Mercedes-Benz 949 Series Reference manual

The New Zetros
Introduction into Service Manual for Model Series 949
Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart
Order No. 6517 1253 02 – Printed in Germany – 08/08
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Mercedes-Benz Service
Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart
The New Zetros
Introduction into Service Manual
for Model Series 949
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Information and copyright
Ordering workshop information
All printed workshop information from GSP/OI, such as Introduction into
Service Manuals, System Descriptions, Function Descriptions, Technology
Guides, Technical Data Manuals and adhesive labels, can be ordered as
follows:
In Germany
Through our GSP/OI Shop on the Internet
Link: http://gsp-ti-shop.de
or alternatively
E-mail: customer.s[email protected]
Phone: [phone]
Fax: [phone]
Outside Germany
Please get in touch with the contact person responsible for your market.
Product portfolio
You can also find comprehensive information on our complete product port-
folio in our Internet portal.
Link: http://aftersales.mercedes-benz.com
Questions and suggestions
If you have any questions or suggestions concerning this product, please write
to us.
E-mail: [email protected]
Fax: [phone]
or alternatively
Address: Daimler AG
GSP/OIS
HPC R822, W002
D-70546 Stuttgart
© 2008 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/OIS, HPC R822, W002, D-70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including
databases and online services.
Image no. of title image: W00.01-1009-00
Order no. of this publication: 6517 1253 02
08/08
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Contents
3
i
The New Zetros, Introduction into Service Manual for Model Series 949
Preface 5
Overview
Models and major assemblies 6
Brief description 7
Overall vehicle
Technical design 8
Product features 9
Cab concept 10
Engine hood 11
Interior compartment 12
Technical data 13
Dimensions 14
Transport by air and rail 16
Body variants 17
Drive
Overall concept 18
Engine OM 926 LA 19
Power curves 20
Engine data 21
Manual transmission G 131-9 22
Transfer case VG 1700-3W 23
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Contents
4iThe New Zetros, Introduction into Service Manual for Model Series 949
Chassis
Frame 24
Suspension 25
Front axle 26
Rear axle 27
Tires 28
Steering 29
Body
Cab 30
Electrical system 31
Heating/climate control 36
Seats 37
Special tools
Transmission/engine 38
Workshop equipment
Tools 39
Abbreviations 40
Index 41
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Preface
5
i
The New Zetros, Introduction into Service Manual for Model Series 949
Dear Reader,
This Introduction into Service Manual presents the
new Zetros, model series 949.
The purpose of this brochure is to acquaint you with
the technical highlights of these vehicles in advance of
their market launch. This brochure is intended to
provide information for people employed in service,
maintenance and repair as well as for aftersales staff.
It is assumed here that the reader is already familiar
with the Mercedes-Benz model series currently on the
market.
In terms of the contents, the emphasis in this Intro-
duction into Service Manual is on presenting new and
modified components and systems.
This Introduction into Service Manual is not intended
as an aid for repairs or for the diagnosis of technical
problems. For such needs, more extensive information
is available in the Workshop Information System (WIS)
and in the Diagnosis Assistance System (DAS).
WIS is updated monthly. Therefore, the information
available there reflects the latest technical status of
our vehicles.
This Introduction into Service Manual presents initial
information relating to the new Zetros in model series
949 and, as such, is not stored in WIS. The contents of
this brochure are not updated. No provision is made
for supplements.
We will publicize modifications and new features in the
relevant WIS documents. The information presented in
this Introduction into Service Manual may therefore
differ from the more up-to-date information found in
WIS.
All information relating to specifications, equipment
and options is valid as of the copy deadline in August
2008 and may therefore differ from the series produc-
tion configuration.
Daimler AG
Technical Information
and Workshop Equipment (GSP/OI)
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Models and major assemblies
6iThe New Zetros, Introduction into Service Manual for Model Series 949
Overview
1) Euro 3 emissions standard
2) Euro 5 emissions standard
Zetros 1833A 2733A
Model series 949.016 949.066
Type of drive 4x4 6x6
Engine OM 926 LA 926.9351)
926.9472)
926.9351)
926.9472)
9-speed manual transmission G131-9
with hydraulic-pneumatic power shift (HPS) 715.570
Transfer case
VG 1700-3W 750.861
Clutch Single-plate clutch dia. 395 mm
Front axle AL7/56 DS-9
730.115
1st rear axle HL7/56 DS-13
748.270
HD7/56 DS-13
748.271
2nd rear axle –HL7/56 DS-13
748.270
Steering LS 8 BK
765.821
Brakes Drum brakes
Wheel suspension Leaf springs
Tires/rims 14.00 R20/10.00 V20
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Brief description
7
i
The New Zetros, Introduction into Service Manual for Model Series 949
Overview
Cab-behind-engine vehicles with all-wheel drive
With the Zetros, Mercedes-Benz is continuing its
tradition of cab-behind-engine vehicles with all-
wheel drive.
The new cab-behind-engine vehicles with all-wheel
drive from Mercedes-Benz are designed to meet the
following requirements of a modern special-
purpose vehicle:
• Reliable handling characteristics on all types of
road and off-road
• Safe and ergonomic controls
• Suitable for special deployments and
specialized transport tasks
• Suitable for worldwide deployment in all climate
zones
• Occupant protection
• Tactical and strategic mobility
• Large ground clearance with a large ramp
breakover angle and large approach/departure
angles for excellent off-road capability
As the first example of the new generation of cab-
behind-engine vehicles with all-wheel drive, the
Zetros naturally benefits from all of the other advan-
tages of the cab-behind-engine vehicle concept:
• Well-balanced load distribution for optimal
handling characteristics and steering ability
• Low overall height to facilitate transport by rail
or air, provide a low clearance height and allow
easy entry/exit by occupants
• Easy access to engine and ancillary assemblies
for maintenance and repair
• On military version, optimized distribution of
weight of armor over front and rear axles to
maintain maneuverability and load reserves for
best possible protection
W00.00-1047-00
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Technical design
8
Overall vehicle
The New Zetros, Introduction into Service Manual for Model Series 949
i
The new Zetros meets the specific requirements of
the current market and is based on tried-and-tested
mass-production technology.
Proven components from the Actros, Atego and
Axor model series have been used on this vehicle to
ensure that general customer requirements for
quality, cost-efficiency and worldwide support can
be met.
The new vehicle concept, particularly the rede-
signed cab, allows the vehicle to meet the specific
requirements placed on a modern special-purpose
vehicle.
W00.10-1048-00
Zetros 1833A Front view
W00.10-1049-00
Zetros 1833A Rear view
W00.10-1050-00
Zetros 1833A Side view
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Product features
Overall vehicle
9
The New Zetros, Introduction into Service Manual for Model Series 949 i
Overview of the most important product features
1Low vehicle height
2Low entry/exit height
3Cab-behind-engine concept
4Medium-long cab
5Full-size three-seater with unhindered
movement between seats (no engine tunnel)
6Fuel tank with 300 l capacity
7Underride guard for radiator
8Planetary front axle
with differential lock
9Reinforced frame
a2-speed transfer case with permanent all-
wheel drive
bPlanetary rear axle
with differential lock
W00.01-1008-00
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Cab concept
10
Overall vehicle
The New Zetros, Introduction into Service Manual for Model Series 949
i
The cab has been developed with particular atten-
tion paid to ergonomics and safe and uncompli-
cated use/operation. The main features are:
• Fixed cab with "3-point mounting"
• Engine hood and roof (optional) can be walked
on
• Easy and safe entry/exit
• Modern adjustable seats
• Ergonomic positioning and design of controls
and displays/indicators
• Spacious cab design for three persons with
stowage space for equipment
• Good visibility and overall view
• Low-noise interior
W60.80-1135-00
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Engine hood
Overall vehicle
11
The New Zetros, Introduction into Service Manual for Model Series 949 i
The engine hood can be tilted forwards to allow direct
access to the engine and all maintenance items. All of
the maintenance items are located under the hood
and are easily accessible. This has the following
advantages:
• Rapid and simple access to engine and ancillary
assemblies
• Cab unloading is not necessary
• Occupants can remain in the cab
• Radio and weapons systems can be used without
limitation
W60.80-1136-00
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Interior compartment
12
Overall vehicle
The New Zetros, Introduction into Service Manual for Model Series 949
i
The spacious interior compartment is equipped with
three full-size adjustable individual seats with enough
room for a 3-man crew and their equipment.
The dashboard has been taken over from the
Atego/Axor with its tried-and-tested ergonomic posi-
tioning of controls and displays/indicators.
W68.00-1009-00
W68.00-1010-00
W68.00-1008-00
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Technical data
Overall vehicle
13
The New Zetros, Introduction into Service Manual for Model Series 949 i
1) Other dimensions supplied upon request
2) Load variant 18 (9.0/9.0) possible, then payload up to 6000 kg depending on equipment
3) Load variant 27 (9.0/9.0/9.0) possible, then payload up to 13000 kg depending on equipment
4) Depending on tires/rims
Zetros 1833A
4x4
2733A
6x6
Dimensions
Wheelbase mm 4,800 4,750 + 1,450
Length (without body) mm 8,406 9,574
Width (without body) mm 2,530 2,530
Height (unladen up to roof)
Load variant FA 7.5 t
Load variant FA 9.0 t
mm
mm
2,832
2,857
2,832
2,857
Standard platform (l/w/h) mm 5,100/2,450/5001) 6,200/2,450/5001)
Approach angle (under rated load) 29.3° 29.3°
Departure angle (under rated load) 30° 35.2°
Zetros 1833A
4x4
2733A
6x6
Dimensions and weights
Curb weight (without body) kg 8,600 10,500
Permissible gross vehicle weight kg 16,500 (18,000)2) 25,000 (27,000)3)
Military payload (without body) kg 4,000-6,000 7,000-10,000
Permissible front axle load kg 7,500 (9,000)2) 7,500 (9,000)3)
Permissible rear axle load kg 9,0004) 2x9,0004)
Electrical system V24 24
Tank capacity l300 300
Turning circle dia. in m 20.6 22.8
Standard fording depth
With special equipment
mm 800
1,195 and 1,500
800
1,195 and 1,500
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Dimensions
14
Overall vehicle
The New Zetros, Introduction into Service Manual for Model Series 949
i
W00.10-1144-00
Dimensions of Zetros 1833A (4x4)
1) Load variant 16.5 (7.5/9.0)
2) Load variant 18 (9.0/9.0)
3) Standard platform 5,100/2,450/500 (l/w/h in mm)
Other dimensions upon request
1565
4800
2530
51003)
28321)
28572)
8406
29,3
12,5
12,5
30
20,6 m
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Dimensions
Overall vehicle
15
The New Zetros, Introduction into Service Manual for Model Series 949 i
W00.10-1145-00
Dimensions of Zetros 2733A (6x6)
1) Load variant 25 (7.5/9.0/9.0)
2) Load variant 27 (9.0/9.0/9.0)
3) Standard platform 6,200/2,450/500 (l/w/h in mm)
Other dimensions upon request
1565
4750
9574
1450
29,3 35,2
2530
62003)
22,8 m
12,5
12,5
28321)
28572)
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Transport by air and rail
16
Overall vehicle
The New Zetros, Introduction into Service Manual for Model Series 949
i
Due to its compact vehicle contour, the Zetros is
suitable for transport by air and rail.
When transported on a Hercules C 130, the
following preparatory measures must be performed
to allow the vehicle to be loaded:
• Lowering of tire pressure
• Clamping down of front axle
• Removal of air intake and roof attachments
• Removal of spare tire
• Adjustment of tank contents
International rail dimension (GICS):
Wagon height 1,300 mm, identical to cargo
area of C 160 Transall
German rail dimension :
Wagon height 1,300 mm
Cargo area of Hercules C 130
W00.10-1147-00
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Body variants
Overall vehicle
17
The New Zetros, Introduction into Service Manual for Model Series 949 i
The various body variants are mounted on a torsion-
free intermediate frame. The body is raised by
approx. 100 mm by the intermediate frame.
The following variants are possible:
•Platform
• Platform with crane (crane remains within cab
contour in transport position)
• Tanker body
•Container
The intermediate frame isolates the body from the
torsional forces transmitted into the vehicle frame
by the suspension system.
This has the following advantages:
• Body and load protected from damage during
transport
• Extremely high degree of axle articulation when
off-road
• Greater comfort of vehicle occupants during
team transport
W31.20-1000-00
Zetros 2733A
1 Intermediate frame
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Overall concept
18
Drive
iThe New Zetros, Introduction into Service Manual for Model Series 949
The drivetrain of the Zetros has been taken over
from the Atego/Axor and consists of the following
components:
• 6-cylinder inline diesel engine with charge air
cooling
• Standard 9-speed synchromesh transmission
with hydraulic-pneumatic power shift (HPS)
• 2-speed transfer case
• Permanent all-wheel drive
• Planetary axles
• Differential locks (interaxle and interwheel
locks)
W00.50-1000-00
Drivetrain of Zetros 2733A (6x6)
– This printout will not be recorded by the update service. Status: 10 / 2008 –

Engine OM 926 LA
Drive
19
i
The New Zetros, Introduction into Service Manual for Model Series 949
Diesel engine OM 926 LA is used as the drive
assembly.
Features:
• 6-cylinder inline engine with turbocharger and
charge air cooling
• Maximum output: 240 kW/326 hp
• Maximum torque: 1,300 Nm
• 3 valves per cylinder
• Displacement: 7,200 cm3
• Pump-Line-Nozzle (PLD)
•Watercooling
• Engine management by fully electronic
Telligent®engine control system
• Euro 3 and Euro 5 engine versions
iNote
The engine can be used at max. 2,500 m above
sea level without any reduction in output.
iNote
The engine can be operated on low quality fuel or
kerosene.
W01.00-1075-00
Engine OM 926.947
– This printout will not be recorded by the update service. Status: 10 / 2008 –