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Mercedes-Benz Arocs, Introduction Into Service Manual

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Mercedes-Benz Arocs Introduction Into Service Manual Download Page 29

Exhaust system

26

Drive

i

Introduction of the New Truck Generation - The New Arocs (Model 964)

W49.00-1007.00

Exhaust system, end pipe downwards (K7A) in combination with exhaust pipe, straight, over second axle (K7R)

– This printout will not be recorded by the update service. Status: 01 / 2013 –

Summary of Contents for Arocs

Page 1: ...ntroduction into Service Manual Daimler AG GSP OR HPC R 822 D 70546 Stuttgart Order No HLI 000 000 11 04 Printed in Germany 01 13 Introduction of the New Truck Generation The New Arocs Model 964 This...

Page 2: ...e Daimler AG Technical Information and Workshop Equipment GSP OR D 70546 Stuttgart Introduction of the New Truck Generation The New Arocs Model 964 This printout will not be recorded by the update ser...

Page 3: ...by Daimler AG This document including all its parts is protected by copyright Any further processing or use requires the previous written consent of Daimler AG Department GSP OIR HPC R822 W002 D 7054...

Page 4: ...Overview New features modifications 6 Overall vehicle Product groups 13 Increased gross combination weights 16 Equipment 17 Drive Engines 19 Engine OM 473 20 Technical data 22 Engine air intake 24 Ex...

Page 5: ...retarder coupling 28 Transmission data 29 Gearshift manual G5H 34 Transmission modes 37 Power take off 40 Transfer case Transmission overview 42 Hydraulic Auxiliary Drive HAD General 44 Front axle 46...

Page 6: ...e New Arocs Model 964 Chassis Frame 48 Axles 50 Suspension 57 Brakes 58 Wheels and tires 59 Steering 60 Fuel tank 64 Body Cab 65 Networking Overall network 71 Lights Exterior lights 78 This printout w...

Page 7: ...Arocs Model 964 Special tools Engine OM 936 80 Engine OM 470 82 Transmission G 140 8 83 Transmission G 280 16 85 VG 2800 3W VG 3000 3W 86 Models 963 964 87 Annex Abbreviations 88 Index 92 This printo...

Page 8: ...py deadline in November 2012 and may therefore differ from the current production configuration We will publicize modifications and new features in the relevant WIS documents only Individual details i...

Page 9: ...uction vehicles and all wheel drive variants will be available The 6x2 4 vehicles will follow in November 2013 For construction vehicles the product group Grounder V1Z will be introduced as well as th...

Page 10: ...s with width 2300 mm Interior trim flannel gray greige Rear axles only with air suspension Only automated manual transmissions with Mercedes PowerShift 3 G5G Rigid frame design W00 00 1070 00 Arocs V1...

Page 11: ...istribution model series are also available for the construction vehicles Unique cab design with fixed entry step for all air sprung construction vehicles and with movable step for all steel sprung co...

Page 12: ...6x4 26 t Steel 744 mm 964 416 6x4 33 t Steel 744 mm Platform trucks 964 000 4x2 18 t Steel 744 mm 964 001 4x2 20 t Steel 744 mm 963 002 4x2 20 t Air 834 mm 964 014 6x4 26 t Steel 744 mm 964 030 8x4 4...

Page 13: ...ehicles launched in July 2013 Model Wheel configuration Permissiblegross vehicle weight Rear suspension Frame width Semitrailer tractors 964 407 4x4 18 t Steel 744 mm 964 408 4x4 20 t Steel 744 mm 964...

Page 14: ...t Steel 744 mm 964 203 4x2 18 t Air 834 mm 964 208 4x4 20 t Steel 744 mm 964 202 4x2 20 t Air 834 mm 964 224 6x4 26 t Air 834 mm 964 238 8x4 4 32 t Air 834 mm 964 241 8x4 ENA 32 t Air 834 mm 964 218 6...

Page 15: ...itrailer tractors 963 422 6x2 4 VLA 22 5 25 t Air 834 mm 964 422 6x2 4 VLA 22 5 25 t Air 834 mm Platform trucks 963 022 6x2 4 VLA 22 5 25 t Air 834 mm 964 022 6x2 4 VLA 22 5 25 t Air 834 mm Vehicles l...

Page 16: ...rounders are vehicles with maximum load rating robustness and offroad capability for customers in the construction business W00 00 1060 00 The main features of the Grounder PG with the example of a du...

Page 17: ...deselectable 1 Compressed air reservoir aluminum B4L 2 Omission of guard plate under bumper M9V Loader standard equipment selectable deselectable 3 Omission of front passenger seat D9Z 4 Bumper center...

Page 18: ...r 33 t 964 218 6x6 Dumper 33 t 964 231 8x4 4 Dumper 41 t 964 232 8x6 4 Dumper 41 t 964 233 8x8 4 Dumper 41 t 964 316 6x4 Concrete mixer 33 t 964 331 8x4 4 Concrete mixer 41 t 964 401 4x2 Semitrailer t...

Page 19: ...e vehicle of 44 t GCW and above a parking brake on the front axle B2Z is necessary Codes for increased gross combination weights Code G0A G0B G0C G0D GCW up to 68 t up to 80 t up to 120 t above 120 t...

Page 20: ...rvice manuals for the new Actros and Antos A new package specifically for the Arocs is the Protection Pack Z9E The Protection Pack comprises a number of items of protective equipment for construction...

Page 21: ...tion as standard The axle load compensation system distributes the load almost equally between the two front axles when the vehicle is driven over bumps and obsta cles This prevents damage due to over...

Page 22: ...M2P 290 kW 394 hp 1900 Nm M2Q 315 kW 428 hp 2100 Nm M2R OM 471 310 kW 421 hp 2100 Nm M3A 330 kW 449 hp 2200 Nm M3B 350 kW 476 hp 2300 Nm M3C 375 kW 510 hp 2500 Nm M3D A new addition for the models 963...

Page 23: ...rview of engine OM 473 1 Rail 2 Diesel fuel metering unit for regeneration of diesel particulate filter 3 Compressor 4 Fuel filter module 5 Oil coolant module with coolant pump 6 Exhaust gas recircula...

Page 24: ...ic energy is delivered directly to the crankshaft of the engine via a 2 gear train with an intermediate hydrodynamic coupling This means that up to 35 kW more power can be delivered with simulta neous...

Page 25: ...265 M2P 290 M2Q 315 M2R 310 M3A 330 M3B 350 M3C 375 M3D 380 M3N 425 M3P 460 M3V Torque Nm 1000 M2A 1100 M2C 1200 M2D 1300 M2E 1400 M2F 1700 M2N 1800 M2P 1900 M2Q 2100 M2R 2100 M3A 2200 M3B 2300 M3C 25...

Page 26: ...Generation The New Arocs Model 964 Performance graph OM 473 W01 00 1113 00 a OM 473 380 kW 2600 Nm M3N b OM 473 425 kW 2800 Nm M3P c OM 473 460 kW 3000 Nm M3V M Torque P Power n Rpm This printout wil...

Page 27: ...The cyclone prefilter can be cleaned easily by pressing the rubber lips on the two dust expulsion valves The cyclone prefilter is only available in conjunction with the optional air intake behind cab...

Page 28: ...The following codes describe the routing of the exhaust system in 4 axle vehicles In these vehicles the exhaust pipe initially runs on the right hand side of the vehicle over the 2nd axle as far as t...

Page 29: ...of the New Truck Generation The New Arocs Model 964 W49 00 1007 00 Exhaust system end pipe downwards K7A in combination with exhaust pipe straight over second axle K7R This printout will not be record...

Page 30: ...25 10 1085 00 Single plate clutch Double plate clutch G5B The double plate clutch with a diameter of 2 x 400 mm is standard for the OM 473 engine with 425 kW and above and optional equipment for all O...

Page 31: ...as special equipment for the Actros 6x4 and for the Arocs with the wheel configurations 6x4 6x6 8x4 4 8x4 ENA 8x6 4 and 8x8 4 with the exception of concrete mixer chassis Moving off In normal driving...

Page 32: ...141 9 G1F 715 571 G 230 16 G1H 715 508 G 231 16 G1I 715 518 G 260 16 G1J 715 528 The most powerful engine variant for the manual shift transmission is the OM 473 at 380 kW W26 10 1161 00 Transmission...

Page 33: ...ratio spread of 14 57 1 00 and is specially adapted for the OM 936 inline engine The G 141 9 is a direct drive transmission with its first gear designed as a crawler gear The transmis sion is characte...

Page 34: ...matic shift force and clutching assistance The transmissions can be connected to power take offs up to 2000 Nm also combined with a secondary water retarder G 230 16 G1H Overdrive transmission with ge...

Page 35: ...ion of the New Truck Generation The New Arocs Model 964 W26 10 1155 00 Transmission G 260 16 with secondary water retarder B3H and DNA MB 135 11b 2c dual power take off N4L This printout will not be r...

Page 36: ...9 58 11 50 7 92 4th gear 4 82 7 92 9 58 6 58 5th gear 3 67 6 50 7 79 5 29 6th gear 2 58 5 37 6 49 4 40 7th gear 1 81 4 40 5 28 3 64 8th gear 1 31 3 64 4 40 3 02 9th gear 1 00 3 22 3 87 2 66 10th gear...

Page 37: ...transmitted to the gearshift lever Together with the power assisted gear shifting function the new shift system provides car like comfort with short shift travel and low control forces In the cab the...

Page 38: ...ion The cables transmit the shift command and shift forces from the driver to the transmission The two cables are the shift cable for the gear selection and the selector cable for the gate selection N...

Page 39: ...dual action pneumatic cylinder and control valves that are actuated by the shift cable If the SKU fails the manual shift remains capable of shifting the transmission in an emergency The SKU is not ac...

Page 40: ...mode the shift operations are performed at an engine speed that is 100 rpm higher regardless of the torque demanded This enables power oriented dynamic driving at higher engine speeds and better utili...

Page 41: ...acceleration provisions for fire fighting vehicles as per DIN 1846 2 not for airport fire engines When the ignition is switched on the fire service transmission mode is always activated G0Y heavy Only...

Page 42: ...smission mode G0W G0V G0X G0S G0Y offroad power fire service municipal heavy G140 8 X S X X G140 8 AWD S X G 211 12 X S X X G 211 12 AWD S X G 230 12 X S X X G 230 12 AWD S X G 281 12 X S X G 330 12 X...

Page 43: ...ff has the same power and gear ratios as the familiar NA 125 However in order to cater for the modified driv etrain length in the new Actros Antos and Arocs the propeller shaft flange on the NA 135 is...

Page 44: ...e transmission and a hollow shaft for the live PTO It is then possible to drive with the NMV running although it is not possible to activate the semi clutch dependent NMV while driving The power consu...

Page 45: ...d engine variant An oil cooler for the transfer case G4Z is available as an option W28 10 1081 00 VG 3000 3W 1 04 G4E Transfer case VG 1600 3W 1 42 1 04 G4C The transfer case with permanent all wheel...

Page 46: ...ngines OM 470 471 and 473 Max input torque 2800 Nm Road step down ratio 1 04 Offroad step down ratio 1 45 W28 10 1079 00 Transfer case VG 3000 3W 1 04 G4E The transfer case with engageable all wheel d...

Page 47: ...471 early 2015 Model 963 964 6x2 6x4 with engine 470 471 mid 2014 The HAD is a starting off aid not a continuous drive system Depending on the drivetrain configuration the HAD can be used in the first...

Page 48: ...he New Truck Generation The New Arocs Model 964 W55 90 1000 00 Overview of HAD system components 1 Front axle 2 Side module 3 Valve control block 4 High pressure pump 5 Expansion reservoir This printo...

Page 49: ...een redeveloped in order to integrate the wheel hub motors and the feed line for the hydraulic fluid The wheel hub motors are supplied with hydraulic fluid directly via the axle journals and spindles...

Page 50: ...f up to 12500 Nm can be built up at the front axle W55 90 1003 00 4 High pressure pump 5 Expansion reservoir Side module The side module is attached to the right side of the frame It consists of Hydra...

Page 51: ...eel sprung Arocs is designed to be even more flexible to enable all the wheels to touch the ground even on very rugged terrain The front axle of model 964 is 100 mm further back than on model 963 in o...

Page 52: ...e guard plate under the bumper M7J and concrete mixers W31 10 1030 00 Bumper center section with towing eyes coupling jaw F7D Frame clearances The different frame clearances presented in the Introduct...

Page 53: ...with drum brakes This variant features a newly designed wheel hub with compact bearing This makes the hub lighter and easier to maintain adjustment of the wheel bearing is unnecessary W33 20 1049 00...

Page 54: ...0 527 2nd FA A1C A1D Front axle 7 5 t Front axle 8 0 t 730 514 1st FA F 8 0 S 22 5 60 10 Drum brakes 730 515 2nd FA A1E Front axle 9 0 t 730 564 1st FA F 9 0 S 22 5 730 565 2nd FA A1C A1D Front axle 7...

Page 55: ...d with a number of different drop measurements The drop for example 60 mm 10 mm describes the dis tance from the axle center to the spring contact sur face and then from this surface to the axle beam...

Page 56: ...t code A2O W33 00 1031 00 Front axle straight version A1Y Drop 60 mm 10 mm Standard for the Arocs Ground clearance with 315 80 R22 5 tires approx 320 mm The exact dimension depends on the ton nage of...

Page 57: ...y hub reduction rear axles with drum brakes 1 1st rear axle with through drive 2 2nd rear axle Rear axle ring gear 390 hypoid 9 5 t single A2O The wide 9 5 t rear axle for single 385 55 R 22 5 HA I2N...

Page 58: ...22 5 Disk brakes 748 281 RT 233 P 13 C 22 5 748 290 R 233 P 13 S 22 5 Drum brakes 748 291 RT 233 P 13 S 22 5 A2G Rear axle ring gear 300 planet gears 13 0 t 748 282 R 300 P 13 C 22 5 Disk brakes 748...

Page 59: ...ered load relief liftable A4Y The new vehicles in model series 964 include air sprung 4 axle vehicles with triple axle Triple axle trucks are 8x4 vehicles with another single tire steered trailing axl...

Page 60: ...nd Antos All wheel drive vehicles are always equipped with planetary hub reduction axles and steel suspension The designation of the steel springs has been changed The new designation refers firstly t...

Page 61: ...sk brakes with partial protection B2D Vehicles for occasional construction site use can be fitted with a cover panel on the brake disk to pro tect it against excessive soiling Special equipment for al...

Page 62: ...distance between the two rear axles is increased by 100 mm to 1450 mm The 1st rear axle is 50 mm further forward and the 2nd rear axle 50 mm further back The result is a wheelbase and frame overhang t...

Page 63: ...c drive sys tem This replaces the second hydraulic steering circuit previously used in 4 axle vehicles Servotwin features an electrical emergency steer ing function in the event of a hydraulics failur...

Page 64: ...009 00 1 Power steering pump 2 Power steering fluid reservoir 3 Power steering fluid cooler 4 Servotwin steering gear 5 Working cylinder A73 Electrohydraulic power steering APS control unit A76 Redund...

Page 65: ...orque MP Hydraulic torque A Electric steering assist B Hydraulic steering assist W46 00 1010 00 Steering gear The ZF steering gear already familiar from the Actros is supplemented by an electromechani...

Page 66: ...4 V when the normal power supply has failed The buffer battery can only be replaced at the work shop W54 10 1165 00 G3 Buffer battery A76 Redundant power supply RPS control unit Warning indicators A r...

Page 67: ...Right 260 735 565 750 K5A Left 290 650 565 950 K5B Left 390 650 565 1250 Guard plate for tank K5R A guard plate for protecting the fuel tank from dam age when driving offroad is available as special...

Page 68: ...e installed at different body floor heights depending on the conditions of service the engine variants and the drive components all wheel drive The body floor height of 765 mm produces a flat floor on...

Page 69: ...00 ClassicSpace S cab body floor height 600 mm W00 00 1075 00 ClassicSpace M cab body floor height 600 mm W00 00 1076 00 ClassicSpace M cab body floor height 600 mm W00 00 1077 00 StreamSpace L cab bo...

Page 70: ...500 2500 2300 2500 2300 2300 2300 2300 2300 2300 Cab height 2300 2100 2100 2100 1486 1750 1486 1750 1750 Floor to ceiling height in front of seat 1910 1910 1840 1840 1397 1590 1397 1600 1600 Body floo...

Page 71: ...neration The New Arocs Model 964 i W68 10 1102 00 Interior concept when equipped with manual shift W68 10 1103 00 Interior concept when equipped with Mercedes PowerShift 3 This printout will not be re...

Page 72: ...t 3 i Note The body floor height ASH designates the distance from the lower edge of the floor panel to the uppermost row of holes in the longitudinal frame member When the cab floor is flat the body f...

Page 73: ...underride guard ECE aluminum C7F Air sprung vehicles feature the fixed cab entry step as standard W60 80 1180 00 Fixed cab entry step F7X W60 80 1181 00 Movable cab entry step F7Y Guard plate under b...

Page 74: ...ng 71 Introduction of the New Truck Generation The New Arocs Model 964 i W00 19 1098 00 Location of control units based on Arocs 8x8 dumper with OM 471 This printout will not be recorded by the update...

Page 75: ...work 72 Networking Introduction of the New Truck Generation The New Arocs Model 964 i W00 19 1096 00 Overall network without single SAM Z3L This printout will not be recorded by the update service Sta...

Page 76: ...twork Networking 73 Introduction of the New Truck Generation The New Arocs Model 964 i W00 19 1097 00 Overall network with single SAM Z3L This printout will not be recorded by the update service Statu...

Page 77: ...nger door module DCMP control unit A18 Electronic Air Processing Unit EAPU control unit A20 Front axle axle modulator Wabco A20a Front axle axle modulator Knorr A1 Instrument cluster ICUC control unit...

Page 78: ...Electrohydraulic power steering APS control unit A76 Redundant power supply RPS control unit A78 Waistrail switch module 3 A83 Hydraulic Auxiliary Drive HAD control unit B42 Alarm siren B43 Interior...

Page 79: ...7a The single SAM is connected to the exterior CAN CAN 1 and interior CAN CAN 2 bus systems Information is distributed across the bus systems by the central gateway CGW control unit A2 The SSAM is loc...

Page 80: ...hassis connections will be modified as of 05 2013 1 LHD vehicles up to 04 2013 2 RHD vehicles up to 04 2013 3 LHD vehicles as of 05 2013 4 RHD vehicles as of 05 2013 All the connectors at the cab chas...

Page 81: ...ytime running lights cornering lights L1N Lower work lamps L3A Work lamps at top of cab rear panel L3C Illuminated Mercedes star F0T Because they require an automatic headlamp range adjustment system...

Page 82: ...le as part of the Protection Pack Z9E or separately L4Z for all Arocs W82 10 1147 00 Rear lamps for construction vehicles in metal surround with mesh L1Q Rear lamps protected by a metal surround and m...

Page 83: ...tool number W 936 589 01 14 00 FG 01 Set B Category Mercedes Benz Truck Basic Operation Note In combination with W 457 589 01 43 00 Puller W58 20 1095 00 Use For pulling the drive gear off the fuel s...

Page 84: ...oval and installation tool W58 20 1096 00 Use For removing installing the complete engine Special tool number W 936 589 01 62 00 FG 01 Set B Category Mercedes Benz Truck Special Operation Note In comb...

Page 85: ...r W 470 589 00 34 00 FG 01 Set B Category Mercedes Benz Truck Basic Operation Note Set of lifting eyes W58 20 1098 00 Use For removing installing the engine or cylinder head Special tool number W 470...

Page 86: ...tool number W 750 589 28 63 00 FG 26 Set B Category Mercedes Benz Truck Basic Operation Note In combination with drift W 750 589 01 15 00 Adjusting sleeve with pressure plate and spacer W58 20 1086 00...

Page 87: ...of or into the transmission housing Special tool number W 715 589 04 59 00 FG 26 Set B Category Mercedes Benz Truck Basic Operation Adapter W58 20 1087 00 Use For pulling off the rear main shaft beari...

Page 88: ...58 20 1085 00 Use For inserting the oil pipe into the clutch housing on transmissions with live power take off Special tool number W 715 589 09 15 00 FG 26 Set B Category Mercedes Benz Truck Basic Ope...

Page 89: ...The New Arocs Model 964 i Reduction adapter M24x1 5 W58 20 1101 00 Use For removing installing the transfer case Special tool number W 750 589 00 40 00 FG 28 Set B Category Mercedes Benz Truck Basic O...

Page 90: ...piece and holder with magnets for various inclination measurements on the propeller shaft and the propeller shaft flange Special tool number W 001 589 91 21 00 FG 41 Set B Category Mercedes Benz Truck...

Page 91: ...matic Power Steering ASA Additional Steering Axle ASH Body floor height ASIC Application System Integrated Circuit ASR Acceleration skid control ATA Anti theft alarm system BESO Battery Emergency Shut...

Page 92: ...ilter EAPU Electronic Air Processing Unit EBS Electronic Brake Control ECE Economic Commission for Europe EIS Electronic Ignition Switch ENA Single tire trailing axle ESP Electronic Stability Program...

Page 93: ...V Live power take off NLA Trailing axle OBD On Board Diagnosis OM Diesel engine PG Product Group PM Particulate Mass PPC Predictive Powertrain Control PSM Parameterizable Special Module PWM Pulse Widt...

Page 94: ...uty truck SRS Supplemental Restraint System SSAM Single SAM SWR Secondary Water Retarder SZF Semitrailer tractor TCC Truck Control Center TCM Transmission Control Module TCO Tachograph TPM Tire Pressu...

Page 95: ...ading axle 56 Loader 14 15 M Mirror cover 65 P Performance graph 23 Power take off NA 135 40 Power take off live 41 Power assisted gear shifting SKU 36 Protection Pack 17 R Rear axle 54 S ServoTwin 60...

Page 96: ...ntroduction into Service Manual Daimler AG GSP OR HPC R 822 D 70546 Stuttgart Order No HLI 000 000 11 04 Printed in Germany 01 13 Introduction of the New Truck Generation The New Arocs Model 964 This...

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