Mercedes-Benz Arocs Reference manual

Introduction of the New
Truck Generation
The New Arocs (Model 964)
Introduction 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)
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Mercedes-Benz Service
Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart
Introduction of the New Truck Generation
The New Arocs (Model 964)
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Information and copyright
Product Portfolio
You can also find comprehensive information on our complete product
portfolio 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]
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© 2013 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-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: W00.01-1025-00
Order no. of this publication: HLI 000 000 11 04
01/13
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Contents
1i
Introduction of the New Truck Generation - The New Arocs (Model 964)
Preface 5
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
Exhaust system 25
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Contents
2iIntroduction of the New Truck Generation - The New Arocs (Model 964)
Transmission
Clutch 27
Turbo 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
High-pressure pump/side module 47
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Contents
3i
Introduction of the New Truck Generation - The 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
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Contents
4iIntroduction of the New Truck Generation - The New 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
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Preface
5i
Introduction of the New Truck Generation - The New Arocs (Model 964)
Dear Reader,
This Introduction into Service manual presents the
new Arocs (model 964) and new features for the
Actros and Antos (model 963).
This brochure is intended for the use of technical
personnel familiar with the service and maintenance
of Mercedes-Benz trucks. 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.
All of the data in this brochure correspond to the tech-
nical status as of the copy 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 in this
brochure may therefore differ from more up-to-date
versions published in WIS.
Daimler AG
Wörth Plant, GSP/TTH
November 2012
iNote
Information about the vehicles and about oper-
ating the vehicle functions can also be found in the
interactive owner's manual on the internet at:
www.mercedes-benz.de/betriebsanleitung
This Introduction into Service manual is also avail-
able in digital form as a PDF in SDmedia.
iNote
All of the information and messages of the multi-
function display are shown in German because the
corresponding versions in other languages were
not available at the copy deadline.
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New features/modifications
6
Overview
Introduction of the New Truck Generation - The New Arocs (Model 964)
i
General
In early 2013, following the successful launch of the
new Actros and Antos, the new Arocs model 964
heavy construction vehicles will be presented.
They will be introduced in 4 stages:
In February 2013 the steel-sprung non-AWD vehi-
cles with the axle configurations 4x2, 6x4 and
8x4/4 will be launched.
In May 2013 these will be followed by the
6x2/2 VLA variants with leading axles and the
6x2 ENA/DNA with trailing axles.
From July 2013 the air-sprung construction 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 the
Loader (V1Y) product group.
Grounders are vehicles with "overloadable" chassis
with steel suspension. They have 9 mm thick longi-
tudinal frame members (standard is 8 mm) and
strengthened springs. Large tires are also available
for extreme conditions.
Loaders are vehicles with weight-optimized stan-
dard and special equipment. Among the construc-
tion vehicles, these are primarily payload-optimized
concrete mixers and the semitrailer tractor
964.403 for tanker/silo service.
W00.01-1026-00
The new Arocs
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New features/modifications
Overview
7
Introduction of the New Truck Generation - The New Arocs (Model 964) i
Distinguishing features of the model series
W00.00-1068-00
New Actros (V1A) model 963
Long-haul vehicles
• L cabs with width 2300 mm or 2500 mm
• Interior trim almond beige
• Rear axles only with air suspension
• Only automated manual transmissions with
Mercedes PowerShift 3 (G5G)
•Rigidframedesign
W00.00-1069-00
Antos (V1C) model 963
Distribution vehicles
• S and M cabs with width 2300 mm
• Interior trim flannel gray/greige
• Rear axles only with air suspension
• Only automated manual transmissions with
Mercedes PowerShift 3 (G5G)
•Rigidframedesign
W00.00-1070-00
Arocs (V1B) model 964
Construction vehicles
• S, M and L cabs with width 2300 mm or
2500 mm
• Interior trim anthracite/greige
• Straight front axle for greater ground clearance
• Unique radiator grille design
• Unique mirror covers
• Also with steel suspension on the rear axle
• Variants with all-wheel drive
• Also with drum brakes
• Front axle set back 100 mm
• Transmission with manual shift available
• Flexible frame
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New features/modifications
8
Overview
Introduction of the New Truck Generation - The New Arocs (Model 964)
i
Construction
• Large number of entirely new vehicle concepts
(axle configurations/tonnages)
• Easier mounting of various bodies through a
wide selection of wheelbases for the different
chassis variants that can be ordered ex factory.
The rear frame overhang can be selected in
300 mm increments
• 2 frame variants for the various operating
conditions. A narrow, soft frame for steel-sprung
vehicles, and a wide, moderately rigid frame for
air-sprung vehicles
• A wide choice of air-sprung construction
vehicles, some overloadable
• All vehicles in the construction model series
feature automated manual transmissions with
Mercedes PowerShift 3 (G5G) as standard
equipment
• Manual shift transmissions with the new cable
shift (Cable Power Shift (G5H)) with power-
assisted gear shifting are available as special
equipment
• Turbo retarder coupling for heavy-duty trucks in
combination with the automated Mercedes
PowerShift 3 transmission G 280-16
• New semi-clutch-independent live power take-
offs (NMV) with two different ratios
• Virtually all the cab variants from the two long-
haul and distribution 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 construction
trucks and all dumper/concrete mixer chassis
• Different axle drops can be selected for the front
axle to produce a variety of ground clearances
• Introduction of the Grounder product group
• Servotwin®electrohydraulic steering (C6H) as
special equipment for 4-axle vehicles and
standard for front axle loads > 7.5 t
• Wide rear axle for single tires
• Air suspension at the rear axle also for models
with max. GVW from 20 t to 32 t
Distribution haulage/long-distance
haulage
• New air-sprung 20 t 4x2 platform trucks and
semitrailer tractors
• New air-sprung 33 t 6x4 platform trucks and
semitrailer tractors
• New air-sprung 25 t 6x2/4 VLA 22.5'' platform
trucks and semitrailer tractors
Distribution haulage/long-distance
haulage/construction
• Engine OM 473 with turbocompound
• Hydraulic Auxiliary Drive (HAD)
Hydraulic drive of the front axle with wheel hub
motors
• DuraFlange aluminum rims in sizes 9.00x22.5
and 11.75x22.5
iNote
Various components of the Arocs, such as the
safety and support systems, are identical to those
in the Actros and Antos model 963, and are there-
fore not described again here.
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New features/modifications
Overview
9
Introduction of the New Truck Generation - The New Arocs (Model 964) i
The new construction vehicles of model series 964 and six new vehicles of model series 963 that will be avail-
able from 2013 are listed below.
Vehicles launched in February 2013
Model Wheel
configuration
Permissible gross
vehicle weight
Rear suspension Frame width
Semitrailer tractors
964.403 4x2 18 t Air 834 mm
964.401 4x2 20 t Steel 744 mm
963.402 4x2 20 t Air 834 mm
964.414 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 32 t Steel 744 mm
964.016 6x4 33 t Steel 744 mm
964.031 8x4/4 41 t Steel 744 mm
Dumpers
964.200 4x2 18 t Steel 744 mm
964.201 4x2 20 t Steel 744 mm
964.214 6x4 26 t Steel 744 mm
964.230 8x4/4 32 t Steel 744 mm
964.216 6x4 33 t Steel 744 mm
964.231 8x4/4 41 t Steel 744 mm
Concrete mixers
964.314 6x4 26 t Steel 744 mm
964.330 8x4/4 32 t Steel 744 mm
964.316 6x4 33 t Steel 744 mm
964.331 8x4/4 41 t Steel 744 mm
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New features/modifications
10
Overview
Introduction of the New Truck Generation - The New Arocs (Model 964)
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Vehicles launched in May 2013
Model Wheel
configuration
Permissible gross
vehicle weight
Rear suspension Frame width
Semitrailer tractors
964.423 6x2/2 VLA 22.5'' 24 t/ 25 t Air 834 mm
964.420 6x2 ENA 25 t Air 834 mm
964.425 6x2 DNA 25 t Air 834 mm
Platform trucks
964.020 6x2 ENA 25 t Air 834 mm
964.025 6x2 DNA 25 t Air 834 mm
Vehicles launched in July 2013
Model Wheel
configuration
Permissible gross
vehicle weight
Rear suspension Frame width
Semitrailer tractors
964.407 4x4 18 t Steel 744 mm
964.408 4x4 20 t Steel 744 mm
964.402 4x2 20 t Air 834 mm
964.424 6x4 26 t Air 834 mm
964.418 6x6 33 t Steel 744 mm
963.426 6x4 33 t Air 834 mm
964.426 6x4 33 t Air 834 mm
Platform trucks
964.007 4x4 18 t Steel 744 mm
964.003 4x2 18 t Air 834 mm
964.008 4x4 20 t Steel 744 mm
964.002 4x2 20 t Air 834 mm
964.024 6x4 26 t Air 834 mm
964.038 8x4/4 32 t Air 834 mm
964.041 8x4 ENA 32 t Air 834 mm
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New features/modifications
Overview
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Introduction of the New Truck Generation - The New Arocs (Model 964) i
Vehicles launched in July 2013
Model Wheel
configuration
Permissible gross
vehicle weight
Rear suspension Frame width
Platform trucks
964.018 6x6 33 t Steel 744 mm
963.026 6x4 33 t Air 834 mm
964.026 6x4 33 t Air 834 mm
Dumpers
964.207 4x4 18 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 6x6 33 t Steel 744 mm
964.226 6x4 33 t Air 834 mm
964.232 8x6/4 41 t Steel 744 mm
964.233 8x8/4 41 t Steel 744 mm
Concrete mixers
964.324 6x4 26 t Air 834 mm
964.330 8x4/4 32 t Air 834 mm
964.338 8x4/4 32 t Air 834 mm
964.341 8x4 ENA 32 t Air 834 mm
964.326 6x4 33 t Air 834 mm
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New features/modifications
12
Overview
Introduction of the New Truck Generation - The New Arocs (Model 964)
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Vehicles launched in December 2013
Model Wheel
configuration
Permissible gross
vehicle weight
Rear suspension Frame width
Semitrailer 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 launched in January 2014
Model Wheel
configuration
Permissible gross
vehicle weight
Rear suspension Frame width
Concrete mixers
964.338 8x4/4 41 t Steel 834 mm
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Product groups
Overall vehicle
13
Introduction of the New Truck Generation - The New Arocs (Model 964) i
Product group: Grounder (V1Z)
The new Arocs will see the introduction of the
product group (PG) Grounder (V1Z). Grounders 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 dumper
1Strengthenedframe
2 Strengthened steel suspension
3 Planetary hub reduction axles
4 Stabilizer bar
5Steelrims
6Largetires
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Product groups
14
Overall vehicle
Introduction of the New Truck Generation - The New Arocs (Model 964)
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Product group: Loader (V1Y)
The product group (PG) Loader (V1Y), first intro-
duced with the Antos, is also available for the Arocs
model 964.
Customers in the construction industry are offered
a payload-optimized semitrailer tractor (964.403),
e.g. for dumper semitrailers, as well as extremely
payload-efficient concrete mixers (964.330/338).
W00.01-1027-00
Equipment packages for the Loader PG with the example of a concrete mixer
Loader standard equipment, not 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 section with towing eyes (F7C)
Loader standard equipment, exclusive, not
deselectable
5 Windshield, weight-optimized (F6G)
6 Floor covering, weight-optimized (D5V)
7 Aluminum battery lines (Z7J)
8 Omission of engine suspension lugs
Loader standard equipment, exclusive,
selectable/deselectable
9 Rear axle, ring gear 390, hypoid, 9.5 t, single (A2O)
10 Tubeless tires, 385/65 R 22.5 on rear axle (I2Q)
11 Batteries 2 x 12 V/140 Ah, low-maintenance (E1F)
12 Omission of roof hatch/roof vent flap (D9T)
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Product groups
Overall vehicle
15
Introduction of the New Truck Generation - The New Arocs (Model 964) i
Models in the Grounder product group
Model Axle configuration Version Max. GVW
964.001 4x2 Platform 20 t
964.008 4x4 Platform 20 t
964.016 6x4 Platform 33 t
964.018 6x6 Platform 33 t
964.031 8x4/4 Platform 41 t
964.201 4x2 Dumper 20 t
964.208 4x4 Dumper 20 t
964.216 6x4 Dumper 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 tractor 20 t
964.408 4x4 Semitrailer tractor 20 t
964.416 6x4 Semitrailer tractor 33 t
964.418 6x6 Semitrailer tractor 33 t
Models in the Loader product group
Model Axle configuration Version Max. GVW
964.330 8x4/4 Concrete mixer 33 t
964.338 8x4/4 Concrete mixer 41 t
964.403 4x2 Semitrailer tractor 18 t
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Increased gross combination weights
16
Overall vehicle
Introduction of the New Truck Generation - The New Arocs (Model 964)
i
Gross combination weights above 44 t
Increased gross combination weights (GCW) can
now be selected by code for the first time. The code
covers all the components necessary to achieve the
desired GCW. The vehicle can then be licensed with
the required GCW.
At gross combination weights above 120 t the turbo
retarder coupling (G3Y) is recommended. Further-
more, on 2-axle 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
Drive one driven axle at least 2 driven axles
Clutch 1-plate 2-plate 2-plate, also turbo retarder coupling
Transmission
G 260-16 (G1J) G 260-16 (G1J) G 260-16 (G1J)
G 280-16 (G2D) G 280-16 (G2D) G 280-16 (G2D)
G 281-12 (G2E) G 330-12 (G2F)
G 330-12 (G2F)
Rear axle
Planetary hub
reduction rear axle
with ring gear 300
(A2G) or hypoid rear
axle with ring gear
485 (A2I)
Planetary hub reduction rear axle with ring gear 300 (A2G) or (A2H)
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Equipment
Overall vehicle
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Introduction of the New Truck Generation - The New Arocs (Model 964) i
General
In addition to the basic equipment and the various
standard equipment packages installed according
to the vehicle model/product group, a number of
additional safety and comfort features are also
available. These are bundled in packages that are
coded at the factory, such as the Safety Pack or the
Comfort Pack. The scope of these packages is
already described in the Introduction into Service
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 site oper-
ations.
The Protection Pack is only available for left-hand
drive vehicles (Z5X) and not for semitrailer tractors
(964.4xx) or the models 964.211 and 964.013.
Code Scope of Protection Pack (Z9E)
K5R Guard plate for tank
L4Z Stone impact protection, metal, for headlamps
L1Q Rear lamps for construction vehicles, in metal surround with mesh
F7Z Step, with handrail on roof
W88.30-1036-00
Step, with handrail on roof (F7Z)
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