Truck Body Mounting Directives 01-09-2006

8/9/2019 Truck Body Mounting Directives 01-09-2006

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Truck body/equipment mounting directives

Actros (BM 93X)

Axor (BM 94X, 95X)

Atego (BM 97X)

Econic

Publication date:

01.09.2006


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Mercedes-Benz body/equipment mounting directives for trucks Issue date: 30.06.2006

! Always print out complete sections from the current version.

Update notes

Amendments made to document dated 01.12.2005

1 Introduction1.1 The aim of these directives . . . . . . . ( page 5)

2 General2.1 Vehicle and model designations . . ( page 11)2.2 Technical advice and contacts. . . . ( page 33)2.6 Body manufacturer information

portal . . . . . . . . . . . . . . . . . . . . . . . ( page 38)2.6.1 Your company profile (ABH profile and

the Qualified Partner List (QPL) . . . ( page 38)2.6.2 MBAS Web (Mercedes-Benz body/

equipment manufacturer system)and order data . . . . . . . . . . . . . . . . ( page 39)

2.6.3 Partnership

and contact options . . . . . . . . . . . . (

page 39)2.7 Workshop Information System(WIS) . . . . . . . . . . . . . . . . . . . . . . . ( page 40)

3 Planning of bodies3.7.2 Euro 4/Euro 5 . . . . . . . . . . . . . . . . ( page 55)

4 Technical threshold values for planning4.1 Vehicle overhang and

technical wheelbase. . . . . . . . . . . . ( page 67)4.2.3 Stabilisers/

Telligent® roll control. . . . . . . . . . . ( page 69)4.3 Steerability. . . . . . . . . . . . . . . . . . . ( page 70)

6 Modifications to the basic vehicle6.6.1 Air-brake system . . . . . . . . . . . . . ( page 105)

7 Types of bodies7.6.2 Loading crane mounted behind

the cab on Atego (BM 97X) . . . . . ( page 201)

8 Calculations8.3 Tipping limit . . . . . . . . . . . . . . . . . ( page 240)8.4 Technical wheelbase . . . . . . . . . . ( page 240)8.4.1 Technical wheelbase regulation

for 3-axle vehicles . . . . . . . . . . . . ( page 240)8.4.2 Technical wheelbase regulation

for 4-axle vehicles . . . . . . . . . . . . ( page 241)


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Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 The aim of these directives . . . . . . . . . . . . . . . 51.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.3 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . 81.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . 9

1.5 Accident prevention. . . . . . . . . . . . . . . . . . . . 10

2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.1 Vehicle and model designations . . . . . . . . . . 112.2 Technical advice and contacts. . . . . . . . . . . . 332.3 Issuing certificates of endorsement. . . . . . . . 342.3.1 Certificate of endorsement . . . . . . . . . . . . . . 342.3.2 Documents required . . . . . . . . . . . . . . . . . . . 352.3.3 Legal claim . . . . . . . . . . . . . . . . . . . . . . . . . . . 352.4 Product liability . . . . . . . . . . . . . . . . . . . . . . . 362.4.1 Ensuring traceability . . . . . . . . . . . . . . . . . . . 36

2.5 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . 372.6 Body manufacturer information portal. . . . . . 382.6.1 Your company profile (ABH profile and the

Qualified Partner List (QPL) . . . . . . . . . . . . . . 382.6.2 MBAS Web (Mercedes-Benz body/equipment

manufacturer system) and order data . . . . . . 392.6.3 Partnership and contact options . . . . . . . . . . 392.7 Workshop Information System (WIS). . . . . . . 402.8 Mercedes star and logo . . . . . . . . . . . . . . . . . 412.9 Reprocessing components – recycling . . . . . 422.10 Quality assurance system . . . . . . . . . . . . . . . 43

3 Planning of bodies . . . . . . . . . . . . . . . . . . . . 443.1 Selecting the chassis. . . . . . . . . . . . . . . . . . . 443.2 Vehicle modifications. . . . . . . . . . . . . . . . . . . 453.3 Dimensions, weights and total vehicle

height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.3.1 Observing the permissible total vehicle height

(large volume transporters) . . . . . . . . . . . . . . 463.4 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473.5 Bolted and welded connections. . . . . . . . . . . 483.5.1 Bolted connections . . . . . . . . . . . . . . . . . . . . 48

3.5.2 Welded connections. . . . . . . . . . . . . . . . . . . . 523.6 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . 533.7 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 543.7.1 Euro 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.7.2 Euro 4/ Euro 5 . . . . . . . . . . . . . . . . . . . . . . . . 553.8 Maintenance and repairs . . . . . . . . . . . . . . . . 613.8.1 Maintenance instructions . . . . . . . . . . . . . . . 613.8.2 Preparation for storing the vehicle. . . . . . . . . 623.8.3 Battery maintenance and storage . . . . . . . . . 623.8.4 Preparation for handing over the

converted vehicle. . . . . . . . . . . . . . . . . . . . . . 633.9 Optional equipment . . . . . . . . . . . . . . . . . . . . 643.10 Pneumatic auxiliary consumers . . . . . . . . . . . 653.10.1 Maximum permissible air consumption . . . . . 66

4 Technical threshold values forplanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.1 Vehicle overhang and technicalwheelbases . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.2 Load distribution, height of centre of gravity,anti-roll bars. . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.2.1 Weight distribution. . . . . . . . . . . . . . . . . . . . . 684.2.2 Height of centre of gravity . . . . . . . . . . . . . . . 684.2.3 Stabiliser/ Telligent® roll control. . . . . . . . . . 694.3 Steerability. . . . . . . . . . . . . . . . . . . . . . . . . . . 704.4 Clearance for assemblies and cab. . . . . . . . . 714.5 Wind deflector . . . . . . . . . . . . . . . . . . . . . . . . 734.6 Telligent® stability control . . . . . . . . . . . . . . . 744.7 Semitrailers . . . . . . . . . . . . . . . . . . . . . . . . . . 754.8 Gross weight of tractor/trailer

combination. . . . . . . . . . . . . . . . . . . . . . . . . . 76

5 Damage prevention . . . . . . . . . . . . . . . . . . . 805.1 Electrical system . . . . . . . . . . . . . . . . . . . . . . 805.2 Brake hoses/ cables and lines. . . . . . . . . . . . 825.3 Mobile communications systems. . . . . . . . . . 835.4 Electromagnetic compatibility (EMC). . . . . . . 845.5 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . 855.6 Corrosion protection measures . . . . . . . . . . . 865.7 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 885.8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 895.9 Leaf springs . . . . . . . . . . . . . . . . . . . . . . . . . . 905.10 Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . 91

5.11 Towing and tow-starting . . . . . . . . . . . . . . . . 925.12 Risk of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . 935.13 Gas system . . . . . . . . . . . . . . . . . . . . . . . . . . 94


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Contents

5.13.1 Regulations and information sheets. . . . . . . . 945.13.2 Safety when working with natural gas . . . . . . 955.13.3 Precautions for the removal of the

compressed-gas reservoirs . . . . . . . . . . . . . . 965.13.4 Removed compressed-gas reservoirs . . . . . . 965.13.5 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

5.13.6 Natural gas high-pressure lines . . . . . . . . . . . 975.13.7 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 985.13.8 Body mounting . . . . . . . . . . . . . . . . . . . . . . . . 985.13.9 Access to the compressed-gas reservoirs . . . 985.13.10Power take-off (NA) output . . . . . . . . . . . . . . 985.14 Storing and delivering the vehicle . . . . . . . . . 99

6 Modifications to the basic vehicle . . . . . 1006.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006.2 Chassis frame material . . . . . . . . . . . . . . . 1016.3 Drilling work on the vehicle frame . . . . . . . 102

6.4 Welding work on the vehicle frame . . . . . . 1036.5 Reinforcements . . . . . . . . . . . . . . . . . . . . . 1046.6 Brake system . . . . . . . . . . . . . . . . . . . . . . . 1056.6.1 Compressed-air brake system . . . . . . . . . . 1056.6.2 Routing lines . . . . . . . . . . . . . . . . . . . . . . . 1066.6.3 Bending radii for plastic lines. . . . . . . . . . . 1066.7 Modifications to the wheelbase . . . . . . . . . 1076.7.1 Certificate of endorsement for modifications

to the wheelbase . . . . . . . . . . . . . . . . . . . . 1076.7.2 Modification to the wheelbase by moving

the rear axle assembly. . . . . . . . . . . . . . . . 108

6.7.3 Modification to the wheelbase by cuttingthe longitudinal frame member . . . . . . . . . 1096.7.4 Propeller shafts . . . . . . . . . . . . . . . . . . . . . 1136.8 Modifications to the frame. . . . . . . . . . . . . 1156.8.1 Frame extension . . . . . . . . . . . . . . . . . . . . 1156.8.2 Standard chassis frame extension. . . . . . . 1166.8.3 Frame shortening. . . . . . . . . . . . . . . . . . . . 1166.8.4 End cross member . . . . . . . . . . . . . . . . . . . 1176.9 Attachments and additional equipment . . . 1196.9.1 Fastening to the chassis frame . . . . . . . . . 1196.9.2 Wheel chocks. . . . . . . . . . . . . . . . . . . . . . . 1196.9.3 Mudguards and wheel arches . . . . . . . . . . 1196.9.4 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . 1196.9.5 Front underride guard . . . . . . . . . . . . . . . . 1206.9.6 Rear underride guard . . . . . . . . . . . . . . . . . 121

6.9.7 Side underride guard . . . . . . . . . . . . . . . . . . 1236.9.8 Compressor installation. . . . . . . . . . . . . . . . 1236.10 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1256.10.1 Adaptation of a crew cabin/ crewcab in the

short cab (code F07) . . . . . . . . . . . . . . . . . . 1256.11 Seats and bench seat . . . . . . . . . . . . . . . . . 127

6.12 Retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286.13 Leading axle/trailing axle . . . . . . . . . . . . . . 1296.14 Retrofitting an automatic transmission . . . . 1306.15 Electrical system/ electronics . . . . . . . . . . . 1316.15.1 Vehicle earth . . . . . . . . . . . . . . . . . . . . . . . . 1336.15.2 Tapping cables to control units . . . . . . . . . . 1336.16 Power supply – auxiliary consumers . . . . . . 1346.16.1 Electrical consumers up to 10 amps . . . . . . 1346.16.2 Explanations of cable plug

(pin assignment) . . . . . . . . . . . . . . . . . . . . . 1366.16.3 Wiring diagram (current draw up to

10 amps) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1386.16.4 Electrical consumers above 10 amps . . . . . 1406.16.5 Installation of lighting . . . . . . . . . . . . . . . . . 1466.16.6 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . 1476.16.7 Cable routing preparation . . . . . . . . . . . . . . 1486.16.8 Anti-theft alarm system . . . . . . . . . . . . . . . . 1496.16.9 Programmable special module (PSM) . . . . . 1506.17 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . 1526.18 Power take-offs . . . . . . . . . . . . . . . . . . . . . . 1596.19 Transmission-driven power take-off (NA). . . 1606.20 Engine-driven power take-off (NMV) . . . . . . 1616.21 Tipper pump. . . . . . . . . . . . . . . . . . . . . . . . . 1626.22 Engine power take-off at the front. . . . . . . . 1636.22.1 Belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 1636.22.2 Propeller shaft . . . . . . . . . . . . . . . . . . . . . . . 1636.23 Engine power take-off at the rear . . . . . . . . 1646.23.1 Rigid drive . . . . . . . . . . . . . . . . . . . . . . . . . . 1656.23.2 Resilient drive . . . . . . . . . . . . . . . . . . . . . . . 1656.23.3 Engine power take-off at the rear . . . . . . . . 1676.24 Installation of propeller shaft. . . . . . . . . . . . 1696.24.1 Types of angle offset . . . . . . . . . . . . . . . . . . 1696.25 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . 1706.25.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

6.25.2 Open-jaw coupling . . . . . . . . . . . . . . . . . . . . 1706.25.3 Ball hitch coupling . . . . . . . . . . . . . . . . . . . . 1726.26 Use of vehicle with centre-axle trailer . . . . . 173


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Contents

6.27 Lowered trailer coupling . . . . . . . . . . . . . . 1746.27.1 Lowered trailer coupling for centre-axle

trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1766.28 Semitrailer tractor vehicles . . . . . . . . . . . . 1786.28.1 Semitrailer tractor chassis . . . . . . . . . . . . . 1786.28.2 Standard chassis for semitrailer tractor

vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . 1786.29 Connections for brake system and

electrical system . . . . . . . . . . . . . . . . . . . . 179

7 Types of bodies . . . . . . . . . . . . . . . . . . . . 1807.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1807.2 Mounting frame . . . . . . . . . . . . . . . . . . . . . 1817.2.1 Mounting frame material . . . . . . . . . . . . . . 1827.2.2 Mounting frame design . . . . . . . . . . . . . . . 1837.2.3 Section dimensions . . . . . . . . . . . . . . . . . . 1877.3 Securing the mounting frame . . . . . . . . . . 188

7.3.1 Friction-locking connection –bracket mounting. . . . . . . . . . . . . . . . . . . . 189

7.3.2 Form-locking rigid connection –tab fixing . . . . . . . . . . . . . . . . . . . . . . . . . . 192

7.3.3 Quick-release lock for demountablebodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

7.4 Self-supporting bodies . . . . . . . . . . . . . . . . 1947.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1947.4.2 Van and box-type bodies . . . . . . . . . . . . . . 1947.5 Platform and demountable bodies. . . . . . . 1957.5.1 Platform body. . . . . . . . . . . . . . . . . . . . . . . 195

7.5.2 Demountable bodies . . . . . . . . . . . . . . . . . 1967.6 Loading crane . . . . . . . . . . . . . . . . . . . . . . 1977.6.1 Loading crane mounted behind the cab

on Actros (BM 93X), Axor (BM 95X),Econic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

7.6.2 Loading crane mounted behind the cabon Atego (BM 97X). . . . . . . . . . . . . . . . . . . 201

7.6.3 Rear-mounted loading crane on Actros(BM 93X), Axor (BM 95X), Econic. . . . . . . . 203

7.6.4 Rear-mounted loading crane on Atego(BM 97X) . . . . . . . . . . . . . . . . . . . . . . . . . . 207

7.6.5 Removable loading crane. . . . . . . . . . . . . . 2097.6.6 Vehicles with lifting trailing axle. . . . . . . . . 2097.7 Tipper bodies . . . . . . . . . . . . . . . . . . . . . . . 2107.7.1 Mounting frame . . . . . . . . . . . . . . . . . . . . . 210

7.7.2 Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2117.7.3 Safety fittings. . . . . . . . . . . . . . . . . . . . . . . . 2117.7.4 Lifting press . . . . . . . . . . . . . . . . . . . . . . . . . 2117.7.5 Vehicles with disc brakes

on the rear axle . . . . . . . . . . . . . . . . . . . . . . 2117.7.6 Special tipper bodies on

standard chassis . . . . . . . . . . . . . . . . . . . . . 2127.8 Roll-off tippers and skip loaders . . . . . . . . . 2137.9 Tank and dry-bulk bodies. . . . . . . . . . . . . . . 2147.9.1 Tank and dry-bulk bodies without continuous

mounting frames . . . . . . . . . . . . . . . . . . . . . 2177.9.2 Platform-mounted tanks . . . . . . . . . . . . . . . 2177.10 Vehicles for the transport of hazardous

goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2187.10.1 Legal regulations . . . . . . . . . . . . . . . . . . . . . 2187.10.2 Transport of class 2 and 3 flammable

substances. . . . . . . . . . . . . . . . . . . . . . . . . . 218

7.10.3 Vehicles for the transport of aggressivesubstances. . . . . . . . . . . . . . . . . . . . . . . . . . 218

7.11 Cement mixer trucks . . . . . . . . . . . . . . . . . . 2197.12 Semitrailer coupling. . . . . . . . . . . . . . . . . . . 2207.12.1 Mounting frame and

semitrailer coupling . . . . . . . . . . . . . . . . . . . 2237.13 Other bodies . . . . . . . . . . . . . . . . . . . . . . . . 2257.14 Loading tailgate/ lifting platform. . . . . . . . . 2267.14.1 Mounting without mounting frame . . . . . . . 2277.14.2 Loading tailgate tables. . . . . . . . . . . . . . . . . 228

8 Calculations . . . . . . . . . . . . . . . . . . . . . . . . 2388.1 Coupling devices . . . . . . . . . . . . . . . . . . . . . 2388.1.1 Trailer coupling (without noseweight) . . . . . 2388.1.2 Trailer coupling (with noseweight) . . . . . . . . 2388.1.3 Semitrailer coupling. . . . . . . . . . . . . . . . . . . 2388.2 Axle load calculation . . . . . . . . . . . . . . . . . . 2398.3 Tipping limit . . . . . . . . . . . . . . . . . . . . . . . . . 2408.4 Technical wheelbase . . . . . . . . . . . . . . . . . . 2408.4.1 Technical wheelbase regulation for

3-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . 2408.4.2 Technical wheelbase regulation for

4-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . 241


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Contents

9 Technical data . . . . . . . . . . . . . . . . . . . . . 2429.1 PSM 3 parameter data record . . . . . . . . . . 2429.2 Transmission-driven

power take-off (NA) . . . . . . . . . . . . . . . . . . 2579.2.1 Mounting directives for the transmission-

driven power take-off . . . . . . . . . . . . . . . . . 2579.2.2 Dimensions of the power take-off

coupling flange. . . . . . . . . . . . . . . . . . . . . . 3499.3 Engine-driven power take-off (NMV) . . . . . 351


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1.1 The aim of these directives

5

1 Introduction

DaimlerChrysler AG, as the manufacturer ofMercedes-Benz vehicles, issues these body/ equipmentmounting directives to provide manufacturers with im-portant technical information about the basic vehicle.This information must be observed by the body manufac-turer in the production of bodies and equipment, fittings

and modifications for Mercedes-Benz vehicles.

Due to the great number of body manufacturers andbody types, DaimlerChrysler AG cannot foresee all pos-sible changes, e.g. to road performance, stability, loaddistribution, position of the vehicle’s centre of gravityand its handling characteristics, caused by bodies andtheir equipment, fittings and modifications. For this rea-son, DaimlerChrysler AG can assume no liability for acci-dents or injuries caused by such modifications to yourvehicle where these modifications have an adverse af-fect on the complete vehicle. As a manufacturer,

DaimlerChrysler AG is accordingly only liable for its owndesigns and products. The body manufacturer itself, asmanufacturer of the complete vehicle, undertakes to en-sure that bodies and their equipment, fittings and modi-fications are not faulty and that they cannot lead tofaults or hazards on the complete vehicle. If this obliga-tion is violated in any way, the body manufacturer will as-sume full product liability. With these body/equipmentmounting directives, DaimlerChrysler AG informs thebody manufacturers of important aspects to observe inall work relating to attachments, bodies, equipment or

modifications.These body/ equipment mounting directives are intend-ed primarily for the professional manufacturers of at-tachments, bodies, equipment or modifications for ourvehicles. For this reason, these body/equipmentmounting directives assume that the body manufacturerpossesses the necessary background knowledge. If youintend to install attachments, special-purpose bodies,equipment or conversions on the vehicle, please beaware that certain types of work (e.g. welding work onload-bearing components) may only be carried out by

qualified personnel. This will avoid the risk of injury andwill attain the degree of quality required for the attach-ments, special-purpose bodies, equipment and conver-sions.


These directives serve as instructions for the manufac-ture of assemblies and of attachments, bodywork, equip-ment or modifications for bodies not manufactured byMercedes-Benz. The following body/equipment mount-

ing directives are divided into 9 cross-referenced sec-tions to help you to find information quickly:

1. Introduction

2. General

3. Planning of bodies

4. Technical threshold values for planning

5. Damage prevention

6. Modifications to the basic vehicle

7. Types of bodies

8. Calculations9. Technical data

Appendix:

Index

iSee the body manufacturer information portal for ad-ditional information and technical data ( page 38).

The index features linked cross-references in the PDFversion to help you find information quickly.

The threshold values chosen in Section 4 must be ad-hered to and must form the basis of planning.

Section 6, entitled "Modifications to the basic vehi-cle", and Section 7, "Types of bodies", are the mainsource of technical information contained in thesebody/equipment mounting directives.


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1 Introduction

6

The following graphics show the distinction between thebasic vehicle and the body:

Basic vehicle

Body

To ensure operating and road safety of the chassis andavoid contravention of warranty conditions, pay particu-lar attention to the following information.

Illustrations and schematic drawings are examples andhelp explain texts and tables.

References to directives, standards, guidelines, etc., arein brief form for information only.

More information is available from any Mercedes-BenzService Centre.

DaimlerChrysler AG

Risk of accident and injury G

Before installing any attachments, special-purposebodies, equipment or carrying out any modificationsto the basic vehicle and/ or its assemblies, you mustread the relevant sections of the vehicle Operating In-structions, as well as the operating and assembly in-structions issued by the manufacturer of theaccessories and items of optional equipment.

You could otherwise fail to recognise dangers and en-danger yourself or others.


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1.2 Symbols

1 Introduction

7

1.2 Symbols

You will find the following symbols used in these direc-tives:

page This symbol indicates the page on which youwill find further information on the subjectand features linked cross-references in the

PDF version.

Warning G

A warning draws your attention to possible risks of ac-cident and injury to yourself and others.

Environmental note H

An environmental note gives you tips on the protec-tion of the environment.

!This note draws your attention to possible hazards toyour vehicle.

iThis tip contains advice or further information youmay find useful.


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1.3 Vehicle safety

1 Introduction

8

1.3 Vehicle safety

Notes on vehicle safety

Mercedes-Benz recommends

that you use only parts and assemblies or conversionparts and accessories that have been recommended byMercedes-Benz for the type of vehicle concerned.

Parts that modify the vehicle such that they:

change the vehicle type approved in the generaloperating permit

can be expected to endanger road users, or

adversely affect exhaust emissions or noise lev-els

will invalidate the vehicle's general operating permit inmany countries.

Risk of accident and injury G

The use of non-approved parts, assemblies or conver-

sion parts and accessories can jeopardise the safetyof the vehicle.

Before installing any attachments, special-purposebodies, equipment or carrying out any modificationsto the basic vehicle and/ or its assemblies, you mustread the relevant sections of the vehicle Operating In-structions, as well as the operating and assembly in-structions issued by the manufacturer of theaccessories and items of optional equipment.


Approval from official test centres or official permitscannot rule out safety risks.

iObserve the national specifications since the installa-tion of attachments, special-purpose bodies andequipment, or the performing of conversion work onthe vehicle could change the approved vehicle type

and may therefore invalidate the general operatingpermit.


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1.4 Operational safety

1 Introduction

9

1.4 Operational safety

Risk of accident G

Before installing any attachments, special-purpose

bodies, equipment or carrying out any modificationsto the basic vehicle and/ or its assemblies, you mustread the relevant sections of the vehicle Operating In-structions, as well as the operating and assembly in-structions issued by the manufacturer of theaccessories and items of optional equipment.


Work on electronic equipment and its software notcarried out properly could prevent this equipmentfrom working correctly. Since the electronic systems

are networked, this might also affect systems thathave not been modified.Malfunctions in the electronic systems could serious-ly jeopardise the operational safety of the vehicle.


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1.5 Accident prevention

1 Introduction

10

1.5 Accident prevention

The equipment fitted during installation, bodywork, as-sembly or conversion must comply with all applicablelaws and directives and with health and safety and acci-dent prevention regulations, safety regulations and infor-

mation sheets issued by accident insurers.All technical means shall be used to avoid operating con-ditions that may be unsafe or liable to cause an accident.

In Germany, information is provided to commercial car-riers by the "Vehicles" Working Group of the "Traffic"Technical Committee at the following address:

Comply with all national laws, guidelines and vehi-cle registration regulations.

The manufacturer of the special-purpose bodies,conversions and of special equipment is responsi-ble for compliance with these laws and regulations.

Telephone: +49 (0) 40 39 80 – 0

Fax: +49 (0) 40 39 80-19 99

E-mail: [email protected]

Postal address: Berufsgenossenschaft fürFahrzeughaltungen (GermanTrade Association of VehicleOwners)

Ottenser Hauptstraße 54

D-22765 Hamburg, Germany


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2.1 Vehicle and model designations


! Always print out complete sections from the current version.11

2 General


These body/ equipment mounting directives are valid forthe following vehicle model series (BM):

Explanation of truck model designation:

Vehicle

Actros (BM 93X) 18t 20t 25t 26t 32t 33t 41tAxor (BM 94X and 95X) 18t 25t 26t 32t

Atego (BM 97X) 7t 8t 9t 10t 12t 13t 15t

Econic 18t 26t

Example 2544 S 6x2/4

25 Permissible gross weight in tons (solo vehicle)

44 Engine output in bhp (* x 10)

S Vehicle specification (brief description)

Chassis/platform truck

A All-wheel-drive

B Cement mixer

K Tipper

S Semitrailer tractor vehicle

L Pneumatic suspension

6x2/ 4 Axle designation

6 Number of wheels or pairs of wheels

x2 Number of driven wheels or pairs of wheels

/ 4 Number of steered wheels


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2 General

12


(BM 93X) 18tVKB 1,832 1,836 1,841 1,844 1,846 1,850 1,854 1,858

Engine type OM 501 LA OM 501 LA OM 501 LA OM 501 LA OM 501 LA OM 502 LA OM 502 LA OM 502 LA

Number of cylinders V6 V6 V6 V6 V6 V8 V8 V8

Output kW/bhp 235/320 265/360 300/408 320/435 335/456 370/503 395/537 425/578

rpm 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800

Maximum torque Nm 1,700 1,850 2,050 2,100 2,200 2,400 2,500 2,700

rpm 1,080 1,080 1,080 1,080 1,080 1,080 1,080 1,080

Cab S(F07) short

M(F05) standard S S S S S S

L(F04) long

Mega (F15) S S

Transmission G211-16 G211-16 G211-16 G211-16 G231-16 G240-16 G240-16 G260-16

Wheelbase (mm) 4,500

4,800

5,100

5,400

5,700

6,000

L 3,900

4,200

4,500

4,800

5,100

5,400

5,700

6,000

NR

4,800

5,400

5,700

NRA

5,400

5,700

LS

3,600

3,900

Permissible axle loads andweights (kg)

A.1 71,00 7,100 7,100 7,100 7,100 7,100 7,100 7,100

A.2 11,500 11,500 11,500 11,500 11,500 11,500 11,500 11,500

Total 18,000 18,000 18,000 18,000 18,000 18,000 18,000 18,000

Permissible total gross weightof combination 40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000


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2 General

13


LS/NR

3,600

LSNRA

3,900

NRL

3,600

K

3,600

3,900

AK 3,600

3,900

(BM 93X) 18tVKB 1,832 1,836 1,841 1,844 1,846 1,850 1,854 1,858



Output kW/bhp 235/320 265/360 300/408 320/435 335/456 370/503 395/537 425/578

rpm 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800


rpm 1,080 1,080 1,080 1,080 1,080 1,080 1,080 1,080

Cab S(F07) short

M(F05) standard S S S S S S

L(F04) long

Mega (F15) S S


Wheelbase (mm) 4,500


A.1 71,00 7,100 7,100 7,100 7,100 7,100 7,100 7,100

A.2 11,500 11,500 11,500 11,500 11,500 11,500 11,500 11,500

Total 18,000 18,000 18,000 18,000 18,000 18,000 18,000 18,000

Permissible total gross weightof combination

40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000


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2 General

14


(BM 93X) 20tVKB 2,032 2,036 2,041 2,044 2,046 2,050 2,054

Engine type OM 501 LA OM 501 LA OM 501 LA OM 501 LA OM 501 LA OM 502 LA OM 502 LA

Number of cylinders V6 V6 V6 V6 V6 V8 V8

Output kW/bhp 235/320 265/360 300/408 320/435 335/456 370/503 395/537

rpm 1,800 1,800 1,800 1,800 1,800 1,800 1,800

Maximum torque Nm 1,700 1,850 2,050 2,100 2,200 2,400 2,500

rpm 1,080 1,080 1,080 1,080 1,080 1,080 1,080

Cab S(F07) short

M(F05) standard S S S S S S S

L(F04) long

Transmission G210-16 G210-16 G210-16 G240-16 G240-16 G240-16 G240-18

Wheelbase (mm)

4,500

4,800

5,100

S

3,600

3,900

AS

3,600

K

3,900

AK

3,900 A

4,500


A.1 7,500 7,500 7,500 7,500 7,500 7,500 7,500

A.2 13,000 13,000 13,000 13,000 13,000 13,000 13,000

Total 20,000 20,000 20,000 20,000 20,000 20,000 20,000


40,000 40,000 40,000 40,000 40,000 40,000 40,000


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2 General

16


(BM 93X) 26tVKB 2,632 2,636 2,641 2,644 2,646 2,650 2,654 2,658



Output kW/bhp 235/320 265/360 300/408 320/435 335/456 370/503 395/537 425/578

rpm 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800


rpm 1,080 1,080 1,080 1,080 1,080 1,080 1,080 1,080

Cab S(F07) short

M(F05) standard S S S S S S S S

L(F04) long

Mega (F15)


Wheelbase (mm) 6 x 4

4,200

4,500

5,100

L 6 x 4

4,200 4,500

4,800

S 6 x 4

3,300

LS 6 x 4

3,300

K 6 x 4

3,300

3,600

3,900

LK 6 x 4

3,300

B

3,300


A.1 7,100 7,100 7,100 7,100 7,100 7,100 7,100 7,100

A.2 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500

Total 26,000 25,000 26,000 25,000 26,000 25,000 26,000 25,000

Permissible total gross weight

of combination

40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000


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2 General

17


(BM 93X) 32tVKB 3,232 3,236 3,241 3,244 3,246

Engine type OM 501 LA OM 501 LA OM 501 LA OM 501 LA OM 501 LA

Number of cylinders V6 V6 V6 V6 V6

Output kW/bhp 235/320 265/360 300/408 320/435 335/456

rpm 1,800 1,800 1,800 1,800 1,800

Maximum torque Nm 1,700 1,850 2,050 2,100 2,200

rpm 1,080 1,080 1,080 1,080 1,080

Cab

M(F05) standard S S S S S

Transmission G210-16 G210-16 G210-16 G240-16 G240-16


5,400

K 8 x 4/4

4,200

4,500

5,100

8 x 6/4

4,500

B 8 x 4

4,200

4,500

5,100

K 8 x 8/4

4,800

Permissible axle loads andweights (kg) A.1 2x7,100 2x7,100 2x7,100 2x7,100 2x7,100A.2 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500

Total 32,000 32,000 32,000 32,000 32,000


40,000 40,000 40,000 40,000 40,000


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2 General

18


(BM 93X) 33tVKB 3,332 3,336 3,341 3,344 3,346 3,350 3,354 3,358



Output kW/bhp 235/320 265/360 300/408 320/435 335/456 370/503 395/537 425/578

rpm 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800


rpm 1,080 1,080 1,080 1,080 1,080 1,080 1,080 1,080

Cab

M(F05) standard S S S S S S S S

L(F04) long

Mega (F15)



4,200

4,500

S 6 x 4

3,300

K 6 x 4

3,300

3,600

3,900

B

3,300

3,600

3,900

6 x 6

4,200

4,500

S 6 x 6

3,600

K 6 x 6

3,600

3,900


A.1 7,500 7,500 7,500 7,500 7,500 7,500 7,500 7,500

A.2 2x13,000 2x913,000 2x13,000 2x13,000 2x13,000 2x13,000 2x13,000 2x13,000

Total 33,000 33,000 33,000 33,000 33,000 33,000 33,000 33,000


40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000


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2 General

20


(BM 94X) 18t 25tVKB 1,836 1,840 1,843 2,536 2,540 2,543

Engine type OM 457 LA OM 457 LA OM 457 LA OM 457 LA OM 457 LA OM 457 LA

Number of cylinders 6R 6R 6R 6R 6R 6R

Output kW/bhp 260/354 295/401 315/428 260/354 295/401 315/428

rpm 1,900 1,900 1,900 1,900 1,900 1,900

Maximum torque Nm 1,850 2,000 2,100 1,850 2,000 2,100

rpm 1,100 1,100 1,100 1,100 1,100 1,100

Cab

L(F04) long S S S S S S

F04+DD5

Transmission G221-9 G221-9 G221-9 G221-9 G221-9 G221-9

Wheelbase (mm) LS

3,600

3,900

L 6 x 2 4,500

4,800

5,100


A.1 7,100 7,100 7,100 7,100 7,100 7,100

A.2 11,500 11,500 11,500 7,100/11,500 7,100/11,500 7,100/11,500

Total 18,000 18,000 18,000 25,000 25,000 25,000


40,000 40,000 40,000 40,000 40,000 40,000


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2 General

21


(BM 94X) 26t 32tVKB 2,636 2,640 2,643 3,236 3,240 3,243

Engine type OM 457 LA OM 457 LA OM 457 LA OM 457 LA OM 457 LA OM 457 LA

Number of cylinders 6R 6R 6R 6R 6R 6R

Output kW/bhp 265/360 295/401 315/428 265/360 295/401 315/428

rpm 1,900 1,900 1,900 1,900 1,900 1,900

Maximum torque Nm 1,850 2,000 2,100 1,850 2,000 2,100

rpm 1,100 1,100 1,100 1,100 1,100 1,100

Cab

S(F07) short S S S S S S

M(F20) standard

L(F04) long

F04+DD5

Transmission G210-16 G210-16 G210-16 G210-16 G210-16 G210-16

Wheelbase (mm) K 6 x 4

3,600

3,900

B 6 x 4

3,600

3,900

K 8 x 4

4,200

4,500

5,100

B 8 x 4

4,200

4,500


A.1 7,100 7,100 7,100 2x7,100 2x7,100 2x7,100

A.2 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500 2x9,500

Total 26,000 26,000 26,000 32,000 32,000 32,000

Permissible total grosscombination weight (kg)

40,000 40,000 40,000 40,000 40,000 40,000


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2 General

22


(BM 95X) 18tVKB 1,823 1,828 1,833

Engine type OM 906 LA OM 906 LA OM 926 LA

Number of cylinders 6R 6R 6R

Output kW/bhp 170/231 205/279 240/326

rpm 2,200 2,200 2,200

Maximum torque Nm 810 1,100 1,300

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600

Cab S(F07) short S S S

M(F20) standard

L(F04) long

F04+DD5

Transmission G85-6 G100-12 G221-9

Wheelbase (mm)

3,900

4,200

4,500

4,800

5,100

5,400

5,700

6,000

6,300

L

3,900

4,200

4,500

4,800

5,100

5,400

5,700

6,000

6,300 NR

4,800

5,400

5,700

A

4,200

4,500

K

3,600

3,900


A.1 7,100 7,100 7,100

A.2 11,500 11,500 11,500

Total 18,000 18,000 18,000


28,000 36,000 36,000


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2 General

23



M(F20) standard

L(F04) long

F04+DD5


AK

3,600

3,900

LS

3600

(BM 95X) 18tVKB 1,823 1,828 1,833



Output kW/bhp 170/231 205/279 240/326

rpm 2,200 2,200 2,200

Maximum torque Nm 810 1,100 1,300

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600


A.1 7,100 7,100 7,100

A.2 11,500 11,500 11,500

Total 18,000 18,000 18,000


28,000 36,000 36,000


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2 General

24


(BM 95X) 25t 26tVKB 2,523 2,528 2,533 2,628 2,633


Number of cylinders 6R 6R 6R 6R 6R

Output kW/bhp 170/231 205/279 240/326 205/279 240/326

rpm 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 810 1,100 1,300 1,100 1,300

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600

Cab S(F07) short S S S S S

M(F20) standard

L(F04) long

F04+DD5

Transmission G100-12 G100-12 G221-9 G100-12 G221-9


4,200

4,500

4,800

5,100

L 6 x 2/4

3,150

3,450

3,750

4,050

L/ NR 6 x 2

4,500

4,800

6 x 4

4,200

4,500

B 6 x 4

3,300

3,900

K 6 x 4

3,300

3,600

3,900


A.1 7,100 7,100 7,100 7,100 7,100

A.2 7,100 11,500 11,500 9,500 9,500

A.3 11,500 7,100 7,100 9,500 9,500

Total 25,000 25,000 25,000 2,600 2,600


32,000 36,000 36,000 40,000 40,000


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2 General

25


(BM 97X) 6.5t 7.49t 8.0tVKB 712 715 812 815 818 815 818 823


Number of cylinders 4R 4R 4R 4R 4R 4R 4R 6R

Output kW/bhp 90/122 110/150 90/122 110/150 130/177 110/150 130/177 170/231

rpm 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 470 580 470 580 675 580 675 810

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600

Cab S(F07) short S S S S S S S S

M(F20) standard

L(F04) long

F04+DD5


Wheelbase (mm)

3,020

3,320

3,620

4,220

4,820

L

3,020

3,320

3,620

4,220

4,820

A

3,020

3,260

K

3,020

3,320

KK

3,320

AK

3,260


A.1 2,900 2,900 3,200 3,200 3,200 3,400 3,400 3,400

A.2 3,800 3,800 4,600 4,600 4,600 5,000 5,000 5,000

Total 6,500 6,500 7,490 7,490 7,490 8,000 8,000 8,000

Permissible total gross weightof combination 13,000 13,000 13,000 18,000 18,000 18,000 20,000 20,000


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2 General

26


(BM 97X) 9.5t 10.5t 12t m. R.VKB 915 918 923 1,015 1,018 1,023 1,215 1,218 1,223

Engine type OM 904 LA OM 904 LA OM 904 LA OM 904 LA OM 904 LA OM 906 LA OM 904 LA OM 904 LA OM 906 LA

Number of cylinders 4R 4R 4R 4R 4R 6R 4R 4R 6R

Output kW/bhp 110/150 130/177 170/231 110/150 130/177 170/231 110/150 130/177 170/231

rpm 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 580 675 810 580 675 810 580 675 810

rpm 1,200 – 1 ,600 1,200 – 1 ,600 1 ,200 – 1,600 1 ,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1 ,600 1 ,200 – 1,600

Cab S(F07) short S S S S S S S S S

M(F20) standard

L(F04) long

F04+DD5

Transmission G56-6 G56-6 G85-6 G60-6 G60-6 G85-6 G56-6 G60-6 G85-6

Wheelbase (mm)

3,020

3,320

3,620

3,560

4,160 4,220

4,760

4,820

5,360

L

3,020

3,320

3,620

3,560

4,160

4,220

4,760

4,820

5,360

A

3,020

3,260

K

3,020

3,320


A.1 3,800 3,800 3,800 4,300 4,300 4,300 4,400 4,400 4,400

A.2 6,200 6,200 6,200 6,700 6,700 6,700 8,100 8,100 8,100

Total 9,500 9,500 9,500 10,500 10,500 10,500 11,990 11,990 11,990


13,000 13,000 22,000 18,000 22,000 24,000 15,500 15,500 15,500


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2 General

27


Cab S(F07) short S S S S S S S S S

M(F20) standard

L(F04) long

F04+DD5

Transmission G56-6 G56-6 G85-6 G60-6 G60-6 G85-6 G56-6 G60-6 G85-6

KK

3,320

AK

3,260

(BM 97X) 9.5t 10.5t 12t m. R.VKB 915 918 923 1,015 1,018 1,023 1,215 1,218 1,223

Engine type OM 904 LA OM 904 LA OM 904 LA OM 904 LA OM 904 LA OM 906 LA OM 904 LA OM 904 LA OM 906 LA

Number of cylinders 4R 4R 4R 4R 4R 6R 4R 4R 6R

Output kW/bhp 110/150 130/177 170/231 110/150 130/177 170/231 110/150 130/177 170/231

rpm 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 580 675 810 580 675 810 580 675 810

rpm 1,200 – 1 ,600 1,200 – 1 ,600 1 ,200 – 1,600 1 ,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1 ,600 1 ,200 – 1,600


A.1 3,800 3,800 3,800 4,300 4,300 4,300 4,400 4,400 4,400

A.2 6,200 6,200 6,200 6,700 6,700 6,700 8,100 8,100 8,100

Total 9,500 9,500 9,500 10,500 10,500 10,500 11,990 11,990 11,990


13,000 13,000 22,000 18,000 22,000 24,000 15,500 15,500 15,500


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2 General

28


(BM 97X) 12t 13.5tVKB 1,215 1,218 1,223 1,228 1,318 1,323 1,328


Number of cylinders 4R 4R 6R 6R 4R 6R 6R

Output kW/bhp 110/150 130/177 170/231 205/279 130/177 170/231 205/279

rpm 2,200 2,200 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 580 675 810 1,100 675 810 1,100

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600

Cab S(F07) short S S S S S S S

M(F20) standard

L(F04) long

F04+DD5


Wheelbase (mm)

3,560

4,160

4,760

5,360

5,960

6,260

L

3,560

4,160

4,760

5,360

3,260

A

3,560

K

3,260

KK

3,560

AK

3,260


A.1 4,400 4,400 4,400 4,400 5,000 5,000 5,000

A.2 8,100 8,100 8,100 8,100 9,000 9,000 9,000

Total 11,900 11,900 11,900 11,900 13,500 13,500 13,500


15,500 22,000 24,000 28,000 22,000 22,000 28,000


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2 General

29


LS

3260

3560

(BM 97X) 12t 13.5tVKB 1,215 1,218 1,223 1,228 1,318 1,323 1,328


Number of cylinders 4R 4R 6R 6R 4R 6R 6R

Output kW/bhp 110/150 130/177 170/231 205/279 130/177 170/231 205/279

rpm 2,200 2,200 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 580 675 810 1,100 675 810 1,100

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600

Cab S(F07) short S S S S S S S

M(F20) standard

L(F04) long

F04+DD5



A.1 4,400 4,400 4,400 4,400 5,000 5,000 5,000

A.2 8,100 8,100 8,100 8,100 9,000 9,000 9,000

Total 11,900 11,900 11,900 11,900 13,500 13,500 13,500Permissible total gross weightof combination

15,500 22,000 24,000 28,000 22,000 22,000 28,000


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2 General

30


(BM 97X) 15tVKB 1,518 1,523 1,528



Output kW/bhp 130/177 170/231 205/279

rpm 2,200 2,200 2,200

Maximum torque Nm 675 810 1,100

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600


M(F20) standard

L(F04) long

F04+DD5


Wheelbase (mm)

3,560

4,160

4,760

5,360

5,960

6,260

L

3,560

4,160

4,760

5,360

3,260

A

3,560

K

3,260

KK

3,560

AK

3,260

LS

3,260

3,560


A.1 5,100 5,100 5,100

A.2 10,500 10,500 10,500

Total 15,000 15,000 15,000


22,000 28,000 34,000


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2 General

31


(BM 957) 18t 26tVKB 1823 1828 1833 2628 2633


Number of cylinders 6R 6R 6R 6R 6R

Output kW/bhp 170/231 205/279 240/326 205/279 240/326

rpm 2,200 2,200 2,200 2,200 2,200

Maximum torque Nm 810 1,100 1,300 1,100 1,300

rpm 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600 1,200 – 1,600

Cab

FH7 S S S S S

FH8

Transmission MD 3,060 MD 3,060 MD 3,066 MD 3,060 MD 3,066

Wheelbase (mm) DNA 4 x 2

3,900

4,200

4,500

L/NLA 6 x 2/4

3,900

4,200

4,500

4,800

L/VLA 6 x 2/4

3,150

3,450

3,900

4,200

LL 6 x 4

3,900

4,200

Permissible axle loads andweights (kg) LL 4 x 2 A.1 7,100 7,100 7,100A.2 11,500 11,500 11,500

Total 18,000 18,000 18,000


36,000 36,000

Permissible axle loads andweights (kg) L/NLA 6 x 2/4

A.1 7,100 7,100

A.2 11,500/7,100 11,500/7,100

A.3 25,700 25,700


36,000 36,000

Permissible axle loads andweights (kg) L/VLA 6 x 2/4

A.1 7,100 7,100

A.2 7,100/11,500 7,100/11,500

A.3 25,700 25,700


36,000 36,000

Permissible axle loads andweights (kg) LL 6 x 4

A.1 7,500 7,500

A.2 9,500/9,500 9,500/9,500

A.3 26,000 26,000

36,000 36,000



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LegendVKB Sales designation

S Standard

Available

Example of transmis-sion designation

G 211-16 G = Transmission211 = Maximum input torque (x10 in Nm)16 = Number of gear speeds

A All-wheel-drive platform truck

AK All-wheel-drive tipper vehicle

AS All-wheel-drive semitrailer tractor vehicle

B Cement mixer vehicle

K Tipper vehicle

L Air-sprung platform truck

LK Air-sprung tipping vehicle

LS Air-sprung semitrailer tractor vehicle

LL Fully air-sprung vehicle

LS/ NR Air-sprung semitrailer tractor vehicle/ low frame

KK Crane-tipper vehicleS Semitrailer tractor vehicle

NR Low frame

NRA Low frame/Car transporter

NRL Low frame/Lowliner

DNA Twin-tyred trailing axle

NLA Trailing axle

VLA Leading axle

A.1 1st axle

A.2 2nd axle

A.3 3rd axle

Total Total

Wheel formulae

4 x 2 Two-axle vehicle with driven rear axle

4 x 4 Two-axle vehicle with all-wheel-drive

6 x 4 Three-axle vehicle with two driven rear axles

6 x 6 Three-axle vehicle with all-wheel-drive

6 x 2 DNA 3-axle vehicle with driven rear axle and a twin- tyred trai ling axle

6 x 2 NLA Rear axle and second rear axle as rigid trailing axle

6 x 2/4 NLA 3-axle vehicle with a driven rear axle and a second rear axle as steered trailing axle

6 x 2/4 VLA 3-axle vehicle with a driven rear axle and a second rear axle

6 x 2/2 VLA 3-axle vehicle with a driven rear axle and a second rear axle

8 x 4 / 4 4-axle vehicle with two driven rear axles and two steered front axles

8 x 6/4 4-axle vehicle with two driven rear axles and two steered front axles, of which the fi rst front axle is driven

8 x 8 /4 4-axle vehicle with all-wheel-drive and two steered front axles


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2.2 Technical advice and contacts

2.2 Technical advice and contacts

The staff members of the TPC/MVC department, theteam responsible for conversion/body manufacturersand the body/equipment mounting directives for theoverall vehicle development of Mercedes-Benz trucks,

issue certificates of endorsement for the Mercedes-Benz

Actros, Axor, Atego and Econic series and answer tech-nical and design-engineering questions regarding vehi-cle registration and product liability. The relevantmembers of staff can be contacted on:

If you have questions, suggestions or criticisms regarding these body/equipment mounting directives, you can contactthe Conversions & Body Manufacturers team; Body/ Equipment Mounting Directives, at the e-mail address shown on ourwebsite:

http:/ / abh-infoportal.mercedes-benz.com

http:/ / bb-infoportal.mercedes-benz.com

Telephone: 0711-17-5 82 11 Atego (BM 97X)Fire brigade (all trucks)

0711-17-5 44 150711-17-5 84 25

Actros (BM 93X), Axor (BM 94X and 95X)Econic

0711-17-5 17 19 Team management and basic questions on all series

Fax: 0711-17-5 21 91

Postaladdress:

DaimlerChrysler AG

HPC (Hauspostcode) C 108

Abteilung TPC/ MVHD-70546 Stuttgart, Germany


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2.3 Issuing certificates of endorsement

2.3.2 Documents required

In particular cases, the body drawings may be presentedto the responsible department before the work is com-menced ( page 33). The drawings must contain the fol-lowing information:

All deviations from the Mercedes-Benz body/equipment mounting directives

Complete data on dimensions, weights and centre ofgravity (weight certificates)

Body mounting to the vehicle

Conditions of vehicle operation, e.g.

on poor roads

in very dusty conditions

at high altitude

at extremely high or low ambient temperatures Certification (e-mark, seat tensile strength test, etc.)

Submitting the required documentation in full will makequeries on our part unnecessary and will speed upprocessing.

If complex calculations and/or vehicle tests are re-quired for the endorsement, the resulting costs must beborne by the company carrying out the conversion ormanufacturing the body, or by this company's customer.The relevant department of Mercedes-Benz Truck Devel-opment will determine the scope of the testing required

( page 33).

2.3.3 Legal claim

No legal claim to the issue of a certificate of endorse-ment can be made.

DaimlerChrysler AG reserves the right to refuse togrant a certificate of endorsement if ongoing techni-

cal development and the knowledge gained from itrender such a refusal necessary, even if a similar cer-tificate was granted in the past.

The certificate of endorsement may be limited to sin-gle vehicles.

The retroactive granting of a certificate of endorse-ment for vehicles already completed or delivered canbe refused.

The body manufacturer alone is responsible for:

the functionality and compatibility of the body and

its equipment, fittings and conversion with the basicvehicle

operating and road safety

all attachments, bodies, equipment or modificationsand fitted parts.


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2.4 Product liability

2.4 Product liability

Legal product liability is the liability of a manufacturer forany consequential damage arising to the user of theproduct or a third party and caused by the product notpossessing the degree of operating safety which the in-

jured party can reasonably expect.With regard to product liability, attention is drawn to thefollowing points:

Each manufacturer is liable for the products it manufac-tures. As manufacturer of Mercedes-Benz vehicles,DaimlerChrysler AG is accordingly only liable for its owndesigns and products.

DaimlerChrysler AG does not therefore accept any liabil-ity for damage resulting from defects in retrofitted prod-ucts produced by third-party manufacturers.

The vehicle body manufacturer/modifier shall bear soleresponsibility for:

the operating and road safety of the body

the operating and road safety of parts and conver-sion parts

testing and maintaining the operating and road safe-ty of the entire vehicle after assembly (handling,braking and steering characteristics must not be ad-versely affected by assembly)

the effects of parts or conversion parts on the chas-sis

consequential damage resulting from the attach-ment, special-purpose body, installation or conver-sion

consequential damage resulting from retrofittedelectrical and electronic systems

operating safety and freedom of movement of allmoving parts of the chassis after the bodywork con-version (e.g. axles, springs, propeller shafts, steer-ing, transmission linkage, etc.) even in the case ofdiagonal torsion with respect to the add-on equip-ment.

Work carried out on or modifications made to the chas-sis or bodywork must be entered in the "Confirmationsby the body manufacturer" section of the MaintenanceBooklet.

2.4.1 Ensuring traceability

Dangers caused by your equipment/ attachment, andwhich are not detected until after delivery may requireaction in the country of delivery (customer information,warning, recall). In order for such measures to be as ef-

fective as possible, it must be ensured that theequipment/ attachment produced by you can be tracedafter delivery.

In order to ensure the above, and in order to be able touse the Central Vehicle Register (ZFZR) of the GermanFederal Bureau of Motor Vehicles and Drivers or similaroffices in other countries to determine the owners con-cerned, we strongly recommend that you record the se-rial number/ identification number of your equipment/attachment together with the associated vehicle identi-fication number in your databases. To this end, it is alsoadvisable to store the addresses of your customers andto make provisions for subsequent purchasers to be ableto register.


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2.5 Warranty claims

2.5 Warranty claims

Warranty claims can only be made within the frameworkof the contract of sale between purchaser and seller.

This means that each seller is liable to the purchaser forthe items supplied by the former to the latter.

In the following cases in particular, DaimlerChrysler AGwill assume no liability:

if the vehicle used does not correspond to the equip-ment version for the country in question and field ofoperation

for damage caused by the body itself or the mannerin which it is mounted.


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2.6 Body manufacturer information portal

2.6.2 MBAS Web (Mercedes-Benz body/equipment manufacturer system) andorder data

The MBAS Web area will help you select a vehicle suita-ble for your customer from more than 10,000 lorry chas-

sis and vehicle versions. Clearly structured filters let youchoose your vehicle with a few mouse clicks. Once youhave selected a vehicle, all relevant technical data andinformation are provided.

Available online in the MBAS Web:

True-to-scale CAD drawings in DXF or PDF format,with approximately 100 dimension specifications

Configurator for individual tender drawings with themost important combinations of optional equipment(tank, exhaust, air intake, cab and back frame over-hang) in PDF and DXF formats

Simplified rough tender drawings (vignettes) in fourviews (side view, top view, back and front view) con-taining the most important main measurements inDXF format

Technical data sheets, engine diagrams, optionalequipment weights

Body/equipment mounting directives for lorries andtransporters in up to 11 languages

Body/equipment mounting directive archive for alllorry series since 1995

Power take-off drawing in installation position in PDFand DXF formats

Equipment of Mercedes-Benz commercial vehicles:code, short descriptions and technical details of thecomplete host of equipment (incl. CTT host)

Body/equipment manufacturer information: archivefor newsletters on changes made to Mercedes-BenzCV that are relevant to body/equipment manufac-turers

Catalogue of electronic and mechanical interface

parts for Mercedes-Benz CV

In "My portal" – "My order data" you can call up the de-livery date, the automatically generated chassis drawingand the vehicle configuration for an order by using theMercedes-Benz order data.

2.6.3 Partnership and contact options

Short direct paths are an important factor in successfulcollaboration. This is why our portal offers several waysto contact us:

Our body manufacturer information portal has an inte-grated mail response system, which has a contact formyou can use at any time to send enquiries to us. The sys-tem ensures that your questions are forwarded to theright contact, who then answers them quickly and com-petently.

Our contact persons database enables you to find a con-

tact at our company from whichever area of expertise isrequired, and to contact that person by telephone, e-mail or post.

There is also a hotline that can answer questions aboutthe portal:

Telephone: +49-(0)711-17-33322

E-mail: [email protected]

[email protected]


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2.7 Workshop Information System (WIS)

2.7 Workshop Information System (WIS)

The Workshop Information System (WIS) is available toyou as an additional source of information. The WIS in-cludes information on basic data (dimensions, tighteningtorques), function descriptions, circuit diagrams, repair

instructions and maintenance sheets.Information about the WIS can be obtained from anyMercedes-Benz Service Centre or from:

Telephone: +49 (0)711-17-83170

Fax: +49 (0)711-17- 40082

Postal address: DaimlerChrysler AG

HPC (Hauspostcode) R800

Abteilung GSP/TIM,

D-70546 Stuttgart, Germany


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2.8 Mercedes star and logo

2.8 Mercedes star and logo

The Mercedes star and Mercedes-Benz logo are trade-marks of DaimlerChrysler AG.

They may not be removed or attached to another pointwithout approval.

Mercedes-Benz stars and Mercedes-Benz logos suppliedseparately must be attached at the points specified byMercedes-Benz.

Vehicle rear end positions

The Mercedes-Benz logo must be attached on the rear ofthe vehicle at the bottom right when viewed in the direc-tion of travel.

Appearance of the entire vehicle

If the vehicle fails to comply with the vehicle image andthe quality standards required by Mercedes-Benz, thetrademarks such as the Mercedes star and theMercedes-Benz emblem must be removed.

Third-party trademarks

may not be affixed next to Mercedes-Benz trade-marks

may only be affixed to other points on the vehiclewith permission from the relevant department ofDaimlerChrysler AG ( page 33)


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2.9 Reprocessing components – recycling

2.9 Reprocessing components – recycling

Materials with risk potential, such as halogen additives,

heavy metals, asbestos, CFCs and CHCs are to be avoid-ed.

It is preferable to use materials which permit recy-cling and closed material cycles.

Materials and production processes that generateonly low quantities of waste during production mustbe selected such that this waste can be easily recy-cled.

Plastics are to be used only where they provide ad-vantages in terms of cost, function or weight.

In the case of plastics, and composite materials inparticular, only compatible substances within onematerial family are to be used.

For components which are relevant to recycling, thenumber of different types of plastics used must bekept to a minimum.

It must be assessed whether a component can bemade from recycled material or admits the additionof recycled components.

Ensure that all recyclable components can be easily

dismantled for recycling purposes, e.g. using snapconnections, pre-weakened points, that they areeasily accessible, and that their dismantling only re-quires the use of standard tools.

It must be ensured that service products can be re-moved simply and in an environmentally-compatiblemanner by means of drain plugs, etc.

Painting and coating components are to be avoidedwherever possible; coloured plastic parts should be

used instead. Components in areas at risk from accidents must be

designed in such a way that they are damage-toler-ant, repairable and easy to replace.

All plastic parts are to be marked in accordance withVDA code of practice 260, e.g. "PP – GF30R".

EU Directive 2000/53/EC must be complied with.

Environmental note H

When planning attachments, bodies, equipment and

modifications, the following principles for environ-mentally-compatible design and material selectionshall be taken into account, in particular with regardto EU Directive 2000/ 53/ EC.

iAdditional information is provided in the "Commercialvehicle recycling, ecology and economy" brochure,Order no. 6702 6187 00-00/ 0952 ( page 38).


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2.10 Quality assurance system

2.10 Quality assurance system

Worldwide competition, increasingly stringent quality re-quirements of the entire product by customers, nationaland international product liability laws, new forms of or-ganisation and increasing cost pressures require effec-

tive quality assurance systems in all areas of theautomotive industry.

To be able to meet these requirements, a working groupof the VDA (Association of German Automobile Manufac-turers) has developed a "Guide to quality assurance forthe manufacturers of trailers, bodies and containers" asVDA volume 8, based on DIN EN ISO 9000 ff.

For the above reasons, DaimlerChrysler AG strongly rec-ommends that body manufacturers set up a quality man-agement system with the following minimumrequirements:

Does the quality management system clearly deter-mine responsibility and authority?

Is there a description of processes/ workflows?

Are the contracts checked/ is the feasibility of con-struction checked?

Are product checks on the basis of specified instruc-tions carried out?

What provisions are made for the handling of faultyproducts?

Are the inspection results documented and ar-

chived?

Do all employees concerned have currently validproof of the qualification required?

Is the test equipment systematically monitored?

Is there a system for labelling materials/parts?

Are quality assurance measures carried out at sup-pliers?


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3.1 Selecting the chassis


! Always print out complete sections from the current version.44

3 Planning of bodies

3.1 Selecting the chassis

In order to ensure safe operation of the vehicle it is es-sential to choose the chassis and its equipment carefullyin accordance with the intended use.

Mercedes-Benz provides special vehicle versions andwheelbases for different areas of operation.

A All-wheel-drive platform truck

AF All-wheel-drive fire engine

AK All-wheel-drive tipper vehicle

AS All-wheel-drive semitrailer tractor vehicle

B Cement mixer vehicle

F Fire engine

K Tipper vehicle

L Air-sprung platform truck

LK Air-sprung tipper vehicle

LS Air-sprung semitrailer tractor vehicle

LS/NR Air-sprung semitrailer tractor vehicle, lowframe

KK Crane /tipper vehicle

S Semitrailer tractor vehicle

NR Low frame

NRA Low frame, car transporter

NRL Low frame, Lowliner

As well as selecting the correct vehicle version, the nec-essary standard and optional equipment in particular,such as:

wheelbase

engine/transmission

power take-off

axle ratio

position of the centre of gravity

legal registration specifications(e.g. underride guard)

permissible and technical gross vehicle weight

should be taken into consideration when planning andbe adequate for the intended use.

!When planning attachments, bodies, equipment ormodification work, the selected vehicle must bechecked to verify whether it fulfils the necessary re-quirements.

!Observe the weight code. An axle designation or its

load-bearing capacity specification only has limitedsignificance for the gross vehicle weight.

iIf a certain vehicle version is not l isted this may meanit is not suitable for the intended purpose.

For more information on the chassis and body vari-ants available:

see the Internet at the following address:http://bb-infoportal.mercedes-benz.com

see Section 2 "Vehicle and model designations"( page 11) or

contact the department responsible ( page 33)


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3.2 Vehicle modifications

3.2 Vehicle modifications

All vehicles delivered from the factory comply with EC di-rectives and national regulations (except for some vehi-

cles for non-European countries).The vehicles must still comply with EC directives or na-tional regulations after modifications have been carriedout.

At the time of vehicle approval, the body manufacturermust inform the officially recognised technical expert orinspector of any modifications to the chassis. Submit acertificate of endorsement from DaimlerChrysler AG(e.g. drawing marked as approved) or the applicablebody/ equipment mounting directive if required.

Whenever any kind of work on the brake system is car-ried out, i.e. even if the work only consists of the removalof parts, a full check (operation, effectiveness and visual)of the entire brake system must be carried out.

Risk of accident G

Do not make any modifications to assemblies (steer-

ing, brake systems, etc.). Modifications to the steer-ing or brake systems could result in these systems nolonger functioning correctly and failing. The drivercould lose control of the vehicle as a result and causean accident.

Modifications to the basic vehicle are only permittedwithin the scopes defined in these body/equipmentmounting directives.


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3.3 Dimensions, weights and total vehicle height

3.3 Dimensions, weights and total vehicleheight

Dimensions and weights are specified in the tenderdrawings and Technical data. These are based on thestandard vehicle equipment. Observe the weight toler-ances of +5 % in manufacture (in the Federal Republic ofGermany, in accordance with DIN 70020).

Do not exceed the permissible axle loads and gross ve-hicle weights listed in the Technical data.

For the technical data, see the vehicle documents, thevehicle identification plate or the code descriptions(codes for weights start with T) of the order data.

3.3.1 Observing the permissible total vehicleheight (large volume transporters)

On vehicles with a low frame height and pneumatic sus-pension (large volume transporters), it is possible to seta raised driving position to improve ride comfort. This is

indicated by an appropriate display on the instrumentpanel.

Observe the permissible total vehicle height and maxi-mum headroom information.

Risk of accident G

The tyre load-bearing capacity of the vehicle must notbe exceeded by overloading the vehicle above thespecified gross vehicle weight. The tyres could over-heat and be damaged. You could thus lose control ofthe vehicle and cause an accident, injuring yourself orothers.Data about the permissible axle loads can be found onthe vehicle identification plate.

Take legal regulations regarding the permissible vehi-cle height into consideration when planning bodies. Inthe Federal Republic of Germany, the permissible ve-

hicle height is restricted to 4 m. For operation in othercountries, the national legislation of the countriesconcerned must be observed (also when the vehicle isused for international transport). Observe the Operat-ing Instructions.

iInformation about changes in weight is available fromthe department responsible ( page 33).


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3.4 Tyres

3.4 Tyres

The body/ equipment manufacturer must ensure that:

the largest permissible tyres can be fitted

the distance between the tyre and the mudguard orwheel housing is sufficient even when snow or anti-skid chains are fitted, with the suspension fully com-pressed (including any twist) (in accordance with theapplicable regulations)

specifications in the tender drawings are observed

If the option of fitting snow and anti-skid chains cannotbe guaranteed, the operator should be informed by thebody manufacturer (Operating Instructions).

Risk of accident G

On vehicles with a Telligent® brake system (BS), the

brake system parameters must be reconfigured if thetyre size is changed. The vehicle's braking and han-dling characteristics could otherwise be affected.

iYou can obtain tender drawings and technical datafrom the Mercedes-Benz body/equipment manufac-turer system MB-AS) ( page 38).


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3.5 Bolted and welded connections

3.5 Bolted and welded connections 3.5.1 Bolted connections

If it is necessary to replace standard bolts with longerbolts, only bolts

of the same diameter

of the same strength grade

of the same type

with the same thread pitch must be used.

VDI guideline 2862 must be applied to all installationwork.

A shortening of the free length of the clamping bolts,a substitution with stretch-shank bolts or the use ofbolts with a shorter thread will definitely not be ap-proved.

If bolts have been tightened to a specific torque andangle by Mercedes-Benz, a design modification willnot be possible.

The settling characteristics of bolted connectionsmust be taken into account.

Additional tensioned parts must be of equal or greaterstrength than the preceding tensioned assembly.

The use of Mercedes-Benz tightening torques assumescoefficients of friction for the bolts within the tolerancerange [=0.08 – 0.14].

Mercedes-Benz recommends that you useMercedes-Benz standard parts.

Risk of accident G

All bolt connections relevant to safety, e.g. for wheel

location, steering and braking functions, must not bealtered.

If bolted connections need to be loosened, make surethat bolted connections of the same characteristicsas the original ones are established once again aftercompletion of work.

Welding work on the chassis/bodywork may only becarried out by qualified personnel.

The assemblies fitted during installation, bodywork,assembly or conversion must comply with all applica-ble laws and directives, with the rules for accidentprevention and occupational health and safety as wellas the safety rules and bulletins issued by accident in-surers.

iFor further information on bolted and welded connec-tions, see Section 5 "Damage prevention"( page 85) and Section 6 "Modifications to the ba-sic vehicle" ( page 100) and the Mercedes-Benzworkshop information system (WIS) ( page 40).


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3.5 Bolted and welded connections

Flange head bolts

The use of flange head bolts means that the bolted con-nections on the chassis of Mercedes-Benz commercialvehicles are maintenance-free, i.e. it is not necessary toretighten the bolts as

Truck Body Mounting Directives 01-09-2006

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Transcript of Truck Body Mounting Directives 01-09-2006