possible the holes already
existing in the chassis longitudinal members.
i Information
For the frame reinforcement tightening torque, refer
to chapter “Tightening Torque for the Fastening of the
Vehicle Components”  page 51.
In the longitudinal member core sufficient distance

must exist between the lower and the upper
reinforcement angle.
i Information
New holes in the longitudinal member core, if
extremely necessary, shall be performed according
to chapter “Drilling in the Vehicle Frame”  page 64.

72
Detail of the reinforcement
The reinforcement elements must have an “L” profile, be
made of material equal to the one of the frame
longitudinal members, and materials with lower
properties and characteristics will not be admitted.
i Information
For more information, see “Vehicle Frame Material”
 page 30.
The “L” profile must be made of folded plate and the

commercially available laminated profiles must not be
used.
For guidance in the manufacturing of these
reinforcements, check the dimensions indicated in the
figure below.

a - 50 mm c - 15 mm
b - 70 mm s - 5 mm

73
5.5.4 Repositioning the Crossmembers in the Vehicle
Frame
After installing the reinforcements in the vehicle frame,
some of crossmembers must be repositioned, added or
removed. The added crossmembers must be equal to
the others already existing in the vehicle.
In the cases of frame extension, additional
crossmembers must be assembled, if the distance
between them is greater than 1,000 mm.
The application of the original frame reinforcements in
the repositioning of the crossmembers must be taken
into consideration.
1 - Longitudinal member 4 - Longitudinal member bores
2 - Crossmember 5 - Squareness
i Information 3 - Strut
For the arrangement of original reinforcements, see When the replaced crossmember is for the propeller
“Vehicle Identification/Proposal Drawings”  page shaft bearing holder attachment, the holes for the
18. attachment must be foreseen to assure the propeller
shaft original position. For drilling to assemble the
For the installation and repositioning of chassis
propeller shafts holder, see figure.
frame components, see chapter “Additional
Components and Major Assemblies”  page 86.
When a crossmember is repositioned and this new

position matches with the region where the longitudinal
members modification (reinforcements region), it must
be replaced by a crossmember with appropriate length,
using for this a Mercedes-Benz genuine part.
! Attention
The fastening of the crossmember must be made by
using bolts and nuts with flange and self-locking
nuts. Attachment of crossmembers by welding will
not be allowed. Utilize, preferably, the already
existing bores of the longitudinal member. a - 35 mm e - 35.5
b - 50 mm f - 124 mm
c - 40.5 mm g - 53 mm
d - 75 mm h - 110 mm
i Information
For the frame crossmembers tightening torque, refer
to chapter “Tightening Torque for the Fastening of the

74
5.6 Rear Overhang Alterations
In the case of alterations in the rear overhang of the
i Note
vehicle, the following items must be observed:
To obtain more information about the welding works
• the prescriptions concerning the vehicle gross
in the frame, refer to Guidelines for the Assembly of
weight rating
• the allowed load on the axles
Splice reinforcements must be performed according to
• the minimum load on the front axle; the recommendations in chapters “Reinforcements in
• the legal limits for the rear overhang the Longitudinal Member Splice”  page 72.
• the output angle. To ensure sufficient torsion resistance of the rear frame
overhang, the distance between the crossmembers
must not exceed 1,200 mm.
i Information
For more information on the technical limitations,
refer to chapter “Extension of the Rear Overhang and
Wheelbase”  page 33.
5.6.1 Rear Overhang Extension

After cutting, the vehicle frame longitudinal members as
well as the sections to be added must be chamfered
according to the standard DIN 1912.
1 - Maximum of 1,200 mm
• The subframe must be extended up to the end of the

vehicle frame.
• For vehicles that have other crossmember in addition
to the leaf springs crossmember, for the frame
closing, it can also be repositioned.
1 Added section 3 Intermediate layer
2 Inner layer 4 External layer • If the closing crossmember, original series version is
not displaced to the rear part, an additional
The filling of the "V" seam must not be made a single crossmember must be assembled for the closing of
time, the filling must be made in layers, as shown in the the frame.
figure. After the welding, it is necessary to pay attention
to enable a slow and homogeneous cooling.

75
5.6.2 Shortening the Rear Overhang.
When shortening the frame end, the closing
i Information crossmember of the frame must be displaced to the
In case the maximum frame overhand is exceeded, remaining end. If necessary, replace the crossmember
the towed weight informed in the vehicle from the spring supports by the frame closing
documentation must be reduced; see the diagram in crossmember.
chapter “Coupling or Engagement for Towing”  page Keep the quantity, diameter and resistance class of the
113. The frame overhang must be correspondingly bolts, assembling with the fastening points as they are
reinforced in the original version
In both cases, the vehicle frame extension must be For vehicles in which the frame closing crossmember is
performed according to the following technical the leaf spring one, it must not be put forward.
prescriptions:
The fastening of the rear springs supports must not be
X The distance between the leaf spring rear affected.
crossmember and the final crossmember closing
the frame must not exceed 1,500 mm. For
extensions in which this measure needs to be
i Information
exceeded, it is necessary to install an additional
crossmember at equal distance between the leaf For the frame screws tightening torque, refer to
spring crossmember and the vehicle frame closing. chapter “Tightening Torque for the Fastening of the
X After welding the vehicle frame longitudinal
members, apply reinforcements symmetrically in
both sides of the frame. In order to prevent cracks
in the welding seams and keep the longitudinal
members elasticity, rivet or screw reinforcements
comprising the longitudinal members core and tabs,
in the form of chamfered angle bars at the ends. In
the longitudinal member core sufficient distance
must kept between the upper and lower
reinforcement corner pieces.
After the conclusion of the vehicle frame extension
works, check the need of repositioning the vehicle tail
lamps in order to assure the proper view of these light
indicators when the vehicle is in operation.
1 Vehicle frame longitudinal member

2 Frame closing crossmember (leaf spring crossmember)
3 Shock absorbers crossmember

76
For vehicles that have other closing crossmember in 5.6.3 Propeller Shafts.
addition to the leaf spring closing crossmember, the last
crossmember must be advanced and attached at the
frame edge, as shown in the figure, thus keeping its
closing function.
Propeller shaft with longitudinal compensation

A - Installation length
B - Allowed variable length
1 Frame longitudinal member crossmember

2 Leaf spring closing 3 Mounting rails
It is recommended that the body structure or

equipment final end is no longer than 450 mm from the
chassis longitudinal members rear ends.
! Attention
The repositioned crossmember fastening must be
made by using bolts. The welding of the
crossmembers to the longitudinal members will not
Propeller shaft without compensation (fixed)
be allowed.
A - Installation length
The correct configuration of the propeller shaft will

prevent noises and oscillations or vibrations. We
recommend to use only Mercedes-Benz genuine parts.
• In case of modifications to the wheelbase, respect
the propeller shafts arrangement and length, similar
to a standard version vehicle (same model and same
wheelbase), in other words, original version.
• The propeller shaft pipe diameter and wall thickness
shall match the propeller shafts for standard
vehicles.
• If necessary, use more than a propeller shaft with
intermediate supports.
 • The bending angles must be equal in both joints (β1

= β2). They must not be higher than 6° or lower than

77
1°. Bending angles higher than 6°, as sell as, errors
in the flange angle (β1 < > β2) will result in the
propeller shaft oscillations. These angles influence in
the major assembly durability (transmission, axles,
etc.), which can lead to damages.
• Upon assembly, the current guidelines must be
observed.
• Balance the propeller shafts before the assembly. The
overhang weights must not be removed.
• The flange surfaces must be completely flat.
• During assembly pay attention to ensure the
concordance of the propeller shafts marks.
• Eliminate the vibrations, optimizing the propeller
shaft angle.
• Fasten the propeller shafts flanges so that universal
joint bearings create phase angles. See the figure Bending angles
below.
Vehicles with four-wheel drive
• In case of modifications to the wheelbase, only the
i Information propeller shafts lines after the transfer case can be
For the propeller shafts tightening torque, refer to changed.
chapter “Tightening Torque for the Fastening of the • The wheelbase can only be shortened up to a
Vehicle Components”  page 51. minimum distance from the series vehicles
wheelbase (original version).

78
5.6.4 Arrangement and Angle of the Propeller Shafts
Flanges Coupling
i Information
For information on the arrangement of the propeller
shafts for standard version vehicles, contact
Mercedes-Benz do Brasil Ltda. on “Technical
i Information
In special cases, it is possible to send drawings that
illustrate the target alteration to the propeller shaft
with exact dimensions (propeller shaft length and
bending angles) for Mercedes-Benz do Brasil Ltda.
approval at the D/VC - BBM (Implementer Support)
department “Technical Consulting and Contacts” 
page 17.
The coupling angle of the flanges must follow the

configuration shown in the figure below, the universal
joint bearings must be 90° far from each other.
CM - Transmission ET - Rear axle

M - Intermediate bearing

79
5.7 Brake System
5.7 Brake System
In the brake system alterations, for instance, in the
cases of wheelbase alterations or frame extension, the ! Attention
brake lines need special care and must be handled by Under no circumstances the metallic lines between
qualified staff. the air compressor and the compressed air drier can
be shortened (“APU” valve set), as well as the
alteration of its position (lines and coil) to a place
with ventilation restrictions or close to high
G Risk of accident
temperature areas (example: near the exhaust
If works are improperly performed in the brake system).
system, its operation can be affected. It can cause
failure in the components or parts related to safety. Additional consumers air intake
This way, you may lose control of the vehicle, causing
accidents and injuries to you or third parties.
i Information
Disc brakes
Refer to chapter “Additional Pneumatic Consumers”
 page 29.
! Attention
The installation of spoilers in the bumper, as well as
hub caps on the wheels or covers in the disc brakes
and other components, they must not impair the
ventilation and cooling.
i Information
For information about the ABS cables extension
(antilock brake system) refer to Guidelines for the
"Specific electro-electronic part".
Air compressor
! Attention
The use of plastic lines between the air compressor
and the compressed air drier ("APU" valve set), in
hydraulic systems and when the ambient
temperature is higher than 80°C will not be
admitted.

80
5.7 Brake System
5.7.1 Air Reservoirs Arrangement
The brake system and accessories air reservoirs are
arranged according to the model and version, i.e., they
may vary according to the vehicles, as well as the
volume and quantity of reservoirs.
1 Rear axle brake system

2 Front axle brake system
3 Accessories
! Attention
For vehicles with two rear axles, the brake system
reservoirs of both rear axles must be interconnected.
i Information
For the air reservoir tightening torque, refer to
chapter “Tightening Torque for the Fastening of the

81
5.7 Brake System
5.7.2 Compressed-air Line Plastic lines joint (“Tecalon”)
Assembly of connections in plastic lines (Tecalon) Compressed-air lines joints shall be performed
according to the figure below.
G Risk of accident
Heating the plastic lines for the assembly of the
connections is not allowed.
Do not use a heat gun.
Appropriate tools must be used for the assembly of the

connections and the plastic lines joint.
Carefully clean the lines before the assembly.
In the cases of wheelbase increase, the plastic lines

must be extended from one of the its ends, i.e., together
with the component to be repositioned.

82
5.7 Brake System
When installing the compressed-air components and/or Plastic lines fastening and installation
line fittings, check for damages to the sealing rings.
• Maintain a safe distance from heat sources, cutting
edge parts and moving parts.
• To secure, use synthetic (plastic) straps. Maximum
distance between the straps, 500 mm.
Respect the following base conditions:
• Seams are not allowed in the bending area.
• The relevant pipe must be in a visible area from
outside.
• As general rule, all pipes damaged or bend during the
disassembly sequence must be replaced.
• If several lines are extended, the separation points
arrangement must be changed.
• In the case of lines with a total length of < 10 m
(measured from connection to connection, including
the line extension), two junction parts can be used,
that is, it is allowed to apply an intermediate line.
• In the case of lines with total length > 10 m, a single
joint piece must be used, i.e., from the connection
part, they must be extended in a single piece.
• Later changes or repairs that imply in the use of other
connection parts are not allowed. In this case, the
line must be replaced starting from the extension
point.
The bending radii must not be lower than the indicated.
Tab 19: Curve diameters and radius for plastic lines
(Tecalon)
1 - Threaded connection 4 - sealing ring
2 - Pin connection 5 - sealing ring Ø x Wall Bending
3 - sealing ring 6 - sealing ring Compressed-air lines
(mm) radii (mm)
Seat, steering column, cab

For the union of the lines only original connections can optionals
6 x 1.0 mm 40 mm
be used, and lines with the same dimensions and
characteristics as the genuine Mercedes-Benz ones Camshaft 8 x 1.0 mm 40 mm
must be used. Air reservoirs, brake cylinders 12 x 1.5 mm 60 mm
After the lines assembly is completed, tests must be Valves feed 16 x 2.0 mm 100 mm
carried out to check if there are no leaks.

83
5.7 Brake System
Basic pneumatic diagram for 6x2 brake system
vehicle
1.01 - Air compressor; 28.01 - Quick discharge valve;

2.01 - Pressure control valve 28.04 - Brake switch-off valve for anti-slip control;
4.03 - 4-way protective valve; 30.04 - Pressure control valve
5.01 - Air reservoir - front axle brake (20 liters); 33.01 - Engine brake actuation;
5.01 - Air reservoir - rear axle brake (20 liters); 33.01 - Auxiliary axle brake locking;
5.01 - Air reservoir - accessories (10 liters); 33.01 - Actuation device for the auxiliary axle lift
6.12 - Air drier (APU); 20.05 - Engine brake cylinder;
10.01 - Pressure switch; 38.02 - Test outlet, measurement points;
13.02 - Brake pedal valve; 43.01 - Suspensor pneumatic spring;
14.01 - Parking brake manual valve; 45.01 - Front axle ABS valve;
16.01 - Parking brake relay valve; 45.12 - Rear axle ABS valve;
20.02 - Front break membrane cylinder;
22.01 - Combined rear brake cylinder (Tristop);
Test to check the tightness Location of the measuring points (38.02);

• At the front service brake line (connection 11).
• At the parking brake line (connection 12).
i Information
• At the front service brake line.
In order to assure the maximum reliability to the
results to be obtained, it is mandatory to use a test • Close to the reservoirs and the “APU” valve.
case, developed for the pneumatic brake system To check the tightness of the service brake circuit, the
tests. For more information regarding accredited manometer must be disconnected from the test case at
manufacturers for this test case contact Mercedes- the measurement points “38.02”. As soon as the
Benz Dealers or Qualified Workshops at the D/VC - pneumatic system is pressurized, actuate the brake
BBM (Implementer Support) department, “Technical pedal until the pressure gauge in the test case shows a
Consulting and Contacts”  page 17. 300 kPa (3 bar) braking pressure. Without altering the
pedal position a pressure fall should not occur,
measured by the manometer during 1 minute to check
the correct splice between the lines and tightness of the
service brake circuit connections (connection 11). A
similar test must be carried out with the parking brake
circuit by connecting another manometer from the test
case to the measurement point 38.02 (connection 12).
With the parking brake lever actuated (depressurized
brake system) and the vehicle parked, perform the
 following sequence to assess tightness:

84
5.7 Brake System
Test sequence
X Pressurize the brake system until the discharge of
the regulating valve (work pressure).
X Shut off the engine and apply wedges to the vehicle
rear wheels.
X Release the parking brake.
X Check the “38.02” (connection 12) measure point in
the pressure gauge; if the circuit pressure is
between 8.1 and 8.5 bar for a service pressure of
8.5 bar.
X Check the “38.02” (connection 12) measure point in
the pressure gauge; for 1 minute, and if there is no
pressure fall, the tightness of the parking brake
system had its tightness confirmed.

85
5.8 Additional Components and Major Assemblies
5.8 Additional Components and Major Assemblies Lateral fastening
Assemble the support, the part or component next to a
crossmember. Additional crossmembers must not be
G Risk of accident and injury assembled. Assemble the reinforcement plate at the
core area, frame internal side.
The use of non-approved parts, major assemblies,
Do not foresee application of force in the longitudinal
equipment and accessories can affect the vehicle
member central area (core). If it is impossible to avoid
safety
it, the total support of the surface at both sides of the
Before working on additional structures, bodies, core, avoiding the "membrane" effect.
installation of pieces of equipment and accessories
in the basic vehicle or in major assemblies, it is
compulsory to read the chapters in vehicle
i Information
“Operator's manual” related to the installation of
these implements and the utilization and assembly For the fuel tank repositioning, refer to chapter
instructions provided by the implements “Assembly/Repositioning the Fuel Tank”  page 87.
manufacturers.
Otherwise, it might not be possible to foresee certain
risks, endangering you and other people.
The acceptance by the inspection and public control
services or the authorizations granted by official
agencies does not exclude the safety risks.
Observe the specific laws, guidelines and licensing
regulations of the respective country!
i Information
Calculate the number of bolts according to the
components weight.
For the vehicle frame components tightening
torques, refer to chapter “Tightening Torque for the
Fastening of the Vehicle Components”  page 51.
i Information
Use the holes in the existing longitudinal member

86
5.8.1 Assembly/Repositioning the Fuel Tank
Tab 20: Connection parts between the tanks
Denomination Part number Qty.
G Risk of accident
1 M16 x 1.5 mm elbows A388 429 70 38 2
Heating the plastic lines for the assembly of the
connections is not allowed. Do not use a heat 2 M14 x 1.5 mm nut N080705014001
Sealing ring A388 997 72 45 2 kit
gun. Pressure ring A388 476 70 20
3 M16 x 1.5 mm nut N080705016003

Sealing ring A388 997 71 45 2 kit
Pressure ring A308 429 70 27
4 M16 x 1.5 mm tap A388 997 79 36 1
5 Pin connection A403 990 01 67

2 kit
Pin connection nut N915 017 010 200
6 Ø 13 mm plastic line A011 997 09 82 2m
When extending the fuel line, the assembly shall be

performed according to the instructions in chapter
“Assembly of connections in plastic lines (Tecalon)” 
page 82.
It is recommended using reservoirs, supports,

reinforcements, and fastening components equivalent
to those originally installed in the vehicle. The additional
reservoir and other components may be purchased at
the Mercedes-Benz Dealers or Qualified Workshops.
During the installation or repositioning the fuel tank it is
essential to install a reinforcement plate on the inner
part of the longitudinal member core.
The connection between the fuel tanks shall be
performed according to the illustration below.
i Information
For the fuel tank supports and belts tightening
torques, refer to chapter “Tightening Torque for the

87
5.8.2 Repositioning of the Chassis Components Repositioning of the battery box
After modifications to the wheelbase, it may be When necessary to reposition the battery case, replace
necessary to reposition the components, such as fuel the cables by new ones, properly dimensioned for the
tank, battery case and air reservoir. This repositioning application.
must be minimized and, when performed, the
orientations contained in these guidelines must be
observed.
i Note
For the repositioning of components that require timely
maintenance and/or repair, make sure there is enough For further information about the electric wires
clearance for this procedure. extension, refer to Guidelines for the Assembly of
Road Implements and Equipment - "Specific electro-
Equally, a free space should be estimated for the air electronic part".
reservoir maintenance.
Repositioning these components directly influence the
load arrangement on axles, therefore, it is necessary to
calculate the load distribution again.
The original supports of the repositioned components
must be kept.
i Information
Battery box
i Information
For the repositioned components tightening torque,
refer to chapter “Tightening Torque for the Fastening
of the Vehicle Components”  page 51. i Information
For the tightening torque for the battery box to the
frame, refer to chapter “Tightening Torque for the
i Information Fastening of the Vehicle Components”  page 51.
For repositioning the catalytic converter and

changing the exhaust pipe refer to chapter
“Alterations in the Exhaust System”  page 117.

88
5.9 Subframes
5.9 Subframes
1 - Subframe
• For the perfect joint between the chassis and the

body, for all types of implements it is necessary to
have a subframe or a lower body that works as a
subframe.
• The subframe longitudinal members must be
continuous, flat, and integrally seat on the chassis
longitudinal members upper tabs, following its shape.
! Attention
Wood strips between the chassis longitudinal
members and the subframe will not be allowed.
• The subframe and the vehicle frame must have the

same thickness and tabs with the same width.
• Put the subframe crossmembers aligned with the
vehicle frame crossmembers.
• For the subframe longitudinal members, use profiles
in folded plates “U”, do not use laminated profiles of
commercial use.
• The longitudinal member dimensions result in the
resistance module (Wx), necessary for dimensioning
the body and the chassis. Refer to chapter
“Dimensions of the Profile for the Subframe”  page
32.
 • The subframe must follow all the vehicle frame

movement, absorbing the requirements that arise.

89
5.9 Subframes
5.9.1 Subframe Configuration
The profile passage at the longitudinal members front If very high longitudinal members are necessary, or if it
ends must be progressive. The edges must be reburred. is necessary to obtain reduced construction heights,
There must be continuous subframes in: the "U" profile in bonded joints may:
• bodies with very high center of gravity; • be closed with a box;
• cases where there is concentrated load in a single • be fitted one inside the other or;
point; • be fitted one on the other.
• cases where there is concentrated load in a single Therefore, we increase the resistance module, but also
side; increase the bending resistance.
• cases in which the bodies/structure are installed on
the cab.
For instance, tilting bodies, concrete mixers, glass
transport, tow services, tow trucks, articulated cranes,
rising platforms etc.
For the construction of subframe, see “Dimensions of

the Profile for the Subframe”  page 32.
A profile “U” open (“Wx” see the diagram of the
profiles dimensions).
B profile “U” closed (“Wx” see the diagram of the
1 - Subframe α - angle of 15° - 45 ° profiles dimensions 1.25).
2 - Vehicle frame
C profile “U” fitted into another profile (“Wx” see the
diagram of the profiles dimensions 1.75).
D profile “U” fitted on another profile (“Wx” see the
diagram of the profiles dimensions 1.9).
! Attention
Displace, as much as possible, the subframe
longitudinal members forward, at least, until it
surpasses the front spring support at the back part

90
5.9 Subframes
5.9.2 Subframe Attachment • In order to avoid longitudinal shifts, there should be
Establish the fastening according to the vehicle and plates screwed to the longitudinal members (rear
body type or expected structure, as well as according to axle area) and welding or screws in the body
the vehicle intended utilization. subframe according to the following figure.
The correct attachment will be decisive for: - Define the quantity of fastening elements in order to
ensure the acceptance of brake force and side forces,
• The shifting behavior and the vehicle operational see “Minimum quantity of fastening elements”  page
safety; 93.
• the chassis frame and body durability.
In both cases, see the guidelines in the related chapters
for each type of body or equipment.
i Information
For information about the types of subframe
fastenings, refer to Guidelines for the Assembly of
i
Utilize in the subframe fastening the holes already
existing in the chassis longitudinal members. New
holes, when extremely necessary, shall be performed
according to the guidelines informed in chapter
Attachment with plates
“Drilling in the Vehicle Frame”  page 64.
! Attention
The subframe fastening to the chassis longitudinal
member shall be screwed, not being permitted to
weld it.
The body fastening to the vehicle frame must ensure

that there is no side and longitudinal shifts, taking into
account the following points:
• To avoid lateral movements, lateral guide plates must
be placed between the first two fastening points.
- Foresee guide plates of enough dimensions.
- There must not have plays between the guide plates
and the subframe.

91
5.9 Subframes
Securing with clamps Rigid fastenings
i Information
Mercedes-Benz do Brasil Ltda. does not recommend
the use of clips for the fastening of the subframe. The
load on the chassis longitudinal member lower
flanges clip may deform it, consequently, the clips
may come lose, resulting in cracks or deformities to
the frame.
If it is not possible to avoid the fastening with clamps, to

avoid deforming the lower rims of the longitudinal
members shims must be installed to increase the
support area. 1 - Weld seam line 5 - Chassis longitudinal member
2 - Clearance ± 15 mm 6 - Subframe
The shims must be made of malleable cast iron and/or 3 - Ø of the bores = 15 mm a - Boring line = 31.5 mm
hardwood, except at the regions close to high 4 - Attachment plate
temperature points.
Elastic fastening
To avoid deforming the subframe and then the loosening
and releasing of the clips, put shims between the inner
rims of the subframe profile.
A - Clearance between the consoles
1 - Vehicle frame 4 - Support shim

2 - Fastening clip 5 - Support shim
3 - Clips support shim 6 - Subframe
1 - Bolt consoles
2 - Elastic element 1 - Bolt
3 - Elastic element 2 - Washer
4 - Washer 3 - Elastic element
5 - Nut 4 - Nut
a - Clearance between the

92
5.9 Subframes
Minimum quantity of fastening elements
i Information
The minimum quantity of subframe fastening
elements depends on the wheelbase distance and
rear overhang of each model, particularly in the
cases of frame lengthening. In all cases, the
maximum distance between the fastening elements
will be of 1,000 mm.
1st FA - Front axle center line P5 - Anchoring point before or after the 2nd RA
2nd FA - 2nd front axle center line P6 - Anchoring point before at the frame end
1st RA - 1st rear axle center line A - Distance between 1st FA and P1 (1st anchorage point)
2nd RA - 2nd rear axle center line B - Anchoring points between P1 and P2 (max. 1 m)
P1 and P2 - Anchoring points at the frame front part C - Anchoring points between P2 and P3 (every 1 m, at least)
P3 - Anchoring point before the 1st RA D - Anchoring points between P5 and P6 (every 1 m, at least)
P4 - Anchoring point before or after the 1st RA E - Maximum variation of the anchoring point (± 300 mm)
5.9.3 Regions Appropriate for the Subframe Fastening

For the fastening of the subframe use, preferably, the
regions between the original crossmembers of the
vehicle frame and the bores already existing in the
longitudinal member.
i Information
New holes, when extremely necessary, shall follow
the guidelines described in chapter “Drilling in the
Vehicle Frame”  page 64.

93
5.9 Subframes
5.9.4 Regions Inadequate for the Fastening of the
Subframe
It is not allowed to fasten the subframe to the load
affected areas, such as:
• Front and rear spring support area.
• Rocker arm area.
• Torsion bars support.
• Dampers support.
• In the suspensor crossmember area for the front
and/or rear axle.
A - Front suspension region

B - Rear suspension region

94
5.10 Fenders and Wheel Wells
5.10Fenders and Wheel Wells
The distance from the tire to the fender or the wheel box
must be enough, even when snow or slippage chains are
installed and, in the case of the suspension total
bending (also in the case of torsion). Observe the
dimensions informed in “Vehicle Identification/Proposal
Drawings”  page 18.

95
5.11 Spare Wheel
5.11Spare Wheel
Securing
• According to the chassis drawing; under the frame,
on the frame side or fixed to the body.
• Observe the legal prescriptions.
• Of easy access and movement
• With dual protection to prevent loss.
• Observe the “Accident prevention” rules.
Installation of spare tire for VUC vehicles
For vehicles that will be subject to conformity to the
VUC (Urban Load Vehicle) legislation, in which the
vehicle total length is limited and, consequently, the
rear overhand is shortened, not being possible to
perform the factory original support fastening, we
suggest a new repositioning and assembly to improve
load distribution.
In order to perform this assembly, it is necessary a new
support for the spare wheel with original components
according to the figure and table below.
Tab 21: Spare wheel fastening parts

Item Number Denomination Quantity
01 A688 400 70 41 Fastening set 01

02 A688 403 71 44 Protective plate 02
03 A308 403 70 75 Threaded pin 02
04 A688 400 70 68 Catch set 01
05 A688 403 70 19 Shim 01
06 A688 403 70 08 Reinforcement 01
07 A011 850 00 95 Chain set 01

96
5.12 Bumper
5.12Bumper
Front lower bumper
i Note
For changes to the front bumper structure, contact
Mercedes-Benz at “Technical Consulting and
For all vehicles used in traffic, front-end underrun

protection is applied with the exception of off-road
vehicles and vehicles that have as purpose something
not related to the front underrun protection
requirements.
The purpose of a vehicle is prescriptively defined by the
type of implement, consequently, the chassis
equipment must always be checked with or without the
front underrun protection requirements.
Mercedes-Benz recommends that the purpose and the
approval are established before the concerned
authorities of the respective country.
Rear lower fender
i Note
In Brazil, the vehicle is delivered from factory without
the rear bumper, its installation must be performed
by the Implementer in accordance with the local
standards and legislation applicable.

97
5.13 Side Protector for Cargo Vehicles
5.13Side Protector for Cargo Vehicles
The purpose of the lateral protector is to avoid or
minimize collisions, preventing motorcycles, bicycles, or
small size vehicles from penetrating inside the inner
part and from being crashed by the truck or towed
vehicle wheels
i Note
The compulsory use and the installation of the lateral
protector for freight vehicles must meet the
requirements of the current local law.
The brake system, pneumatic and hydraulic lines must

not be fixed on the underride guard.
In the manufacturing of the lateral protector, an access
for the refuel, maintenance and repair of components of
the vehicle, such as:
• Spare wheel.
• Fuel tank and "AdBlue®".
• Air and/or fuel filter.
• Batteries box and general switch;
• Cab tilting pump, when applicable.
• Other components as required.
We recommended the manufacturing of a removable
protection as shown in the figure.
 1 - Locking cotter pin 2 - Threaded handle

98
5.14 Cab
5.14Cab 5.14.2Seats
The operation, access and stability of major assemblies,
equipment and actuation devices, as well as, the
stability of supporting parts shall not be negatively ! Attention
affected by changes to the cab.
The replacement of the original seats and their
For the assembly of other equipment and/or structure anchoring elements is not permitted.
on the cab roof, see “Additional Structure on the Cab It is not permitted to drill the cab footwell to install
Roof”  page 40. additional seats.
5.14.1Cab Extension
The tilting long cab is not dimensioned for eventual
extensions and its articulation and support system is
appropriate only for the original conditions in which the
vehicle was tested, approved and homologated.
Therefore, in cases in which it is necessary to extend
long cabs, the equipment manufacturer is responsible
for this modification.
i Note
For information on changes to the cab structure,
contact Mercedes-Benz at “Technical Consulting and
i Information
Refer to the technical values in “Cab Extension” 
page 39.

99
5.15 Retarder
5.15Retarder
i Note
Not applicable!

100
5.16 Auxiliary Axle or Trailing Axle
5.16Auxiliary Axle or Trailing Axle braking is also carried out with the auxiliary trailing
axle with the ASR mode activated must be adopted.
Before the assembly of an auxiliary axle, the following
provisions must be taken into consideration: • The braking of the auxiliary or trailing axle must be
proportional according to the load.
• Additional reinforcement elements must be installed
in the frame. When changing the original chassis • The regulation of the ALB valve or the overload
frame, make sure its elasticity, resistance and torsion protection devices must be adapted.
capacity are preserved, mainly in the area between • The fastening of the auxiliary or trailing axle to the
the front axle and the leaf springs supports for the chassis frame must be performed so that the
drive axle. longitudinal and transversal forces may be safely
• It is not permitted to change the load incidence supported without being transfered to the propeller
points (e.g. axle suspension, spring supports etc.). shafts.
• Respect the minimum load on the front axles, see • Provide sufficient distance with regard to the
chapter “Driveability”  page 36. propeller shaft.
• The permitted loads on axles shall not be exceeded, • The standard pneumatic system must have the load
the values are defined in chapter “Total Technical compensation on the axle.
Weight of the Vehicle and Loads on the Axles”  page
44.
• The braking system must operate also in the auxiliary
axle. The basic characteristics of the brake system
must remain unaltered with regard to braking safety
and efficiency elements.
• The service and parking brake for the auxiliary or
trailing axle shall remain consistent with the vehicle
original braking system, such as:
- the brake cylinders dimensions;
- the length of the brake regulators rods;
- the dimensions of the drum or disc;
- the brake linings (pads or linings).
• In vehicles with automatic transmission and ABS
brakes, the auxiliary axle brake or trailing axle must
be installed together with the original rear axle brake
and, if necessary, for proper ABS operation, the
braking pressure must be reduced.
• The reaction times and the legally established limit
times must not be exceeded.
• The compressed air volume for the original rear axle
brakes circuit must be accordingly increased.
• The air compressor power must be sufficient to fill in
the reservoirs and for the required air consumption.
• In the case of "ASR" traction control in the rear axle,
the auxiliary axle or trailing axle must be adapted to
the existing brake control.
 • In the case of vehicles with traction control system

“ASR”, the measures necessary to prevent that the

101
5.16.1Instructions to Adapt the Rear Auxiliary Axle Axles suspension
The objective of these instructions is to establish the The suspension developed by the Implementer must
conditions required for the installation of the vehicle meet the load arrangement according to the
axle, aiming to meet good principles of technical, specifications in chapter “Total Technical Weight of the
maintenance, traffic safety, durability and performance Vehicle and Loads on the Axles”  page 44.
of the vehicle and its components.
The angle created by the drive axle pinion geometric
axle in relation to the longitudinal member shall not be
i Information
changed, refer to chapter “Arrangement and Angle of the
The later assembly of an auxiliary axle can only be Propeller Shafts Flanges Coupling”  page 79.
carried out by specialized companies qualified by an
The drive axle kinematic, with load application, shall not
"OFFICIAL TECHNICAL INSTITUTION”, meeting the
compromise the perfect longitudinal displacement of
standards and requirements established by the local
the propeller shaft, even on extreme points of the axle
laws.
motion. Otherwise, the propeller shaft can be affected,
In Brazil, the vehicle adapted with an automotive seriously compromising the vehicle safety.
auxiliary axle will only be registered, licensed or have
When designing the suspension, the tensioning bars
its annual license renewed when the installation is
must have the work geometry defined, so that the
previously authorized by the transit authorities and
original travel is not changes in the propeller shaft axial
the safety of the vehicle is confirmed by INMETRO -
direction, considering the vehicle empty and loaded in
Instituto Nacional de Metrologia, Normalização e
the condition of metallic stopper.
Qualidade Industrial (National Institute of Metrology,
Regulatory and industrial quality), During the suspension project, take into account the
chassis original heights defined in the related proposal
In other countries, the current specific "legal
drawings, see chapter “Vehicle Identification/Proposal
requirements", as well as the guidelines and
Drawings”  page 18.
standards must be observed!
Auxiliary axle wheel hubs
Vehicle frame
In order to make it possible to install the wheels and
In the adaptation of the automotive auxiliary axle to tires exactly like the original, check the wheel hub
meet the strain demands that are caused by the dimensions for the rear axle in “Technical Data
increase of the gross vehicle weight rating, the Concerning the Rear Axle”  page 50.
longitudinal members need a reinforcement (increase of
the resistance module), which must be designed
according to the bending moments diagram for the new
loading condition. i Note
The reinforcements must not suffer substantial profile For special wheels and tires adaptation contact
variations, ending gradually, to avoid the formation of Mercedes-Benz do Brasil Ltda. according to chapter
strain peaks, otherwise damages can occur in the “Technical Consulting and Contacts”  page 17
vehicle frame. To attach these reinforcements in the
longitudinal members, welding is not allowed.
i Information
Holes, when extremely necessary, shall follow the
guidelines described in chapter “Drilling in the Vehicle
Frame”  page 64.
Additional crossmembers must be installed at the load

incidence points (springs supports).

102
Braking system for the auxiliary axle Additional reservoir power diagram
i Information
! Attention For information on the air reservoir arrangement,
refer to chapter “Air Reservoirs Arrangement”  page
Modifications in the original brake system of the 81.
vehicle are not allowed.
For 4x2 vehicle versions are equipped with 20 l (V1) air
We recommend that the implemented auxiliary axle reservoir for the rear circuit, 20 l (V2) for front circuit
brake regulators are equal to the original vehicle ones. and 5 L (V4) for accessories.
For the adapted auxiliary axle braking system, the same During the adaptation of the auxiliary axle, an additional
dimensions of the propeller original axle brake system 20 l (V3) reservoir must be installed, interconnected to
must be used, mainly for the brake combined cylinder the original reservoir, at output 21 on the 4-circuit
(“TRISTOP”). protective valve (4.03).
The Implementer must calculate/dimension the The air capacity for the reservoirs must ensure that
balancing between the front and rear brake system after 8 complete actuations of the brake pedal, the air
according to the load increase and the adaptation of the pressure is enough for the system to perform an
auxiliary axle. emergency stop.
For the auxiliary axle pneumatic suspensor, it is
necessary to install at least one additional 10 l (V5) air
i Information reservoir, on the same line of the accessories reservoir
For more information, refer to chapter “Technical (V4), the only one recommended because it has no
Data Concerning the Rear Axle”  page 50. connection to the brake system, see chapter “Additional
Pneumatic Consumers”  page 29.
The parking brake actuation must be in a single point, For dimensioning, installing and fastening the
for both rear axles, so that the actuation occurs compressed-air lines for the auxiliary axle brake system
simultaneously in both. observe the recommendations in chapter “Compressed-
The work pressure of the original pneumatic system air Line”  page 82.
must remain unaltered after the auxiliary axle
adaptation.
i Information
For more information on the brake system, refer to
chapter “Brake System”  page 80.

103
Pneumatic diagram for auxiliary axle installation.
1.01 - Air compressor; 20.02 - Front break membrane cylinder;

2.01 - Pressure control valve 22.01 - Combined rear brake cylinder (Tristop);
4.03 - 4-way protective valve; 28.01 - Quick discharge valve;
5.01 - Air reservoir - front axle brake (V2); 28.04 - Brake switch-off valve for anti-slip control;
5.01 - Air reservoir - rear axle brake (V1); 30.04 - Pressure control valve
5.01 - Additional air reservoir - auxiliary axle brake (V3); 33.01 - Engine brake actuation;
5.01 - Air reservoir - Accessories (V4); 33.01 - Auxiliary axle brake locking;
5.01 - Air reservoir - auxiliary axle suspensor (V5); 33.01 - Actuation device for the auxiliary axle lift
6.12 - Air drier (APU); 20.05 - Engine brake cylinder;
10.01 - Pressure switch; 38.02 - Test outlet, measurement points;
13.02 - Brake pedal valve; 43.01 - Suspensor pneumatic spring;
14.01 - Parking brake manual valve; 45.01 - Front axle ABS valve;
16.01 - Parking brake relay valve; 45.12 - Rear axle ABS valve;

104
5.17 Retrofitting of an Automatic Transmission
5.17Retrofitting of an Automatic Transmission
! Attention
It is not permitted to retrofit an automatic
transmission.

105
5.18 Auxiliary Power Take-off
5.18Auxiliary Power Take-off • In the power take-off axle or transmission flange,
belts or chains must not be assembled.
Types of auxiliary power take-off that can be supplied
from the factory: • When exceptionally required, provide Mercedes-Benz
do Brasil Ltda. with the drawings and data required
• Auxiliary power take-off coupled to the transmission. for approval, according to Guidelines for the Assembly
• Front power take-off, actuated by the engine pulley. of Road Implements and Equipment - "General
Manual".
In the retrofitting of the auxiliary power take-off, it must
be observed: • The use of power take-off at full power, will only be
approved for applications in which it is used for a
• After the assembly, refuel the transmission with oil
short period.
up to the filler neck lower edge.
• Run the engine during 2 minutes and, at the same
time, turn on the auxiliary power take-off.
i Note
• Check the transmission oil level and correct it, if
Maximum continuous operation period is of
necessary.
approximately 30 minutes, with cooling intervals, of
at least 30 minutes.
! Attention
If these recommendations are not respected, there i Information
may be damages to the transmission.
For more information on power take-off that may be
In case inappropriate outlets are used, it is not supplied and/or recommended from factory refer to
possible to ensure the transmission operation. chapter “Power Take-off Technical Characteristics” 
page 47.
• The type of auxiliary power take-off, as well as the
choice of the transmission ration, depend on the
power and rotation of the equipment to be actuated.
• Auxiliary power take-off actuated by the transmission i Information
can only be turned On and OFF with the vehicle For the proper installation of the power take-off
stopped. actuation switch and/or for the actuation of the
• It is not recommended to move the vehicle while the attached equipment speed control, refer to
power take-off is coupled. For some applications this Guidelines for the Assembly of Road Implements and
procedure will be possible since associated to the Equipment - "Specific electro-electronic part". After
vehicle electronics to avoid operation faults and this installation, the function must be activated and
consequently, damages to the transmission. configured by appropriate equipment at Mercedes-
Benz Dealers or Qualified Workshops.
• The indication regarding the maximum power
moments transmissible (Nm) for each power take-off
constitute of reference values for the operation free
from oscillation or vibrations.
• Size the system actuated by the power take-off so
that the engine minimum rotation is maintained at
900 rpm (revolutions per minute) with the power
take-off in torque system.
• The power take-off must be within the engine
maximum torque range.
 • Install a protection in propeller shafts and exposed

pulleys.

106
5.18 Auxiliary Power Take-off
Actuation switch

107
5.19 Auxiliary Power Take-off Coupled to the Transmission
5.19Auxiliary Power Take-off Coupled to the
Transmission
i Information
The power take-off is not available as sales CODE,
however, it may be supplied by the CTT Mercedes-
Benz Customization Center).
It is possible to apply power take-off in vehicles with

transmission actuation to enable the actuation of
auxiliary equipment, such as: tilting bucket, cranes,
rescue hoist, etc.
i Information
Only Mercedes-Benz G56 model transmission, the Tab 22: Coupling flange dimensions (mm).
power take-off may be installed on the side and the
rear of the transmission with simultaneous operation. aØ bØ cØ D and Ø guide No. of holes
For other transmissions the actuation is performed by 100 84 + 0,1 57 f8 7 2 8,1+ 0,15 6
means of the transmission with a single actuation and
revolution direction.
Actuation with flange for propeller shaft.
Power take-off with flange
i Information
For more information on the power take-off technical

characteristics and arrangement for each application,
refer to chapter “Power Take-off Technical
Characteristics”  page 47.

108
Attached pump actuation Pneumatic diagram for the power take-off
When the attached pump weight is higher than 18 kg or
the set length is longer than 450 mm (X distance, from
the center of the power take-off to the attached pump
rear limit), an additional supported must be used
fastened to the attached pump rear end and the
transmission.
! Attention!
In case the power take-off and attached pump set
meets the weight and distance conditions defined
above and, there is still excessive vibration in this set
due to the system load, it is necessary to apply a
fixed support between the attached pump rear end
and the transmission.
4.03 - 4-way protective valve (APU)

5.01 - Air reservoir - Accessories;
10.01 - Pressure switch A006 545 11 14
33.01 - Air-electronic valve A000 997 36 12
A - Output for the power take-off actuator
B - Pneumatic connection A 003 997 90 89
i Information
1 - Power take-off 3 - Support
2 - Attached pump x - Distance (mm) For the proper installation of the power take-off
actuation switch and/or for the actuation of the
attached equipment speed control, refer to
i Information Equipment - "Specific electro-electronic part". After
this installation, the function must be activated and
For the calculation of the tilting pump power configured by appropriate equipment at the
according to the power take-off power, refer to Mercedes-Benz Dealers or Qualified Workshops.
chapter “Power Take-off Technical Characteristics” 
page 47.

109
5.19.1Assembly of the Propeller Shafts for the Power
Take-off
Types of bending
Bending angle • Bending in a plan (bi-dimensional bending).

• Bending in W or Z.
When installing the propeller shafts, observe:
• Bending in two plans (three-dimensional bending).
• The manufacturer's guidelines related to the
propeller shafts assembly. In the case of three-dimensional bending, the primary
and secondary shaft cross displaced in the space
• If necessary, use various propeller shafts with (combined bending W and Z).
intermediate bearings and additional crossmembers
to support the bearings. In order to compensate irregularities, the joints internal
universal joint bearings must be arranged misaligned.
• It is necessary to build a fastening support for
intermediary bearings according to the angles
predefined for the new propeller shaft.
• The flange surfaces must be completely flat.
• The bending angles must be equal in both joints (β1 =
β2). They must not be greater than 6°, or smaller
than 1°. Bending angles greater than 6°, as well as
errors in the flange angle (β1 < > β2) will result in
oscillations of the propeller shafts. These angles
influence in the major assemblies durability, which
can lead to damages.
• Balance the propeller shafts before the assembly. The
overhang weights must not be removed.
• During assembly pay attention to ensure the
concordance of the propeller shafts marks.
- Eliminate the vibrations, optimizing the propeller
shaft angle.
 Types of bending.

110
5.20 Power Take-off Actuated by the Engine
5.20Power Take-off Actuated by the Engine
5.20.1Power Take-off in the Engine, Front Part, Actuated
by Belts
Additional equipment, such as compressors and
hydraulic pumps may be actuated by means of a belt
through the pulley installed in the front of the engine in
addition to an extra support, installation available only
at the CTT (Mercedes-Benz Customization Center) or by
Mercedes-Benz do Brasil Ltda. Implementer Support
refer to chapter “Technical Consulting and Contacts” 
page 17.
• Power take-off driven by the engine pulley
On systems driven by the engine pulley, for its proper
dimensioning, the implementer shall take into account Additional compressor set
the type of equipment, transmission ratio, engine 1 - Additional pulley
output and engine rotation. 2 - Support set
3 - Additional air compressor
! Attention
Tab 23: Engine technical data
Exceptionally in vehicles whose applications are
Engine OM 924 LA Euro 5
freezer and cash transport, where the cooling device
needs to operate for extended periods and low Idle speed 750 rpm
engine rotation, it is not permitted to use Maximum torque rpm 1,200 - 1,600 rpm
compressors with output above 5 Kw (17000 Btu/h
Maximum power rpm 2,200 rpm
capacity).
Maximum rpm 2,600 rpm
A load above this specification for extended periods
directly affect the engine operation temperature and Maximum free rpm 2,750 rpm
may cause damages to the SCR - Selective Catalytic
Reduction System.
i Information
The power transmissible will be limited to
i Information approximately 25 kw. In case it is necessary a higher
For the proper operation of the SCR - Selective power, contact Mercedes-Benz do Brasil Ltda.
Catalytic Reduction System, the vehicle engine “Technical Consulting and Contacts”  page 17.
should reach its operation temperature; therefore, The following information will be necessary:
too low engine rotation (idle) for extended periods
• Transmission ratio.
(above 3 hours) may cause damages to the SCR
system and, consequently, engine output loss. • Speed.
• Operating time.
• Equipment to be actuated.

111
5.20 Power Take-off Actuated by the Engine
5.20.2Power Take-off in the Engine, Back Part, Actuated
by the Engine Flywheel
i Information
Not applicable.
In case it is necessary to install an outlet in the
behind the engine, contact Mercedes-Benz do Brasil
Ltda. refer to chapter “Technical Consulting and

112
5.21 Coupling or Engagement for Towing
5.21Coupling or Engagement for Towing
• The rear coupling assembly (engagement) for towing
must comply with the legislation in force and the
safety standards for the respective countries.
• Consider the free space dimensions according to the
standard DIN 74058.
• Only couplings approved by Mercedes-Benz do Brasil
Ltda. should be used, as well as the original terminal
crossmembers (frame closing crossmembers)
Mercedes-Benz.
i Information
For the assembly of short assemblies, it is necessary
to obtain Mercedes-Benz do Brasil Ltda.'s approval,
according to chapter “Technical Consulting and
Contacts”  page 17
For the installation of the tightening torque, the terminal
In order to calculate the assembly dimension, refer to crossmember must be reinforced according to the rear
chapter “Dimensioning of the Trailer Coupling”  tightening torque traction capacity, and have tie rods or
page 43. mounting rails.
Measurements for free space
1 Inner reinforcement 5 Lamps Support

2 Crossmember 6 Rear bumper
3 Bumper support 7 External reinforcement
4 Support

113
For the vehicles that have a closing crossmember
beyond the springs crossmember, or when an additional
rear crossmember is installed, it should be estimated a
connection element, tie rod, in order to assure the
proper reinforcement to the structure according to the
coupling capacity.
Between the two last crossmembers, a minimum
distance of 350 mm should be kept, in order to enable
the coupling assembly and disassembly in the
crossmember.
• Reinforce the auxiliary and closing frame closing
crossmember of the vehicle frame with a plate.
• Join the subframe to the vehicle frame, between the
rear springs support and the frame end. Assemble
diagonals in the subframe.
Frame closing crossmember.

1 Longitudinal member 3 Reinforcement in angle bar
2 Leaf spring closing 4 Final crossmember
crossmember 5 Additional crossmember
6 Tie rod

114
5.21.1Use of the Vehicle with the Center Axle Trailer
Center axle trailer is a trailer with an axle or group of
axles, where: i Information
• The connection to the vehicle is made using the More information about the types of trailers, refer to
towing device rigidly connected to the tow chassis, Guidelines for the Assembly of Road Implements and
• According to its construction, no important part of its
gross weight is supported by the towing vehicle. For a good driveability, it is necessary to observe the
minimum loads on the front axle. During the
According to the normative projects for coupling with
configuration, take in consideration the load in the town
automatic pins 40 and 50 at DIN 74051 and 74052, only
sphere.
the respective dimensions DIN of the couplings will be
allowed with center axle trailer for the following towable
weights:
Tab 24: Allowed towable weight
Coupling Allowed towable weight with

dimensions center axle trailer, in kg
G 135 6.500
Towable weight calculation diagram

The diagram must not be applied when the vehicle is
used with center axle trailers.
Diagram
A - maximum towable weight (%)
Ü - Extension
R - Wheelbase

115
5.22 Tractor Trucks for Semitrailers (“Tractor Truck”)
5.22Tractor Trucks for Semitrailers (“Tractor Truck”)
i Information
Not applicable.

116
5.23 Alterations in the Exhaust System
5.23Alterations in the Exhaust System
In vehicles that have the Bluetec 5® technology, the
displacement of the catalytic converter set is allowed, G Risk of accident and injury
and limited for each vehicle model, the project length During operation, the catalytic converter surface
(original of the vehicle) and allowed maximum length reaches high temperatures, which decrease slowly
variation. after turning the vehicle off. Therefore, take the
precautions to avoid burns during the maintenance
In the case of implements that are very close to the

! Attention catalytic converter area, the need of applying counter-
The catalytic converter position has a direct influence measures for the components thermal protection must
on the emissions level according to the temperature be analyzed.
variation of exhaust gas. The catalytic converter As shown in the figure below, the temperature in the
displacement is limited to the distance of the engine, catalytic converter surface can reach high temperatures
which can change the temperature of the gases under conditions of extreme use, maximum torque and
inside it, thus affecting the "SCR" correct operation. full load engine in low speeds.
Consequently, there is an increase in the emissions
levels, which no longer complies with PROCONVE P- SCR Catalytic Converter
7. It may also cause loss of engine power.
Procedures for the catalytic converter

displacement
• Release all catalytic converter connection parts and
remove the whole system.
• Assemble the catalytic converter in the new position.
In case it is necessary to make new holes in the
longitudinal member, refer to chapter “Drilling in the
Vehicle Frame”  page 64.
• In the installation of the catalytic converter in its new
position, it is necessary to use new supports and
other genuine parts, the Implementer may develop
additional supports.
• It is not permitted to replace the catalytic converter 1 High temperature area
by a system from a different brand.
• Do not perform connections of the supports in the
longitudinal member core (membrane effect).
i Information
• If there is the need of extending the catalytic
For the SCR catalytic converter module tightening
converter sensors wiring harnesses, follow the
torque, refer to chapter “Tightening Torque for the
instruction according to the Guidelines for the
"Specific electro-electronic part" .
! Attention

The components are heavy, therefore take care
during the assembly works.

117
Extension of the Exhaust Pipe • The length and location of the flexible metal pipe,
assembled between the intake and the exhaust pipe,
must not be changed.
! Attention • The exhaust pipe free cross section behind the noise
muffler must not be reduced.
The pipe maximum torsion must be up to 90°. If
necessary, use additional elbows. • The minimum distance for the synthetic material
lines, electrical cables and spare wheels must have:
- 200 mm with exhaust system without protection;
- 80 mm with protective plates;
- 40 mm with protections in places with additional
thermal insulation.
If these distances can not be kept, change the synthetic
material lines by Tombak steel pipes, according to the
DIN 1755, CuZn 20 material guide 33, with the same
internal diameter. Except for the "AdBlue®" system line
that prohibits the use of any material different from the
original one.
Additional protections will be required in the area of the
vehicle major assemblies and components, in the case
they are not made of high temperature resistant
material.
The extension must be made through pipes as
described in this chapter, which must have its ends
connected with the following parts and conditions:
• The joint with the flexible pipe will be performed
using the original clamp indicated in the figure or it
may be welded according to the instructions in
“Exhaust pipe welding”  page 120.
• The connection with the catalytic converter must be
performed using the original clamp. Under no
circumstances can this joint be welded.
r - exhaust pipe radius d - pipe Ø
• In the case of changes in the exhaust system,

Mercedes-Benz genuine parts must be used. If it is
not possible, the parts used must have the same
characteristics as the Mercedes-Benz genuine parts.

118
Indications for the exhaust pipe extension. Maximum length of the exhaust pipe
• For the extension, stainless pipes DIN EN 10296-2 -
1.4513 + WO or the optional DIN EN 10296-2 -
1.4301 + WO must be used. Pipe external diameter
Ø88.9 mm and thickness 1.5 mm.
• The stainless steel pipes must be welded according
to the TIG or MAG method, hermetically.
• The flexible pipe part can not have any bends or
displacements.
• The exhaust pipe extension must be always
performed after the flexible pipe, keeping the original
alignment.
• Add the support for line extension, maximum every
1,100 mm. Tab 25: Maximum allowed length of the pipe between
• Changes must not be performed in the catalytic the engine and the catalytic converter
converter, such as welding. Pipe length (mm)
• The sum of all the pipe extension angles must not be Model
Maximum allowed
higher than 270°. Series
variation
“A”
• The connections and joints must have total tightness, 815; 1016; 1316 1150 600 1,750
in order to assure the exhaust gases treatment.
i Note
H Note
The pipe maximum length (measurement “A”) is
Improper changes in the exhaust gases pipe, before made by the sum of the original pipe length with the
the catalytic converter, can lead to non-treated gases maximum allowed variation.
emission due to leakages.

119
Exhaust pipe welding
1 Overlapping weld (clamp option) 4 Original clamp Nº N07 1555090502 (weld option)
2 Extension (intermediate pipe) 5 Original support Nº A6954901240
3 Flexible pipe 6 Primary pipe
i Information
performed by specialized personnel. We recommend
that these works are performed outside the vehicle in
proper conditions in order to assure the welded
connection tightness.
To obtain more information about the welding, refer
to Guidelines for the Assembly of Road Implements
and Equipment - "General Manual".

120
Reservoir and/or "AdBlue®" pump displacement Procedure for the "AdBlue®" Reservoir
Displacement
The reservoir and/or "AdBlue®" pump displacement is
allowed provided that the following instructions are met. • Loosen all the lines and remove the entire system.
Original supports must be used for the components • Assemble the reservoir in the new position.
securing.
• In the installation of the reservoir in its new position,
It is permitted to replace the "AdBlue®" reservoir by a it is necessary to use new supports and other
variant of other Mercedes-Benz products. genuine parts, the Implementer may develop
additional supports.
If necessary, it is possible to position the reservoir and/
or pump height according to the height limits informed • The "AdBlue®" line maximum length between the
in the figure. reservoir and the metering device must be shorter
than 5 m.
! Attention • Do not perform connections of the supports in the
In case the "AdBlue®" pump is repositioned, its longitudinal member core (membrane effect).
original working position must be maintained, in If there is the need of extending the reservoir sensors
other words, never tilt the pump horizontally. Fail to wiring harnesses, follow the instruction according to the
meet this observation may result in malfunction, "AdBlue®"Guidelines for the Assembly of Road
damage to the "AdBlue®" pump and to the SCR Implements and Equipment - "Specific electro-electronic
system, as well as in the warranty being void. part".
1 Reservoir (Position 1) C - Fluid lower limit

A - Fluid upper limit 4 "AdBlue®" Pump
2 Reservoir (Position 2) 5 Metering device

121
"AdBlue®" line extension In case there is no option for the exact length for direct
application, the Implementer shall choose a line longer
• It is not allowed any kind of splice to the suction,
than required and wind the exceeding length, being
holding pressure and return line for the "AdBlue®"
careful not to pinch the line.
reservoir.
The pressure lines have connections with different
• "AdBlue®" lines must be arranged up to the reservoir
diameters from the other lines.
or to the connection point, prevailing the shortest
one.
• The lines can not be bent or crushed at all, for this, Tab 26: "AdBlue®" line available lengths
you should take care during the attachment of the
Length
section with plastic straps. MB Code
(mm)
Use
• Plan the line layout in order to prevent the siphon A 695 476 17 01 2,400 Suction/Return
effect.
A 695 476 27 01 2.140 Suction/Return
• The "AdBlue®" line maximum length between the
A 695 476 19 01 1,080 Suction/Return
reservoir and the metering device must be shorter
than 5 m. A 695 476 20 01 800 Suction/Return
• In the case of the displacement, the lines must be A 695 476 18 01 2,020 Pressure
changed by factory original lines available at A 695 476 16 01 3,320 Pressure
Mercedes-Benz Dealers or Qualified Workshops
according to the table.
Illustrative diagram of "AdBlue®" line - “Liquid Only”
1 "AdBlue®" reservoir 5 Catalytic converter unit

2 "AdBlue®" pump A - Feed/Suction
 3 Metering device
4 Engine control unit “MR”
P - Pressure
R- Return

122
Contact
Mercedes-Benz do Brasil Ltda., by means of the

Mercedes-Benz Qualified Workshops.
Internet
www.mercedes-benz.com
Text preparation
Mercedes-Benz do Brasil Ltda.
Number:BMD-BR020003BE3
Edition: 11/2020
End of text preparation: 11.26.2020
Contact
BBMgt - Body Builders Management Team
Telephone: +55 11 4173-8095/8919/8071, or through
Mercedes-Benz do Brasil Customer Relationship Center.
Telephone: +55 0800 970 90 90

123
Body/Equipment Mounting Directives for Trucks Accelo E3 EN 11.26.2020

Body Equipment Mounting Directives For Trucks - Accelo

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Body Equipment Mounting Directives For Trucks - Accelo

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Body/Equipment Mounting Directives for

i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

2 Body and Equipment Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 Limit technical values during the planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

3.7.1 Cab Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5 Basic Vehicle Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

5.8.2 Repositioning of the Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

H Environment Protection Related Indication

page This symbol will indicate the page where

G Risk of Accident and Injury

G Risk of Accident and Injury

The approval for the implement assembly does not

Tab 4: Accelo Design number 979.0XX - Designation / Application

Dry cargo, Box, Sider, Refrigerated, 156 CV (MW6 +

The modifications necessary in the vehicle due to

G Risk of accident and injury

The allowed loads on the axles and the allowed total

In case of installing special or optional pieces of

On the other hand, a very short implement may cause

2.4.1 Hydraulic Steering Reservoir

In case the Body Builder needs to change the reservoir

G Risk of accident and injury

Vehicles equipped with air drier filter (Code B66)

Tab 6: APU valve - Air feeding ports

21 Brakes circuit I (rear)

22 Brake circuit II (front)

23 Parking brake, trailer (Optional)

In the case of auxiliary equipment assembly, it must be

Tab 7: Longitudinal members dimensions and material

Accelo Dimensions (mm)

Tab 8: Material mechanical properties

Resistance modules (Wx)

• The rear axle overhang determination must be

For the technical wheelbase (Ri), it is applied the

If G2 is equal G3, the formula is simplified:

• Tolerance 5,000 X 4% = 200 kg (maximum load G Component = Component weight in [kg]

 correct mathematic signals and record them on a table.

i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

Tab 9: Minimum load on the front axle

Version 4x2 25%

i Body/Equipment Mounting Directives for Mercedes-Benz Trucks, date: 11/26/20

1 Fuel float and float tube set

Front and rear axle lift

Tab 10: Clearance with Atego cab

The D value is defined as theoretical comparison force

Coupling to towing (with vertical load)

Table of dimensions and weights

* IN OPERATION Theoretical weight (kg)

Chassis with cab Total Gross Weight

Euro 5 2.220 1.140 3.360 3.000 5.300 8.300 1.220 360

Euro 5 2.280 1.150 3.430 3.000 5.300 8.300 1.475 360

* IN OPERATION Theoretical weight (kg)

Chassis with cab Total Gross Weight

1316 Euro 5 6x2 3.900 Extended * * * * * * * *

• To turn ON and OFF the power take-off, see the

A1 - Distance up to the front axle center line

Tab 12: Power take-off coupled to the transmission

Pneumatic Cardan 28,3/1000

Eaton Pump Inverse

When the flow is known.