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Introduction of the New Truck Generation The New Antos (Model 963)
Introduction into Service Manual
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Mercedes-Benz Service
Introduction of the New Truck Generation The New Antos (Model 963)
Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart
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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: customer.support@daimler.com Fax: +49-(0)18 05/0 10-79 78
© 2012 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: W00.00-1059-00 Order no. of this publication: 6517 1263 02 – HLI 000 000 08 94 06/12
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Contents
Preface
7
Overview New features/modifications
8
Overall vehicle LOADER product group Equipment
12 15
Drive Engine OM 936 Engine OM 470 Technical data Engine air intake Engine power take-off Exhaust system
18 20 22 25 26 28
Transmission Transmission data Transmission modes Power take-off
30 35 37
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Contents
Chassis Frame Fifth wheel coupling Axles Wheels and tires Steering Fuel tank
38 40 41 43 45 46
Design Cab Center seat Beds and bunks Instrument panel
48 54 55 57
Networking Overall network Parameterizable Special Module
58 62
Lights Exterior lights
64
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Contents
Safety Active Brake Assist 3 Attention Assist
65 67
Assistance systems Integrated Predictive Powertrain Control FleetBoard® EcoSupport
68 70
Special tool Engine OM 936 Engine OM 470 Transmission G 140-8 Model 963
71 82 86 87
Annex Abbreviations Index
88 91
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Notes
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Preface
Dear Reader, This Introduction into Service Manual presents the new Antos (model 963) for heavy distribution haulage over 18 t as well as new features of the Actros (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 Introduction into Service Manual is on presenting new and modified components and systems. All of the data in this brochure correspond to the technical status as of the copy deadline in June 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 June 2012
i Note
All of the information and messages of the multifunction display are shown in German because the corresponding versions in other languages were not available at the copy deadline.
i Note
Information about the vehicles and about operating 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 available in digital form as a PDF in SDmedia.
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Overview
New features/modifications
General
In October 2012, one year after the launch of the new Actros, the Axor, which is primarily used for distribution haulage, is being replaced by the new Antos. The new vehicles for heavy distribution traffic as of 18 t have the same model designation as the new Actros but differ from it through their short S cabs and medium-length M cabs with engine tunnel and new front end design. Other features of the distribution vehicles include a low, step-type entrance. All distribution vehicles are equipped with the Mercedes PowerShift 3 transmission as standard and an air-sprung rear axle. The vehicle interior features a new color concept. The interior trim and surfaces on the driver side of the cockpit are black, while the rest of the interior is flannel gray. The LOADER product group (PG) is being introduced at the same time, both for long-haul and distribution vehicles. The LOADER product group incorporates various weight-optimized standard and special equipment items developed exclusively for these vehicles. Accordingly, the LOADER product group is particularly suited to customers who have a strong focus on payload. In the VOLUMER product group, the Antos provides the ideal conditions for economical large-volume transport with its particularly low frame and coupling point height. The unobstructed loading height of up to 3 m, the full range of wheelbases, frame overhangs which can be selected ex factory and the application-optimized drivetrain configurations also ensure high efficiency.
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W00.10-1176-00
The New Antos A Semitrailer tractor with S cab, air intake behind cab, fitted on (M8B) B Platform vehicle with M cab, front air intake (M8A)
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Overview
9
New features/modifications
Overview
New features/modifications
Distribution haulage
• The New Antos with its independent design is distinguished from the long-haul model series by its short S cabs and medium-length M cabs. • Newly designed entrance for easier access to cab • Engine OM 936 with 7.7 l displacement in five power categories (175, 200, 220, 235 and 260 kW) • New automated manual transmission G140-8 • Sturdy steel corners in bumpers (SA) • 6x2 semitrailer tractors (SZF) with 17.5" rims and leading axle (VLA) • Optimized dash support for variant with center seat for generous legroom in center seat
Distribution haulage/long-distance haulage
• Engine OM 470 with 10.7 l displacement in four power categories (240, 265, 290 and 315 kW) • New automated manual transmissions G230-12 and G280-16 • 6x2 platform vehicles and semitrailer tractors with single and dual-tired trailing axle (NLA) • Vehicles with swap body frame ex factory with ground clearance of 1120 and 1320 mm • Defined clearances on frame managed by codes e.g. for swap body frame or crane support feet • Attention Assist (S1L) detects any increase in driver fatigue based on the activity of the driver and shows corresponding messages on the multifunction display • Predictive Powertrain Control (G0T) for particularly fuel-efficient driving operation • Active Brake Assist 3 (S1M) • 6x4 platform vehicles and semitrailer tractors with an extended wheelbase range • LOADER product group, consisting of selected models with specially weight-optimized standard equipment
Long-distance haulage
• New cabs with a width of 2.30 m in standard roof, flat roof and Aero roof versions • 4x2 car transporters as platform vehicles and semitrailer tractors with lowered L cab with flat roof
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The following table shows the models for distribution and long-distance haulage newly available as of October 2012 with their possible wheelbases:
Wheelbase C1W C1N C1Q C3H C2U C1G C3K C2C C3B C2P C3P C1Y C2L C1J Code Model designation Platform 18 t 18 t 4x2 L nRA Platform 25 t 25 t 6x2 L DNA Platform 26 t 26 t 6x4 L Semitrailer tractor 18 t 18 t 4x2 LS nRA Semitrailer tractor 24 t 24 t 6x2/2 LS VLA 17.5" Semitrailer tractor 25 t 25 t 6x2 LS ENA 25 t 6x2 LS DNA Semitrailer tractor 26 t 26 t 6x4 LS S Standard 963.424 X Special equipment — S X X — — X — — — — — — — 963.420 963.425 — — S S X X X X — — — — — — — — — — — — — — — — — — — — 963.427 S — — — — — — — — — — — — — 963.405 — — — — — S — — — — — — — — 963.024 — — — — S — X X X X X X X — 963.025 — — — — — — S X X X X X X X 963.005 — — — — — — — — — — — S X — [mm]
2,990
3,250
3,400
3,550
3,700
3,850
4,000
4,300
4,600
4,900
5,200
5,500
5,800
- not available
L LS DNA ENA VLA nRA
Air-sprung platform vehicle Air-sprung semitrailer tractor Twin-tired trailing axle Single-tired trailing axle Leading axle Low frame/car transporter
6,100
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Overview
New features/modifications
Overall vehicle
LOADER product group
With the new Antos, the LOADER (V1Y) product group (PG) is also being introduced. The PG LOADER is available both for the Antos and for the Actros and incorporates various weight-optimized standard and special equipment items developed exclusively for this product group. All LOADER equipment has been specially developed for the requirements of customers who have a particular focus on payload. The following vehicles are available as LOADER models as of October 2012: • • • • • 4x2 L, model 963.003 6x2 L, model 963.020 4x2 LS, model 963.403 6x2/2 LS VLA 22.5", model 963.423 6x2/2 LS VLA 17.5", model 963.427 The PG LOADER contains the following equipment items, among others: • Aluminum rims, aluminum fuel tank, aluminum underride guard and aluminum compressed air reservoirs as standard equipment • 140 Ah battery (exclusively for LOADER vehicles) • Thinner windows, no roof hatch as standard, uncontrolled coolant pump, thinner cab floor, thinner end crossmember • Single-leaf front springs • The optimized rear axle guide is omitted on 4x2 vehicles. 13 kg of weight is saved on the closed wishbone control arms • LOADER vehicles have particularly light tires (supersingle) as standard Steel fuel tanks and steel rims are not available, nor is the larger OM 471 engine. Furthermore, some equipment used to lower fuel consumption on standard vehicles is omitted (aerodynamic underfloor paneling and radiator shutters). This allows the vehicle weight of a 4x2 SZF to be reduced by approx. 500 kg compared to a conventionally equipped standard vehicle.
Basically, there are four different equipment variants which define the LOADER vehicles: • Standard equipment available exclusively for LOADER vehicles, cannot be omitted • Standard equipment available exclusively for LOADER vehicles, can be omitted if necessary • Standard equipment which cannot be omitted but is also available for other product groups • Standard equipment which can be omitted and is also available for other product groups
W00.00-1060-00
PG LOADER with example of tank vehicle
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Standard equipment for LOADER vehicles based on model 963.403 (18 t 4x2 LS)
Code
Name
Weight saving (kg)
Equipment exclusively for LOADER, cannot be omitted D5V F6G F7S Z7J Floor covering, weight-optimized Windshield, weight-optimized (tinted, with or without band filter) Entrance carrier, aluminum Aluminum battery lines 2 5 13 2
Equipment exclusively for LOADER, can be omitted D3G D9T E1F C7W Lower bed, lowered Omission of roof hatch/roof vent flap Batteries 2 x 12 V/140 Ah, low-maintenance Omission of front axle stabilizer bar (only possible with ASH 420 and S or M cab) 20 4 16 28
Q8U M9U
End crossmember, weight-optimized Omission of lower anti dust swirl shell
7 3
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Overall vehicle
LOADER product group
Overall vehicle
LOADER product group
Standard equipment for LOADER vehicles based on model 963.403 (18 t 4x2 LS)
Code Standard equipment, cannot be omitted M9Z Q0A Q1Q B4L C8W Omission of radiator shutters
Name
Weight saving (kg)
4 38 21 12 3
Front spring bracket, aluminum Front springs 7.5 t, 1-leaf, hard Compressed air reservoir, aluminum Omission of underfloor paneling, aerodynamic
Standard equipment, can be omitted F4G K1H D9Z R2W I2Z Cab side wall, closed, right Tank 300 l + 75 l AdBlue®, left, 650 x 700 x 1050 mm, aluminium Omission of front passenger seat Aluminium rims 17.00 x 22.5, RA, single tires, shiny, Alcoa Tubeless tires, 495/45 R 22.5 RA 5 75 23 182
14
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The packages which are controlled ex factory combine safety or comfort equipment. The following package variants are available for the new Antos:
Safety Pack Code S1I S1H S3A S1F S1L D1C J1E S1M Proximity Control Assist Lane Keeping Assist Airbag, driver Roll control assistant (platform vehicles only) Attention Assist Comfort driver suspension seat Instrument cluster, 12.7 cm with additional indicators Active Brake Assist 3
Basic Z0S X X X X X X X —
Classic Z0T X X X X X X X X
Economy Pack Code S1Y F5B Tire pressure monitor Clip-in air guides, with side deflectors or F5A Clip-in air guides or F5C E2J B3H G0T Clip-in air guides without base panel Circuit breakers Secondary water retarder Predictive Powertrain Control
Basic Z9B X X
Classic Z9C X X
Top Z9D X X
X
X
X
X X — —
X X X —
X X X X
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Overall vehicle
Equipment
Overall vehicle
Equipment
Comfort Pack (Z0R) Code D0S D4Z F0T F6R Compressed air connection in cab Side roller sun blind, driver and passenger side Illuminated Mercedes star Air horns, cab roof or F6Q F3B F8B Air horn Cab mounting, comfort, steel-sprung 2 remote control keys or F8C F8F J2K 1 multifunction + 1 remote control key Comfort locking system Speakers, 2-way system
Cold Climate Pack Code D7A F3Z M8Z M9A B1F B4A D6N E1C Additional heat insulation Tilting hydraulics fluid, below -25°C Fuel preheating Preinstallation for engine coolant preheater Heater, electronic compressed air supply unit Condensation sensor, for compressed air system Auxiliary water heater, cab and engine Batteries 2 x 12 V/220 Ah, low-maintenance
16
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W68.00-1021-00
Interior concept
W68.00-1029-00
W68.00-1030-00
Stowage compartments
Passenger-side folding table
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Overall vehicle
Equipment
Drive
Engine OM 936
In order to meet the requirements of distribution haulage, engine OM 936 is a completely new development as the successor to engines OM 906 and OM 926. The OM 936 is a 6-cylinder in-line engine with a displacement of 7.7 l with turbocharger and cooled exhaust gas recirculation. The OM 936 is only available in Euro VI and the following power categories: • • • • • 175 kW, 1000 Nm (M2A) 200 kW, 1100 Nm (M2C) 220 kW, 1200 Nm (M2D) 235 kW, 1300 Nm (M2E) 260 kW, 1400 Nm (M2F) The excellent characteristics of the engines, in particular their low fuel consumption in relation to their high power, have been achieved with a range of technical innovations: • The Common Rail injection system reduces the fuel quantity required for combustion to a minimum. • The engine brake provides greater performance and is now designed as a decompression brake which replaces the constant throttle and exhaust flap brake. • The engines fulfill the Euro VI emission standard with Selective Catalytic Reduction (SCR), cooled and regulated exhaust gas recirculation and diesel particulate filters.
The engines with 235 kW and 260 kW feature twostage charging.
i Note
An Introduction into Service Manual will be available for engine OM 936 as of October 2012: Order no. 6517 1262 02 – HLI 000 000 08 99
W01.10-1091-00
Engine OM 936 Euro VI
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W01.10-1112-00
Overview of engine OM 936 1 Rail 2 Diesel fuel metering unit (for regeneration of diesel particulate filter) 3 Fuel filter module 4 Compressor 5 Refrigerant compressor 6 Power steering pump 7 Power steering pump (additional with steering axle) 8 High-pressure fuel pump 9 Exhaust gas recirculation cooler 10 11 12 13 Oil/coolant module Turbocharger Low-pressure stage turbocharger High-pressure stage turbocharger
G2 Alternator M1 Starter A OM 936.912 with 1-stage charging A OM 936.916 with 2-stage charging
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Drive
Engine OM 936
Drive
Engine OM 470
The OM 470 is a 6-cylinder in-line engine with a displacement of 10.7 l with turbocharger and cooled exhaust gas recirculation. The OM 470 differs from the previously introduced OM 471 in the following areas: • • • • • • 10.7 l displacement Fuel filter module with just one filter Gear drive with 2 instead of 3 gear planes No coolant collector External crankcase ventilation system in pipe Modified exhaust gas recirculation cooler The engine is available in the following power categories: • • • • 240 kW, 1700 Nm (M2N) 265 kW, 1800 Nm (M2P) 290 kW, 1900 Nm (M2Q) 315 kW, 2100 Nm (M2R)
W01.10-1109-00
Engine OM 470
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W01.10-1110-00
Overview of engine OM 470 1 Rail 2 Diesel fuel metering unit (for regeneration of diesel particulate filter) 3 Oil/coolant module with coolant pump 4 Fuel filter module 5 Compressor 6 Power steering pump 7 Oil separator of crankcase ventilation system 8 Turbocharger 9 Exhaust gas recirculation cooler G2 Alternator M1 Starter
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Drive
Engine OM 470
Drive
Technical data
Unit Displacement Cylinder number/arrangement Valve timing Number of valves per cylinder (intake/exhaust) Idle speed Power rpm kW cm3 OM 936 7698 6/inline DOHC 2/2 OM 470 10677 6/inline DOHC 2/2
600 175 (M2A) 200 (M2C) 220 (M2D) 235 (M2E) 260 (M2F) 1000 (M2A) 1100 (M2C) 1200 (M2D) 1300 (M2E) 1400 (M2F) 17.0
500 240 (M2N) 265 (M2P) 290 (M2Q) 315 (M2R)
Torque
Nm
1700 (M2N) 1800 (M2P) 1900 (M2Q) 2100 (M2R)
Compression ratio ε Stroke Cylinder bore Total piston height Connecting rod length Cylinder spacing Rail pressure (max.) Weight (approx.)
1
17.6 145 125 105 245.5 155 900 980-11201
mm mm mm mm mm bar kg
135 110 110 215 128 2400 750-8501
Depending on design/output
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Performance graphs
W01.00-1115-00
W01.00-1116-00
a OM 936, 175 kW (M2A) b OM 936, 200 kW (M2C) c OM 936, 220 kW (M2D)
d OM 936, 235 kW (M2E) e OM 936, 260 kW (M2F)
M P n
Torque Output Rpm
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Drive
Technical data
Drive
Technical data
Performance graphs
W01.10-1113-00
W01.10-1114-00
a OM 470, 240 kW (M2N) b OM 470, 265 kW (M2P)
c OM 470, 290 kW (M2Q) d OM 470, 315 kW (M2R)
M P n
Torque Output Rpm
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Distribution vehicles have a standard body floor height of 420 mm. With this body floor height, only a front air intake (M8A) via an air filter mounted above the radiator is possible. The same applies to M cabs with flat roof and a body floor height of 600 mm. The front air intake is also available as special equipment for vehicles with S or M cab with standard roof. On vehicles with front air intake, the waterprotected intake point is located directly behind the trim grille. This provides an optimized implement mounting space behind the cab and above the cab roof and a payload increase of approx. 25 kg compared to an air intake behind the cab.
The maintenance interval for the air filter is 180,000 km. An electronic sensor on the air filter continuously monitors the intake pressure. A message on the multifunction display indicates to the driver when a filter change is due.
W09.00-1010-00
Front engine air intake (M8A)
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Drive
Engine air intake
Drive
Engine power take-off
Front engine power take-off
The front engine power take-offs are preinstallations for the new water-cooled FRIGOBLOCK asynchronous engine alternator model series 28 kW – 37.5 kW, 400/500 V. They consist of a belt pulley, belt drive, bracket, modified aluminium oil pan and coolant lines. The engine power take-offs are available as special equipment for all 963 models (except LL, LD, CC) with engine OM 936 and OM 470. With OM 936 only in combination with: • Air compressor, 1-cylinder (M6N) or • Air compressor, two-stage, consumptionoptimized (M6M) The preinstallation is not available in combination with a controlled coolant pump, high-speed fan drive and air-sprung front axle.
Code N7G N7H
Name Front engine power take-off, Frigo alternator preinstallation AW22.5 Front engine power take-off, Frigo alternator preinstallation AW30
W15.40-1114-00
Front engine power take-off, Frigo alternator preinstallation AW22.5 (N7G), shown on engine OM 936 1 Belt pulley 2 Poly-V belt 3 Aluminum oil pan 4 Bracket 5 Coolant lines
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Rear engine power take-off
The rear engine power take-offs with their various connections are all non-switchable. Engine power take-off (N7I) may only be used in combination with a flexible coupling to insulate it from engine vibrations. The flexible coupling is available as special equipment (N6E) and is supplied loose with the vehicle. It must be installed by the body manufacturer between the engine power take-off and the driven assembly. The main features of the rear engine power takeoffs are: • • • • • • Flange version or for direct installation of pumps Non-switchable Integrated into gear drive of engine Can be used with vehicle stationary Continuous operation permissible Max. permissible torque depending on variant 275 – 650 Nm
Code N7I N7K N7L N7M
Name Rear engine power take-off, b, flange 100 mm, 650 Nm Rear engine power take-off, c, hydraulic pump SAE A Rear engine power take-off, c, hydraulic pump SAE B Rear engine power take-off, c, hydraulic pump ISO 7653D
Engine OM 470/471 OM 470/471, OM 936 OM 470/471, OM 936 OM 470/471
i Note
The direction of rotation of the rear engine power take-offs is different on engines OM 470/471 and OM 936. • OM 470/471: Counterclockwise direction of rotation • OM 936: Clockwise rotation
W23.20-1092-00
OM 936 with rear engine power take-off (N7L)
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Drive
Engine power take-off
Drive
Exhaust system
As of October 2012, the following exhaust systems will be newly available:
Exhaust system on right of frame, inward tailpipe (K7I), (only for engine OM 936)
The exhaust aftertreatment unit on the right of the frame directs the exhaust inward towards the vehicle center via the tailpipe. The installation space behind the exhaust aftertreatment unit can be used for fuel tanks or attachments.
Exhaust system, tailpipe towards outer left (K7C), (only for engine OM 470/471)
The exhaust aftertreatment unit directs the exhaust outwards via the tailpipe on the left towards the center of the road. The equipment is recommended for vehicles with controls on the right-hand side (e.g. fuel oil distributor etc.).
Exhaust system, two-piece mounting console (K7P)
Due to the two-piece mounting console, the exhaust aftertreatment unit can be disassembled from the side irrespective of the body. The mounting console is standard equipment on platform vehicles.
W49.10-1006-00
Example of exhaust system (K7I)
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W49.00-1004-00
Exhaust system, tailpipe towards outer left (K7C), OM 470 1 2 3 4 Exhaust aftertreatment unit Exhaust aftertreatment (ACM) control unit Pump module AdBlue® metering device 5 Exhaust temperature sensor 6 Exhaust pressure sensor 7 NOx sensor
W49.00-1005-00
Exhaust system on right of frame, inward tailpipe (K7I), OM 936 1 Exhaust aftertreatment unit 2 Exhaust aftertreatment (ACM) control unit 3 Pump module 4 AdBlue® metering device 5 Exhaust temperature sensor 6 Exhaust pressure sensor
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Drive
Exhaust system
Transmission
Transmission data
Automated manual transmissions with Mercedes PowerShift 3 (G5G) are standard equipment on all vehicles of the distribution haulage model series. In addition to the transmissions already available: • G 211-12 (G2B)/715.352 • G 281-12 (G2E)/715.371 • G 330-12 (G2F)/715.381 the following transmissions have been newly introduced: • G 140-8 (G1E)/715.310 • G 230-12 (G2C)/715.360 • G 280-16 (G2D)/715.523 The new G 140-8 automated manual transmission has been developed to suit the new engine model series OM 936 and the G 211-12 is also available as special equipment for this engine. The G 230-12 automated manual transmission, which has also been newly developed, is available for engines OM 470 and OM 471. The G 280-16, which is available as special equipment, allows increased gross combination weights to be achieved.
W26.10-1143-00
Transmission G 140-8
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Transmission G 140-8
For medium-duty applications, the automated constant-mesh transmission G 140-8 (G1E) with a gear ratio spread of 9.30-0.79 has been developed completely from scratch and adapted to the OM 936 inline engine. The maximum possible gross combination weight is 32 t. This transmission closes a previous gap in the automated transmission range. The G 140-8 is a single overdrive transmission which is characterized by its very compact design and low weight (approx. 190 kg). The transmission consists of a combination of a synchronized splitter group and a constant-mesh main transmission. The 8 forward gears and two reverse gears are formed from just 6 gear sets.
W26.10-1144-00
Transmission G 140-8
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Transmission
Transmission data
Transmission
Transmission data
Transmission G 230-12
The new 12-speed transmission G 230-12 (G2C) with a gear ratio spread of 11.673-0.780 is a single overdrive transmission with 12 forward and 4 reverse gears. It consists of a 3-speed main transmission with splitter group and range group. The maximum input torque is 2400 Nm.
W26.10-1145-00
Transmission G 230-12
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Transmission G 280-16
The transmission G 280-16 (G2D) with a gear ratio spread of 11.70-0.69 is a double overdrive transmission with 16 forward and 4 reverse gears. It consists of a 4-speed main transmission with splitter group and range group. Increased gross combination weights can be achieved with the G 280-16.
W26.10-1146-00
Transmission G 280-16 with secondary water retarder (B3H)
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Transmission
Transmission data
Transmission
Transmission data
Transmission ratios
Designation Code Model designation 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear 7th gear 8th gear 9th gear 10th gear 11th gear 12th gear 13th gear 14th gear 15th gear 16th gear 1st reverse gear 2nd reverse gear 3rd reverse gear 4th reverse gear G 140-8 G1E 715.310 9.296 5.837 3.673 2.306 1.593 1.252 1.000 0.786 — — — — — — — — 8.538 5.361 — — G 230-12 G2C 715.360 11.673 9.101 7.056 5.501 4.400 3.431 2.653 2.068 1.604 1.250 1.000 0.780 — — — — 11.673 9.101 2.653 2.068 G 280-16 G2D 715.523 11.722 9.747 7.916 6.583 5.291 4.400 3.636 3.023 2.664 2.215 1.799 1.496 1.203 1.000 0.826 0.687 10.656 8.861 2.422 2.014
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Fleet transmission mode (G0Z)
In addition to the familiar transmission modes of power (G0V) and economy (G0U) which are supplied as standard, the fleet transmission mode (G0Z) can be ordered for model 963 as of October 2012. The fleet transmission mode is set up to match the economy transmission mode. However, the fleet transmission mode cannot be switched off, the button on the right multifunctional lever is non-functional. This means that it is not possible to switch to manual mode, but manual intervention in the shift mechanism is still possible. This always ensures an optimally economical driving style. This transmission mode is comparable with the Mercedes PowerShift 2 fleet series.
W54.32-1032-00
Display in multifunction display
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Transmission
Transmission modes
Transmission
Transmission modes
Transmission modes Driving mode Fleet Economy Power Shift mode Automatic Manual
In combination with Power transmission mode (G0V) In combination with Economy transmission mode (G0U) In combination with Fleet transmission mode (G0Z)
—
—
•
•
•
—
•
—
•
•
•
—
—
—
—
Kickdown
—
—
•
•
—
EcoRoll can be deactivated
—
—
•
•
—
Maximum speed [km/h]
85.0
85.0
89.8
89.8
—
Cruise control • available
Softcruise — not available
Softcruise
Standard
Standard
—
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Transmission power take-offs
Two power take-offs are available for the new G140-8 transmission.
MB 121-2b (N2H) This switchable power take-off is mounted to the countershaft of the transmission with a drive flange and is used to drive additional assemblies via a propeller shaft. The flange diameter is 100 mm. Its main application is to drive hydraulic pumps or small compressors e.g. for street cleaning vehicles.
MB 121-2c (N2I) This switchable power take-off is mounted to the countershaft of the transmission and is driven by it via a spur gear drive. A hydraulic pump (Meiller pump attachment (MPA)) is directly flange-mounted to the power take-off. For applications with continuous PTO operation, a transmission cooling system (N6Z) is available. The oil/air cooler with 7 kW cooling output is located under the entrance on the passenger side.
W26.45-1334-00
Transmission G140-8 with power take-off MB 121-2c (N2I)
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Transmission
Power take-off
Chassis
Frame
Defined clearances on frame
Defined clearances on the frame are available ex factory as a new equipment feature. This eliminates the need for complicated modifications to the frame by body manufacturers.
Clearance on right of frame (C7R) and clearance on left of frame (C7S) The left/right clearance makes it possible to install customer-specific tank and silo compressors, refrigeration units and stowage boxes. The clearance is approx. 900 mm (min. 750 mm) and extends underneath and within the longitudinal frame member up to the propeller shaft. • Clearance on platform vehicles with 4000 mm wheelbase: 1500 mm with 4300 mm wheelbase: 1700 mm • Clearance on semitrailer tractors with 3600 mm wheelbase: 993 to 1384 mm (depending on configuration)
W31.00-1084-00
Clearance for crane support feet (C7Q) In order to create the clearance for crane support feet, it may be necessary to relocate the battery carrier, exhaust system and fuel tank. • Clearance approx. 600 mm • Only in combination with Battery carrier, stacked batteries (C7K) • Combination with crane skids available ex factory
1 2 3 4 5 6 Exhaust aftertreatment unit AdBlue® tank Battery carrier Electronic Air-Processing Unit (EAPU) Fuel tank Fender carrier
W31.00-1085-00
F Clearance
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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New swap body frame
The familiar Saxas swap body frames from model 930 are also available for the new model 963 in modified and extended form. For model 963, modifications were necessary to accommodate the new frame track width and for attachment to the new frame; some reinforcements were also added. The frame for swap bodies of length 7150 mm/ 7450 mm is a standard format for fully air-sprung platform chassis and can be used to mount standardized swap bodies of type C715 and C745. Swap body frames, 7150 mm/7450 mm/1320 mm (P5Z): With standard ground clearance of 1320 mm for airsprung 2-axle platform vehicles with 5500 mm wheelbase and 3-axle platform vehicles 6x2 ENA with 4600 and 4900 mm wheelbase. Swap body frames, 7150 mm/7450 mm/1120 mm (P5Y): With lower ground clearance of 1120 mm e.g. for Cargoliner.
W31.00-1086-00
Examples of swap body frames
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Chassis
Frame
Chassis
Fifth wheel coupling
Fifth wheel coupling
Various heights are available to accommodate different coupling point heights. The fifth wheel couplings are available in both conventional and compact designs and in low-maintenance and manually lubricated versions. In addition, sensed fifth wheel couplings from Jost are also available ex factory for the first time. No fifth wheel couplings are available ex factory for car transporters. In October 2012, a slider from Jost with integrated, manually lubricated fifth wheel coupling JSK 36 D will become available (Q5B). The desired position of the fifth wheel coupling can be adjusted in 50 mm steps using the slider. Technical data: Slide travel: Height: Drawbar ratio: Weight: 12 x 50.8 mm (total 609.6 mm) 263 mm (Q4S) 152 235 kg On 6x2 DNA and 6x4 SZF vehicles, a 50 mm raised coupling angle (Q6W) forms part of the standard equipment. The advantage of this is that lower coupling heights can be used and the ISO angles to the frame rear are more favorable. The raised angle extends 50 mm past the upper edge of the frame while the Coupling angle with hole pattern (Q6Z) only extends 4 mm. It also has a 50 mm hole pattern, a length of 1650 mm and is made of sheet metal with a thickness of 7 mm. Its weight is approx. 37 kg.
Fifth wheel load: 20 t
W31.10-1028-00
Jost slider
End crossmember, weight-optimized (Q8U)
A weight-optimized end crossmember with a sheet thickness of 2.5 mm is used for semitrailer tractors of the LOADER product group. It is not possible to attach a towing coupling. This produces a weight saving of approx. 7 kg.
W31.00-1087-00
1 End crossmember
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Rear axle
With the introduction of the new Antos, the robust planetary hub reduction rear axles will again be available for model 963. The new axles have been taken over almost in their entirety from the predecessor model series. No modifications were necessary for attachment to the modified frame track width due to the identical distance between spring centers of 930 mm. The 13t planetary hub reduction rear axle is available in the following versions: • Steel-sprung with disk brakes as single and through-drive axle • Air-sprung with disk brakes as single and through-drive axle • Steel-sprung with drum brakes as single and through-drive axle
W35.10-1052-00
Planetary hub reduction rear axles 1 748.283 2 748.282
Code A2F A2F A2G A2G
Model designation 748.280 748.281 748.282 748.283
Designation R 233 P – 13/C 22.5 RT 233 P – 13/C 22.5 R 300 P – 13/C 22.5 RT 300 P – 13/C 22.5
Name Rear axle, ring gear 233, planet gears, 13.0 t Rear axle, ring gear 233, planet gears, 13.0 t Rear axle, ring gear 300, planet gears, 13.0 t Rear axle, ring gear 300, planet gears, 13.0 t
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Chassis
Axles
Chassis
Axles
Leading axle (VLA)
All leading axles feature slightly modified geometry and the wheel head of the new front axles. As of October 2012, a new 4.3t leading axle with 17.5" tires will be available additionally. Due to the 17.5" tires and reduced distance from the drive axle of 1010 mm, the installation space on the frame sides is optimized for larger fuel tanks. In addition, greater tractor/trailer combined gross weights are possible due to the optimized axle load distribution.
Trailing axle (NLA)
The unsteered trailing axles have been taken over from current series production. The steered trailing axles are based on the new front axles with the same wheel head but modified steering geometry. Trailing axles are only available with disk brakes. A steered trailing axle is also available for platform vehicles.
Twin-tired trailing axle (DNA)
The twin-tired trailing axle (axle model designation 749.126) will be available as of October 2012 for the first time. The air-sprung variant is a new development which will be also available for platform vehicles for the first time. Here, the axle housing of the front axles was used as a basis. The axle is air-sprung, liftable and has 22.5" tires as well as disk brakes. The load on it can be relieved as a starting-off aid in accordance with countryspecific requirements (E4W/E4X/E4Y/E4Z). The distance from the drive axle is 1350 mm. It can be raised if the vehicle is empty or only partially loaded. The lift travel is 120 mm. All of the trailing axles on low frame vehicles can only be lifted but not fully raised (A4W).
Code A4H
Model designation 749.121
Designation M – 4.3 LA/C 17.5
Name Leading axle, 4.3 t, load relief, liftable
A4K
749.126
T – 10 LA/C 22.5
Trailing axle, 10 t, load relief, liftable, twin tires
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Air pressure gauge, digital (Y4P)
A digital air pressure gauge is available as special equipment. The device features an integrated measuring rod for determining the tire tread depth and is operated by a battery or the integrated solar cell. The battery can be changed by opening the housing. When not in use, the air pressure gauge shuts off automatically.
W40.15-1044-00
Tires
The following items are newly available for model 963.427 with 17.5" leading axle: • Steep-shoulder rims 6.75 x 17.5, VLA (R1D) • Aluminum rims 6.75 x 17.5, VLA, Speedline (R2B) • Aluminum rims 6.75 x 17.5, VLA, Dura-Bright, Alcoa (R5Y) • Aluminum rims 6.75 x 17.5, VLA, matt, Alcoa (R5Z)
i Note
The tire/rim coding system has been completely revised. In future, a separate rim code is required in each case to order the rims for the front axle, leading axle, rear axle and trailing axle.
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Chassis
Wheels and tires
Chassis
Single wheel load 2,500 2,500 2,120 3,650 3,650 3,650 3,550 4,125 4,125 4,125 4,125 4,000 4,500 4,500 4,500 4,500 5,000 4,500 5,800 120 120 -67 120 120 25.0 25.0 27.0 28.0 35.7 120 25.0 120 25.0 150.5 28.0 R2N R2P R5E R2R R5A R2T R2U — 154.0 23.2 R2G 154.0 23.2 R2M 154.0 23.2 R2Z R5L R5N R5J R6A R2Q R5F R2S R5B — R2V — R2W 154.0 23.2 R2L R5Q 145.5 27.0 R6D R6E — — — — — — R2O R5G R5D R5C — 145.0 24.0 R6G R6H — 145.0 24.0 R6J R6K — 145.0 24.0 R5V R5T — R5U R6L R6I R6F R5R R5M R5O R5K R6B R5S R5H R5P R5I — R6C — 124.8 13.0 — R2B — — 123.0 13.3 — R5Y — — 123.0 13.3 — R5Z — — — — — R2D R2E R2C R2F R2I R2Y R2J R2H R2K — — — — — — — ET [mm] Weight [kg] Code VA Code VLA Code HA Code NLA All-round
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Aluminum rims
6.75 x 17.5, VLA, matt, Alcoa
6.75 x 17.5, VLA, Dura-Bright, Alcoa
Wheels and tires
6.75 x 17.5, VLA, Speedline
8.25 x 22.5, shiny, Alcoa
8.25 x 22.5, matt, Alcoa
8.25 x 22.5, Dura-Bright, Alcoa
8.25 x 22.5, Speedline
9.00 x 22.5, shiny, Alcoa
9.00 x 22.5, Dura-Bright, Alcoa
9.00 x 22.5, matt, Alcoa
9.00 x 22.5, Dura-Flange, Alcoa
9.00 x 22.5, Speedline
i Introduction of the New Truck Generation - The New Antos (Model 963)
11.75 x 22.5, shiny, Alcoa
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11.75 x 22.5, Dura-Bright, Alcoa
11.75 x 22.5, matt, Alcoa
11.75 x 22.5, Dura-Flange, Alcoa
11.75 x 22.5, matt, Alcoa Workhorse
11.75 x 22.5, Speedline
17.00x22.5, RA, single tires, shiny, Alcoa
Power steering pump, controlled (C6I)
In addition to an uncontrolled power steering pump (C6J), a controlled power steering pump (C6I) is used as an innovation on engine OM 470/471. The controlled power steering pump is installed as standard on all long-haul vehicles which are not equipped with a steered leading or trailing axle. On distribution vehicles with a body floor height of 600 mm, the controlled power steering pump is available as special equipment under the aforementioned conditions.
Function
On the controlled power steering pump, the flow rate is kept constant irrespective of the pump rpm. If the rpm increases above the idle level, the compression volume of the pump is continuously reduced. This reduces the flow rate, which significantly reduces power consumption at high pump speeds, and results in a lower power steering fluid temperature. Control takes place through a mechanical-hydraulic control loop within the power steering pump.
W46.30-1030-00
Power steering pump
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Chassis
Steering
Chassis
Fuel tank
With the introduction of the new Antos, a wide range of new standard and combined fuel tanks are available. In particular, the range of fuel tanks available for the right-hand side has been significantly extended.
Standard fuel tank Second left tank Right tank Second right tank Left tank Volume [liters] Length [mm] Width [mm] Height [mm]
K2X K2W K2V K2U K2T K3F K3E K3D — K3C K3B K3A K2Z — — — — — K3K K3J K3I —
K4F — — K4C K4B K4N — — — K4K K4J — K4H — — K4W — — K4U — — —
K6F K6E K6D K6C K6B K6N K6M K6L — K6K K6J K6I K6H K6G K6Q — K6O — K6U K6T K6S K6R
K1F K1E K1D K1C K1B K1P K1N K1M K1O K1L K1K K1J K1I — K1Y K1S — K1X K1W K1V K1U K1T
500 390 330 290 230 630 570 510 450 430 390 330 290 220 330 260 540 510 480 430 360 320
1600 1250 1050 950 750 1600 1450 1300 1170 1100 1000 850 750 600 950 750 1250 1170 1100 1000 850 750
650 650 650 650 650 650 650 650 650 650 650 650 650 650 735 735 735 735 735 735 735 735
565 565 565 565 565 700 700 700 700 700 700 700 700 700 565 565 700 700 700 700 700 700
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Combined fuel tank Left tank K1R K2D K1Q K1H K2E K1G K2J K2B K2C K2A Volume [liters] 720 + 75 680 + 120 660 + 75 300 + 75 300 + 25 660 + 75 880 + 90 820 + 90 790 + 120 760 + 90 Length [mm] 2170 2170 2020 1050 900 2200 2305 2170 2170 2020 Width [mm] 650 650 650 650 650 735 735 735 735 735 Height [mm] 700 700 700 700 700 565 700 700 700 700
A
B
W47.10-1053-00
1 2 3 4 5
AdBlue® tank Exhaust aftertreatment unit Narrow fuel tank, 390 liters Battery Space for attachments
6 Space e.g. for second fuel tank 7 Space e.g. hydraulic fluid tank A Example of semitrailer tractor B Example of platform vehicle
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Chassis
Fuel tank
Design
Cab
General
The New Antos is available with the short S cab and medium length M cab. The new cabs have an aerodynamically favorable bodyshell design. The bodyshell of the cabs is based on a frame structure made up of the floor assembly, the continuous roof frame, the A and B-pillars, the rear panel pillars, the roof bows and the front end carrier. The panels for the individual function groups such as the roof, rear panel, side walls and front end are welded to this frame structure. The bodyshell concept is designed so that the height of the frame structure is largely standardized up to the roof frame. The different cab heights are achieved by means of corresponding side roof carriers and panels above the roof frame. A new feature of the floor assembly are the hot worked inner and outer longitudinal members, which meet increased strength requirements while conforming to the necessary tolerances. Compared to the cab of the predecessor model, the outer longitudinal members have a significantly stronger design. The cab fulfills the Swedish test and standard ECE R29 version 02 and 03, which comes into force as of 2014. The cab is made out of 100% fully galvanized sheet metal. The entire bodyshell undergoes cathodic dip painting (KTL) as a corrosion prevention measure.
W00.00-1062-00
W00.00-1063-00
S cab with body floor height 420 mm
M cab with standard roof and body floor height 600 mm
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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S cab (Antos only)
As of October 2012, the S cab with standard roof will be available for the Antos with an engine tunnel height of 170 mm or 320 mm. With a length of 1.70 m, it is shorter than the M cab and is only available with a width of 2.30 m. The S cab with standard roof optimizes the space for bodies behind the cab.
L cab (Actros only)
The L cab was introduced along with the new Actros in September 2011. As of October 2012, the L cab with flat roof with an engine tunnel height of 170 mm or 320 mm will be introduced, along with the standard or Aero roof version with an engine tunnel height of 320 mm. The flat roof version with a 320 mm engine tunnel height is particularly suited to the requirements of a car transporter. A special body floor height of 390 mm is available for this version.
M cab (Antos only)
The M cab is being introduced for the new Antos. The M cab is available in flat roof and standard roof versions, each with an engine tunnel height of 170 mm or 320 mm. With a length of 2.00 m, it is shorter than the L cab and is only available with a width of 2.30 m. The M cab with flat and standard roof provides a great deal of space for attachments above the cab roof.
i Note
The body floor height (ASH) designates the distance from the lower edge of the floor panel to the uppermost row of holes in the longitudinal frame member. With a flat cab floor, the body floor height is always 765 mm and with an engine tunnel always 420 mm or 600 mm (a special body floor height of 390 mm is also available for car transporters in combination with a 320 mm engine tunnel height).
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Design
Cab
Design
Cab
W00.10-1178-00
Dimensions based on example of platform vehicle with M cab, engine tunnel 320 mm, ASH 420 mm
L1 Length H1 Height H2 Floor-to-ceiling height in front of seat
H3 Floor-to-ceiling height on engine tunnel H4 Body floor height (ASH) H5 Engine tunnel height
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W00.00-1061-00
Overview of S cabs (Antos only) ClassicSpace (standard roof) Code Length Width Height Floor-to-ceiling height in front of seat Floor-to-ceiling height on engine tunnel Body floor height H1 H2 L1 F1A 1700 2300 1750 1600 F1S 1700 2300 1750 1600
H3
1460
1310
H4
600
420
Height of engine tunnel
H5
170
320
All dimensions in mm
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Design
Cab
Design
Cab
Overview of M cabs (Antos only) CompactSpace (flat roof) Code Length Width Height Floor-to-ceiling height in front of seat Floor-to-ceiling height on engine tunnel Body floor height H1 H2 L1 F1C 2000 2300 1486 1397 F1N 2000 2300 1486 1397 F1B 2000 2300 1750 1600 ClassicSpace (standard roof) F1O 2000 2300 1750 1600
H3
1215
1065
1460
1310
H4
600
420
600
420
Height of engine tunnel
H5
170
320
170
320
All dimensions in mm
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Overview of L cabs (Actros only) CompactSpace (flat roof) Code Length Width Height Floor-to-ceiling height in front of seat Floor-to-ceiling height on engine tunnel Body floor height H1 H2 L1 F1K 2300 2300 1486 1397 F1V 2300 2300 1486 1397 ClassicSpace (standard roof) F1T 2300 2300 1750 1600 StreamSpace (Aero roof) F1W 2300 2300 2100 1840
H3
1215
1065
1310
1635
H4
600
420
420/600
420/600
Height of engine tunnel
H5
170
320
320
320
All dimensions in mm
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Design
Cab
Design
Center seat
Center seat, with seat belt (D1Z)
An additional center seat with seat belt (D1Z) is available as special equipment for the new S and M cab with standard roof. The center seat is mounted on the engine tunnel. It features backrest adjustment with a folding backrest, a vertically adjustable head restraint and a 3-point seat belt.
W91.14-1002-00
Center seat
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Beds and bunks
No beds or bunks are available for the S cab. A lower bunk (D3I) is available for the M cab as special equipment. The range of beds has been extended for the new L cabs (Actros only).
Overview of beds and bunks Code D3B Standard/special Standard for all L cabs SA for all L cabs SA for all L cabs with Aero, high and Giga roof Beds Lower deluxe bed
D3C D3F
Lower bed Upper deluxe bed, narrow
D3A
SA for all L cabs with Aero, high and Giga roof
Upper deluxe bed, wide, level-adjustable
D3D
SA for L cabs with flat roof
Upper bed, narrow, for car transporter
D3I
SA for M cabs
Lower bunk
D3G
Standard for LOADER
Lower bed, lowered
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Design
Beds and bunks
Design
Beds and bunks
W91.75-1005-00
Lower bunk (D3I) for M Cab
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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W68.10-1094-00
Instrument panel with 320 mm engine tunnel
W68.10-1096-00
Instrument panel with center seat
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Design
Instrument panel
Networking
Overall network
W00.19-1082-00
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Overall network i Introduction of the New Truck Generation - The New Antos (Model 963)
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W00.19-1057-00
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Networking
Overall network
Networking
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A10 A10b A10c A11 A12b A26 A58 A60 A28 A30 A33 A34 A35 A40 A43 A70 A72 A13 A14 A15 A16 A17 A18 A20 A20a A25a A57 A25 A56 A22 A55 A21a A54 Antilock brake system (ABS) control unit, 4-channel Electronic brake control (EBS) control unit Electronic brake control (EBS) control unit Retarder control unit (RCM) Heating, ventilation and air conditioning (HVAC) control unit TRUCK auxiliary heater (ITH) control unit Stationary air conditioning (IAC) control unit Front radar sensor (RDF) control unit Driver door module (DCMD) control unit Front passenger door module (DCMP) control unit Electronic Air-Processing Unit (EAPU) control unit Front axle axle modulator (Wabco) Front axle axle modulator (Knorr) A21 Rear axle axle modulator (Wabco) Rear axle axle modulator (Knorr) Parameterizable special module (PSM) control unit Electronic Stability Program (ESP®) control unit (Wabco) Electronic Stability Program (ESP®) control unit (Knorr) Level control (CLCS) control unit Driver switch group FleetBoard® control unit Battery disconnect switch control unit (BESO) Additional steering axle (ASA) control unit Tire pressure monitor (TPM) control unit Supplemental restraint system (SRS) control unit Modular switch panel (MSF) control unit A53
A1
Overall network
Instrument cluster (ICUC) control unit A2 Central gateway (CGW) control unit A2 a1 Central data memory (CDS) A2 a2 Communications interface (COM) control unit A2 a3 Maintenance system (MS) control unit A3 Drive control (CPC) control unit A4 Engine management control unit (MCM) A5 Transmission control unit (TCM) A6 Anti-theft alarm system (ATA) control unit A7 Cab sensor and actuator module (SCA) A8 Frame sensor and actuator module (SCH) A9 Truck Control Center (TCC)
Driver assistance system (VRDU) control unit Lower radiator shutters controller unit Upper radiator shutters controller unit Predictive Powertrain Control (PPC) NOx sensor control unit, exhaust aftertreatment unit outlet SCR control unit Exhaust aftertreatment control unit (ACM) - On left with OM 936 - At rear with OM 470 NOx sensor control unit, exhaust aftertreatment unit inlet Lane Assistant camera
i Introduction of the New Truck Generation - The New Antos (Model 963)
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B42 B43 B66 CAN 1 CAN 2 CAN 3 CAN 4 CAN 5 CAN 6a LIN 4 LIN 5 LIN 6 LIN 7 LIN 8 LIN 9 LIN 10 LIN 11
X100.16 X102.15 X12.7 X167.12
ASIC
LIN 1 LIN 2 LIN 3
B81 G1a P1 S1 S20
S22 S23
Rain/light sensor LIN Battery sensor LIN Right multifunction control lever LIN Left multifunction control lever LIN Radiator shutters LIN SCA/SCH redundancy LIN Button group LIN Level control LIN Driver switch panel LIN EAPU-LIN ATA-LIN
S110
S111
Alarm siren Interior protection sensor Steering wheel angle sensor (SAS) Rain and light sensor (RLS) Battery sensor (IBS) Tachograph Electronic ignition lock (EIS) Left multifunction control lever Level control operating unit Right multifunction control lever Left multifunction steering wheel button group Right multifunction steering wheel button group CAN 6b CAN 6c CAN 6d CAN 7 CAN 8 CAN 9 CAN 10 CAN 11 CAN 12 CAN 13
Diagnostic socket Trailer socket (15-pin) ABS trailer socket (7-pin) Electrical connector X910 Electrical connector XR-E1H Cable weld point Exterior 1 CAN-H XR-E1L Cable weld point Exterior 1 CAN-L XR-E1M Cable weld point Exterior 1 CAN ground Z1 CAN bus star point cab instrument panel Z3 CAN bus star point frame Z4 CAN bus star point powerplant
ASIC data bus (Application System Integrated Circuit) Exterior CAN Interior CAN Frame CAN Drive train CAN Climate control CAN Front axle brakes CAN Rear axle brakes CAN Redundant brakes CAN ESP® brakes CAN Trailer CAN (PSM) Body CAN (PSM) Telematics CAN Diagnostic CAN Trailer CAN (EBS) Radar CAN NOx CAN
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i Note
With the introduction of the distribution vehicles, the overall network of model 963 is being expanded with the Predictive Powertrain Control (PPC) control unit (A56).
Introduction of the New Truck Generation - The New Antos (Model 963) i
Overall network
61
Networking
Networking
Parameterizable Special Module
The familiar parameterizable special module (PSM) from other model series will also be available in the new Actros and Antos. The PSM is an electronic interface for connecting bodies, equipment, trailers and semitrailers via CAN interfaces. The following versions are available: • PSM, body and trailer CAN, ISO 11992 (E3Y) • PSM, body CAN, ISO 11898 instead of 11992 (E3Z) The PSM enables the direct exchange of information between the vehicle electronics and the bodies, attachments, equipment and trailer or semitrailer. The communication interfaces between the vehicle electronics and retrofitted systems are clearly defined and standardized. The following information can be displayed e.g. on the multifunction display: • Driver assistance systems such as trailer or semitrailer identification, lighting check • Cargo monitoring on tank vehicles, refrigerated or gas transports • Display of current cargo temperature, quantity and cargo pressure • Monitoring of temperature, quantity and pressure for threshold values (minimum/maximum), which can be parameterized on board In addition, certain functions can be controlled at the request of auxiliary equipment e.g.: • • • • • Engine start/stop Starter lockout Accelerator pedal lock Gear lock Engine speed limitation
W54.21-1572-00
Location in electronics compartment on passenger side A22 Parameterizable special module (PSM) control unit
i Note
An Introduction into Service manual for the parameterizable special module (PSM) is available as of October 2012: Order No. 6517 1265 02 – HLI 000 000 09 09
62
i Introduction of the New Truck Generation - The New Antos (Model 963)
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Communication between vehicle and body
1 PSM and an optimized electronic architecture for the simple exchange of information between the vehicle and body
5 ABH interface for connection of body
electrical system and electronics
2 Switches for ABH
electrical system to the left of the steering column for operating various body functions
3 Integration of
ABH information in multifunction display
4 Wide range of power
take-offs to shorten modification time at ABH
W00.01-1018-00
W54.25-1203-00
Body manufacturer (ABH) electrical system switch slots
Introduction of the New Truck Generation - The New Antos (Model 963) i
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63
Networking
Parameterizable Special Module
Lights
Exterior lights
Headlamps
W82.10-1132-00
W82.10-1133-00
Halogen headlamp with front fog lamp (L1H)
Halogen headlamp with front fog lamp and LED daytime running lamp (L1I)
W82.10-1138-00
Bi-xenon headlamp (L1A) with front fog lamp, halogen (L1H)
The following lighting equipment comes as standard in the new Antos: • Standing lights, low beams and high beams with additional "Ambient illumination" function • Turn signals and hazard warning system with additional "One-touch turn signaling" function • Rear foglamp, backup lamps and brake lights • LED clearance lamps • LED side marker lamps
Available as special equipment: • • • • • • • • Code (L1A) Bi-xenon headlamps Code (L1B) Daytime running lights Code (L1H) Front fog lamps, halogen Code (L1I) Front fog lamps, LED daytime running lights Code (L1N) Front fog lamps, LED daytime running lights, cornering lights Code (L3A) Lower work lamps Code (L3C) Work lamps at top of cab rear panel Code (F0T) Illuminated Mercedes star
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Active Brake Assist 3 (S1M) is a further developed version of the previously introduced Active Brake Assist 2 (S1C). Active Brake Assist 3 (ABA) extends the speed range for autonomous accident avoidance of stationary objects from 10 km/h to 60 km/h. In addition, automatic emergency braking can also be triggered for stationary objects. 1st warning phase Visual (red) warning on multifunction display and acoustic warning in the form of an intermittent warning tone, radio is muted. 2nd warning phase A gentle brake intervention is carried out in addition to the visual and acoustic warning (deceleration of approx. 3 m/s2). 3rd warning phase Emergency braking is triggered automatically. Until the 3rd warning phase occurs, emergency braking can be aborted as follows by driver intervention: • • • • • Actuation of right multifunction control lever Actuation of brake pedal Actuation of accelerator pedal Actuation of steering wheel Actuation of button "ABA OFF"
ABA can be shut off manually at any time. The status "ABA deactivated" is shown by an indicator lamp on the instrument cluster. The visual warning on the instrument cluster remains active even when the system is switched off.
As of the 3rd warning phase, the emergency braking can only be canceled by pressing the "ABA OFF" button or with the kickdown function of the accelerator pedal.
"ABA OFF" button
W54.25-1202-00
i Note
Emergency braking is always carried out with the maximum brake pressure and does not adjust automatically to the weather and road conditions. After the emergency brake application, the vehicle is held by the brake automatically for a maximum of 5 s.
Introduction of the New Truck Generation - The New Antos (Model 963) i
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65
Safety
Active Brake Assist 3
Safety
Active Brake Assist 3
Active Brake Assist 2 (S1C) Vehicles in front and stopping vehicles (quicker than 8 km/h) Autonomous accident avoidance 1. Visual/acoustic warning 2. Warning brake application 3. Emergency braking Active Brake Assist 3 (S1M) Autonomous accident avoidance 1. Visual/acoustic warning 2. Warning brake application 3. Emergency braking
Stationary objects
Autonomous accident avoidance up to 10 km/h 1. Visual/acoustic warning 2. Warning brake application 3. No emergency braking, driver has to apply the brakes further
Autonomous accident avoidance up to 60 km/h 1. Visual/acoustic warning 2. Warning brake application 3. Emergency braking with distance of < 17 m to obstacle
W42.32-1018-00
Active Brake Assist 3 with Proximity Control Assist
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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General
Attention Assist (S1L) is a safety system which monitors the attentiveness of the driver based on steering behavior, adherence to lane and other driver activities (turn signal actuation, clutch operation, engine brake operation etc.). If the attentiveness limits stored in the system are reached after a defined driving distance, the driver is visually warned by an indicator on the multifunction display (yellow pop-up menu with stylized bed symbol and "Please take a break"). In addition, a brief warning tone is output on the instrument cluster. The pop-up menu is displayed until the driver confirms the warning message or deactivates Attention Assist. The driver must confirm the visual warning signal on the multifunction display using the "OK" button or deactivate the system, otherwise the visual warning signal will be displayed again every 15 minutes. Attention Assist automatically activates Lane Keeping Assist upon the first warning if it has been switched off. The system is purely a support system and does not actively intervene in driving operations.
Function
The technology of Attention Assist is based on Lane Keeping Assist (S1H). It is therefore only available in combination with Lane Keeping Assist. For Attention Assist, the display on the instrument cluster (selection menu for activation/deactivation, pop-up menu with warning signal) is modified and a steering angle sensor is installed if not already present. Attention Assist is activated every time the vehicle is restarted or after 30 minutes with the engine running but can be deactivated via the instrument cluster. All system-relevant data are recorded in the first 15 minutes. A precondition is that the vehicle must be traveling at over 60 km/h on a road with visible lane markings. If the vehicle is traveling at a lower speed, the warning signal appears later.
W54.32-1030-00
Attention Assist display
Introduction of the New Truck Generation - The New Antos (Model 963) i
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Safety
Attention Assist
Assistance systems
Integrated Predictive Powertrain Control
Adaptive driving calculation is a special equipment item with code (G0T) Predictive Powertrain Control. Predictive Powertrain Control (PPC) uses a 3D map to replicate the foresighted driving style of an experienced driver who is familiar with the topography in order to reduce fuel consumption. PPC can be activated/deactivated via the multifunction display (Systems menu) and the permissible deviation (upper and lower hysteresis) of the set vehicle speed can be adjusted. The driver sets the speed with the cruise control. PPC then uses the information supplied by the driver to plan a suitable shift strategy for a performance and consumption-optimized vehicle speed. Here, the kinetic energy of the vehicle is used as an energy store. This is "emptied" before a downhill slope, i.e. the speed is lowered, so that during the upcoming downhill slope the energy store can be "refilled" by building up speed on the slope without using additional fuel.
W54.32-1029-00
PPC display in multifunction display
i Note
Information about the PPC is stored in WIS in the new function/function subgroup 30.37 – Adaptive driving calculation.
W54.32-1031-00
Hysteresis display in multifunction display
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Overview of Predictive Powertrain Control
Increase in speed ahead of a hill in order to avoid gearshifting on the hill (predictive wide open throttle).
W30.16-1001-00
Coasting over hilltops in order to avoid braking on downhill sections.
W30.16-1002-00
Automatic EcoRoll activation on gentle downhill sections to utilize kinetic energy in coasting phases.
W30.16-1003-00
a b H1 H2 s VS V
Speed with PPC Speed without PPC Upper hysteresis Lower hysteresis Distance Set speed (cruise control) Vehicle speed
Introduction of the New Truck Generation - The New Antos (Model 963) i
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Assistance systems
Integrated Predictive Powertrain Control
Assistance systems
FleetBoard® EcoSupport
The standard FleetBoard® EcoSupport function helps the driver to achieve a driving style with lower consumption. In addition, the system displays tips while driving in order to optimize the driver's individual driving style to achieve greater efficiency, lower consumption and fewer emissions. The FleetBoard® EcoSupport system recognizes the driver from the tachograph driver card and can store the assessments for max. 2 drivers. The on-board computer records and evaluates the driving style in eight categories: 1 2 3 4 5 6 7 8 Uniformity Coasting/braking Stopping Speed Use of permanent brake Shifting Use of accelerator pedal Truck check
W54.32-1033-00
The menu window shows the average rating in % for the corresponding category, a bar display as well as a message about the current assessment.
Display on multifunction display (example shows accelerator pedal use)
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i Introduction of the New Truck Generation - The New Antos (Model 963)
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Claw wrench
Use Claw wrench for removing and installing the water sleeve of the injector.
Special tool W 936 589 00 07 00 number FG 01 Set B Category Mercedes-Benz Truck Special Operations
W58.20-1051-00
Sleeve
Use For installing the front crankshaft radial sealing ring in the oil pump cover.
Special tool W 936 589 00 14 00 number FG 03 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with assembly tool W 904 589 04 15 00
W58.20-1052-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 936
Special tool
Engine OM 936
Drift
Use Drift for fixing the crankshaft at TDC via the starter ring gear.
Special tool W 936 589 00 15 00 number FG 05 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1053-00
Template
Use For positioning the camshafts at TDC.
Special tool W 936 589 00 23 00 number FG 05 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1054-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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Adapter
Use For fixing the high-pressure fuel pump and compressor in place when disassembling and assembling the drive gear.
Special tool W 936 589 00 31 00 number FG 07 Set B Category Mercedes-Benz Truck Special Operations Note In combination with locating tool W 470 589 08 40 00
W58.20-1055-00
Extraction tool
Use For pulling injectors out of the cylinder head.
Special tool W 936 589 00 33 00 number FG 07 Set B Category Mercedes-Benz Truck Special Operations
W58.20-1056-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 936
Special tool
Engine OM 936
Valve tool kit
Use For removing and installing the valve springs, incl. puller and drift for mounting the valve stem seal.
Special tool W 936 589 00 61 00 number FG 05 Set C Category Mercedes-Benz Truck Special Operations Note Available as of march 2013
W58.20-1057-00
Adapter
Use For filling, flushing and bleeding the oil circuit at the oil filter module.
Special tool W 936 589 00 63 00 number FG 18 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with oil replenishing canister W 352 589 11 63 00
W58.20-1058-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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Adapter
Use Adapter for checking compression via the injector bore.
Special tool W 936 589 00 91 00 number FG 01 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1059-00
Drift
Use For knocking pilot bearing with retaining ring into flywheel.
Special tool W 936 589 01 15 00 number FG 03 Set C Category Mercedes-Benz Truck Basic Operations
W58.20-1060-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 936
Special tool
Engine OM 936
Mounting tool
Use For pulling O-rings onto injectors.
Special tool W 936 589 01 33 00 number FG 07 Set B Category Mercedes-Benz Truck Special Operations
W58.20-1061-00
Stop plug
Use For sealing the rail connections during testing operations.
Special tool W 936 589 01 91 00 number FG 01 Set B Category Mercedes-Benz Truck Special Operations
W58.20-1062-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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Guide pin
Use For fitting flywheel on crankshaft.
Special tool W 936 589 02 15 00 number FG 03 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1063-00
Puller
Use For pulling off main bearing bridges.
Special tool W 936 589 02 33 00 number FG 03 Set C Category Mercedes-Benz Truck Special Operations Note Available as of march 2013 In combination with puller W 470 589 02 33 00
W58.20-1064-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 936
Special tool
Engine OM 936
Leak tester
Use For leak testing the EGR cooler.
Special tool W 936 589 02 91 00 number FG 14 Set C Category Mercedes-Benz Truck Basic Operations Note In combination with pressure pump W 124 589 24 21 00
W58.20-1065-00
Tool kit
Use For pulling the heat protection sleeve out of the cylinder head and pressing the heat protection sleeve onto the injector.
Special tool W 936 589 03 33 00 number FG 07 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1066-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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Extraction tool
Use For pulling out the seals of the pressure pipe connections on the injector line.
Special tool W 936 589 04 33 00 number FG 07 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with impact extractor W 355 589 01 63 00
W58.20-1067-00
Adapter
Use For function testing of engine brake.
Special tool W 936 589 03 9100 number FG 14 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1068-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 936
Special tool
Engine OM 936
Adapter
Use For measuring fuel return quantity of injectors.
Special tool W 936 589 04 9100 number FG 07 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with test adapter W 470 589 02 21 00
W58.20-1069-00
Collet
Use For mounting pistons in cylinder barrel.
Special tool W 936 589 00 37 00 number FG 03 Set B Category Mercedes-Benz Truck Basic Operations Note Available as of march 2013
W58.20-1070-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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16-pin adapter cable
Use For testing injectors.
Special tool W 936 589 01 63 00 number FG 07 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with test box W 000 589 00 21 00
W58.20-1071-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 936
Special tool
Engine OM 470
Guide pin
Use For guiding cylinder head during assembly.
Special tool W 470 589 06 61 00 number FG 01 Set C Category Mercedes-Benz Truck Basic Operations
W58.20-1072-00
Sector gear
Use For fixing gear on compressor in place.
Special tool W 470 589 12 40 00 number FG 07 Set C Category Mercedes-Benz Truck Special Operations Note In combination with locating tool W 470 589 08 40 00
W58.20-1073-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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Assembly tool
Use For assembling piston in cylinder barrel.
Special tool W 470 589 03 59 00 number FG 03 Set C Category Mercedes-Benz Truck Basic Operations Note Available as of march 2013
W58.20-1074-00
Collet
Use For disassembling water channel cap in cylinder head.
Special tool W 470 589 00 34 00 number FG 01 Set B Category Mercedes-Benz Truck Basic Operations Note Available as of november 2012
W58.20-1075-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 470
Special tool
Engine OM 470
Spacer ring
Use For assembling front radial shaft sealing ring.
Special tool W 470 589 01 34 00 number FG 03 Set B Category Mercedes-Benz Truck Special Operations Note In combination with extraction and insertion device W 541 589 02 33 00
W58.20-1076-00
Stop plug
Use For sealing connections when measuring the fuel return quantity on the Mahle fuel filter module.
Special tool W 470 589 18 91 00 number FG 07 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with test adapter W 470 589 02 21 00
W58.20-1077-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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14-pin adapter cable
Use For testing injectors.
Special tool W 470 589 05 63 00 number FG 07 Set B Category Mercedes-Benz Truck Basic Operations Note In combination with test box W 000 589 00 21 00
W58.20-1078-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Engine OM 470
Special tool
Transmission G 140-8
Support plate
Use For removing transmission with an inspection pit lift.
Special tool W 715 589 26 63 00 number FG 26 Set B Category Mercedes-Benz Truck Special Operations
W58.20-1079-00
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Introduction of the New Truck Generation - The New Antos (Model 963)
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Socket wrench bit
Use For loosening and tightening the bolts on the front springs/air bellows support.
Special tool W 963 589 00 09 00 number FG 32 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1080-00
Release tool
Use For non-destructive disconnection of compressed air line connection.
Special tool W 963 589 01 63 00 number FG 42 Set B Category Mercedes-Benz Truck Basic Operations
W58.20-1081-00
Introduction of the New Truck Generation - The New Antos (Model 963)
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Special tool
Model 963
Annex
Abbreviations
ABA Active Brake Assist ABH Body manufacturer ABS Antilock Brake System ACM Aftertreatment Control Module AGR Exhaust gas recirculation (EGR) ASA Additional Steering Axle ASH Body floor height ASIC Application System Integrated Circuit ASR Acceleration skid control ATA Anti-theft alarm system BESO Battery Emergency Switch Off CAN Controller Area Network
CC Car Carrier CDS Central Data Storage CGW Central gateway control unit CLCS Chassis Level Control System COM Communication Interface CPC Common Powertrain Controller DCMD Door Control Module Driver DCMP Door Control Module Passenger DNA Twin-tired trailing axle DOHC Double Overhead Camshaft DPF Diesel Particulate Filter
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EAPU Electronic Air-Processing Unit EBS Electronic Brake Control ECE Economic Commission for Europe EIS Electronic Ignition Switch ENA Single-tired trailing axle ESP® Electronic Stability Program ET Wheel offset FHS Cab HA Rear axle (RA) HVAC Heating Ventilation Air Conditioning IAC Independent Air Conditioning (stationary air conditioner) IBS Battery sensor ICUC Instrument Cluster Unit Common
ITH Independent Truck Heating (TRUCK auxiliary heater) KTL Cathodic immersion painting LD Low Deck LED Light Emitting Diode LIN Local Interconnect Network LL Low Liner MCM Motor Control Module MS Maintenance System MSF Modular switch panel NLA Trailing axle OM Diesel engine PG Product Group
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Annex
Abbreviations
Annex
Abbreviations
PPC Predictive Powertrain Control PSM Parameterizable Special Module PTO Power Take-Off RCM Retarder Control Module RDF Radar Front End RLS Rain and Light Sensor SA Special equipment SAS Steering wheel angle sensor SCA Sensor and Actuator Module, Cabin SCH Sensor and Actuator Module, Chassis SCR Selective Catalytic Reduction SRS Supplemental Restraint System SWR Secondary Water Retarder
SZF Semitrailer tractor TCC Truck Control Center TCM Transmission Control Module TPM Tire Pressure Monitoring System VA Front axle (FA) VLA Leading axle VRDU Video and Radar Decision Unit (driver assistance system control unit)
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A
Air pressure gauge . . . . . . . . . . . . . . . . . . 43
M
M cab . . . . . . . . . . . . . . . . . . . . . . . . . 49
B
Body floor height . . . . . . . . . . . . . . . . . . . 49
P
Performance graphs
OM 470 . . . . . . . . . . . . . . . . . . . . . . . 24 OM 936 . . . . . . . . . . . . . . . . . . . . . . . 23 Power steering pump . . . . . . . . . . . . . . . . 45
C
Cab dimensions . . . Clearances on frame Cold Climate Pack . . Comfort Pack . . . .
. . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . . . . 38 . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . . . 16
Predictive Powertrain Control . . . . . . . . . . . . 68
R
Rear axle . . . . . . . . . . . . . . . . . . . . . . . 41
D
Distribution haulage . . . . . . . . . . . . . . . . . 10
S
S cab . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Safety Pack . . . . . . . . . . . . . . . . . . . . . . 15 Swap body frame . . . . . . . . . . . . . . . . . . . 39
E
Economy Pack . . . . . . . . . . . . . . . . . . . . . 15 End crossmember . . . . . . . . . . . . . . . . . . . 40
T
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Trailing axle . . . . . . . . . . . . . . . . . . . . . . 42 Transmission
G 140-8 . . . . . . . G 230-12 . . . . . . G 280-16 . . . . . . Transmission cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 32 33 37 36 36 36 34
H
Headlamps . . . . . . . . . . . . . . . . . . . . . . . 64
I
Instrument panel . . . . . . . . . . . . . . . . . . . 57 Interior concept . . . . . . . . . . . . . . . . . . . . 17
L
L cab . . . . . . . . . . Leading axle . . . . . . LOADER . . . . . . . . Long-distance haulage
. . . . . . . . . . . . . . . . 49 . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . 8, 12 . . . . . . . . . . . . . . . . 10
Transmission modes
Economy . . . . . . Fleet . . . . . . . . Power . . . . . . . . Transmission ratios .
W
Wheelbase . . . . . . . . . . . . . . . . . . . . . . 11
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Annex
Index
Daimler AG, GSP/OR, HPC R 822, D-70546 Stuttgart Order No. 6517 1263 02 - HLI 000 000 08 94 – Printed in Germany – 06/12
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