Mercedes-Benz Arocs 964 Service Manual

Introduction of the New

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Truck Generation
The New Arocs (Model 964)

Introduction into Service Manual

Mercedes-Benz Service

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Introduction of the New Truck Generation

The New Arocs (Model 964)

Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart

Information and copyright

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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: [e-mail]
Fax: [phone]

© 2013 by Daimler AG

This document, including all its parts, is protected by copyright.
Any further processing or use requires the previous written consent of
Daimler AG, Department GSP/OIR, HPC R822, W002, D-70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including
databases and online services.

Image no. of title image: W00.01-1025-00
Order no. of this publication: HLI 000 000 11 04

01/13

Contents

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Preface 5

Overview

New features/modifications 6

Overall vehicle

Product groups 13

Increased gross combination weights 16

Equipment 17

Drive

Engines 19

Engine OM 473 20

Technical data 22

Engine air intake 24

Exhaust system 25

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

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Contents

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Transmission

Clutch 27

Turbo retarder coupling 28

Transmission data 29

Gearshift, manual (G5H) 34

Transmission modes 37

Power take-off 40

Transfer case

Transmission overview 42

Hydraulic Auxiliary Drive (HAD)

General 44

Front axle 46

High-pressure pump/side module 47

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

Contents

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Chassis

Frame 48

Axles 50

Suspension 57

Brakes 58

Wheels and tires 59

Steering 60

Fuel tank 64

Body

Cab 65

Networking

Overall network 71

Lights

Exterior lights 78

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Contents

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Special tools

Engine OM 936 80

Engine OM 470 82

Transmission G 140-8 83

Transmission G 280-16 85

VG 2800-3W, VG 3000-3W 86

Models 963, 964 87

Annex

Abbreviations 88

Index 92

4 i

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

Dear Reader,

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This Introduction into Service manual presents the
new Arocs (model 964) and new features for the
Actros and Antos (model 963).

This brochure is intended for the use of technical
personnel familiar with the service and maintenance
of Mercedes-Benz trucks. It is assumed here that the
reader is already familiar with the Mercedes-Benz
model series currently on the market.

In terms of the contents, the emphasis in this 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 November 2012
and may therefore differ from the current production
configuration.

Preface

We will publicize modifications and new features in the
relevant WIS documents only. Individual details in this
brochure may therefore differ from more up-to-date
versions published in WIS.

Daimler AG

Wörth Plant, GSP/TTH

November 2012

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:

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

www.mercedes-benz.de/betriebsanleitung

This Introduction into Service manual is also avail­able in digital form as a PDF in SDmedia.

5i

New features/modifications

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Overview

General

In early 2013, following the successful launch of the
new Actros and Antos, the new Arocs model 964
heavy construction vehicles will be presented.

They will be introduced in 4 stages:

In February 2013 the steel-sprung non-AWD vehi­cles with the axle configurations 4x2, 6x4 and
8x4/4 will be launched.

In May 2013 these will be followed by the
6x2/2 VLA variants with leading axles and the
6x2 ENA/DNA with trailing axles.

From July 2013 the air-sprung construction vehicles
and all-wheel-drive variants will be available.

The 6x2/4 vehicles will follow in November 2013.

For construction vehicles the product group
Grounder (V1Z) will be introduced as well as the
Loader (V1Y) product group.

Grounders are vehicles with "overloadable" chassis
with steel suspension. They have 9 mm thick longi­tudinal frame members (standard is 8 mm) and
strengthened springs. Large tires are also available
for extreme conditions.

Loaders are vehicles with weight-optimized stan­dard and special equipment. Among the construc­tion vehicles, these are primarily payload-optimized
concrete mixers and the semitrailer tractor

964.403 for tanker/silo service.

The new Arocs

6

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New features/modifications

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Distinguishing features of the model series

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New Actros (V1A) model 963

Overview

Long-haul vehicles

• L cabs with width 2300 mm or 2500 mm

• Interior trim almond beige

• Rear axles only with air suspension

• Only automated manual transmissions with
Mercedes PowerShift 3 (G5G)

•Rigid frame design

Distribution vehicles

• S and M cabs with width 2300 mm

• Interior trim flannel gray/greige

• Rear axles only with air suspension

• Only automated manual transmissions with
Mercedes PowerShift 3 (G5G)

•Rigid frame design

Antos (V1C) model 963

Arocs (V1B) model 964

W00.00-1069-00

W00.00-1070-00

Construction vehicles

• S, M and L cabs with width 2300 mm or
2500 mm

• Interior trim anthracite/greige

• Straight front axle for greater ground clearance

• Unique radiator grille design

• Unique mirror covers

• Also with steel suspension on the rear axle

• Variants with all-wheel drive

• Also with drum brakes

• Front axle set back 100 mm

• Transmission with manual shift available

• Flexible frame

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New features/modifications

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Overview

Construction

• Large number of entirely new vehicle concepts
(axle configurations/tonnages)

• Easier mounting of various bodies through a
wide selection of wheelbases for the different
chassis variants that can be ordered ex factory.
The rear frame overhang can be selected in
300 mm increments

• 2 frame variants for the various operating
conditions. A narrow, soft frame for steel-sprung
vehicles, and a wide, moderately rigid frame for
air-sprung vehicles

• A wide choice of air-sprung construction
vehicles, some overloadable

• All vehicles in the construction model series
feature automated manual transmissions with
Mercedes PowerShift 3 (G5G) as standard
equipment

• Manual shift transmissions with the new cable
shift (Cable Power Shift (G5H)) with power­assisted gear shifting are available as special
equipment

• Turbo retarder coupling for heavy-duty trucks in
combination with the automated Mercedes
PowerShift 3 transmission G 280-16

• New semi-clutch-independent live power take­offs (NMV) with two different ratios

• Virtually all the cab variants from the two long­haul and distribution model series are also
available for the construction vehicles

• Unique cab design with fixed entry step for all
air-sprung construction vehicles and with
movable step for all steel-sprung construction
trucks and all dumper/concrete mixer chassis

• Different axle drops can be selected for the front
axle to produce a variety of ground clearances

• Introduction of the Grounder product group

• Servotwin
special equipment for 4-axle vehicles and
standard for front axle loads > 7.5 t

• Wide rear axle for single tires

• Air suspension at the rear axle also for models
with max. GVW from 20 t to 32 t

®

electrohydraulic steering (C6H) as

Distribution haulage/long-distance
haulage

• New air-sprung 20 t 4x2 platform trucks and
semitrailer tractors

• New air-sprung 33 t 6x4 platform trucks and
semitrailer tractors

• New air-sprung 25 t 6x2/4 VLA 22.5'' platform
trucks and semitrailer tractors

Distribution haulage/long-distance
haulage/construction

• Engine OM 473 with turbocompound

• Hydraulic Auxiliary Drive (HAD)
Hydraulic drive of the front axle with wheel hub
motors

• DuraFlange aluminum rims in sizes 9.00x22.5
and 11.75x22.5

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

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i Note

Various components of the Arocs, such as the
safety and support systems, are identical to those
in the Actros and Antos model 963, and are there­fore not described again here.

New features/modifications

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The new construction vehicles of model series 964 and six new vehicles of model series 963 that will be avail­able from 2013 are listed below.

Vehicles launched in February 2013

Model Wheel

configuration

Semitrailer tractors

964.403 4x2 18 t Air 834 mm

964.401 4x2 20 t Steel 744 mm

963.402 4x2 20 t Air 834 mm

964.414 6x4 26 t Steel 744 mm

964.416 6x4 33 t Steel 744 mm

Platform trucks

964.000 4x2 18 t Steel 744 mm

964.001 4x2 20 t Steel 744 mm

Permissible gross

vehicle weight

Rear suspension Frame width

Overview

963.002 4x2 20 t Air 834 mm

964.014 6x4 26 t Steel 744 mm

964.030 8x4/4 32 t Steel 744 mm

964.016 6x4 33 t Steel 744 mm

964.031 8x4/4 41 t Steel 744 mm

Dumpers

964.200 4x2 18 t Steel 744 mm

964.201 4x2 20 t Steel 744 mm

964.214 6x4 26 t Steel 744 mm

964.230 8x4/4 32 t Steel 744 mm

964.216 6x4 33 t Steel 744 mm

964.231 8x4/4 41 t Steel 744 mm

Concrete mixers

964.314 6x4 26 t Steel 744 mm

964.330 8x4/4 32 t Steel 744 mm

964.316 6x4 33 t Steel 744 mm

964.331 8x4/4 41 t Steel 744 mm

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New features/modifications

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Overview

Semitrailer tractors

Platform trucks

Vehicles launched in May 2013

Model Wheel

configuration

964.423 6x2/2 VLA 22.5'' 24 t/ 25 t Air 834 mm

964.420 6x2 ENA 25 t Air 834 mm

964.425 6x2 DNA 25 t Air 834 mm

964.020 6x2 ENA 25 t Air 834 mm

964.025 6x2 DNA 25 t Air 834 mm

Vehicles launched in July 2013

Model Wheel

configuration

Permissible gross

vehicle weight

Permissible gross

vehicle weight

Rear suspension Frame width

Rear suspension Frame width

Semitrailer tractors

964.407 4x4 18 t Steel 744 mm

964.408 4x4 20 t Steel 744 mm

964.402 4x2 20 t Air 834 mm

964.424 6x4 26 t Air 834 mm

964.418 6x6 33 t Steel 744 mm

963.426 6x4 33 t Air 834 mm

964.426 6x4 33 t Air 834 mm

Platform trucks

964.007 4x4 18 t Steel 744 mm

964.003 4x2 18 t Air 834 mm

964.008 4x4 20 t Steel 744 mm

964.002 4x2 20 t Air 834 mm

964.024 6x4 26 t Air 834 mm

964.038 8x4/4 32 t Air 834 mm

964.041 8x4 ENA 32 t Air 834 mm

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New features/modifications

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Vehicles launched in July 2013

Model Wheel

configuration

Platform trucks

964.018 6x6 33 t Steel 744 mm

963.026 6x4 33 t Air 834 mm

964.026 6x4 33 t Air 834 mm

Dumpers

964.207 4x4 18 t Steel 744 mm

964.203 4x2 18 t Air 834 mm

964.208 4x4 20 t Steel 744 mm

964.202 4x2 20 t Air 834 mm

964.224 6x4 26 t Air 834 mm

964.238 8x4/4 32 t Air 834 mm

Permissible gross

vehicle weight

Rear suspension Frame width

Overview

964.241 8x4 ENA 32 t Air 834 mm

964.218 6x6 33 t Steel 744 mm

964.226 6x4 33 t Air 834 mm

964.232 8x6/4 41 t Steel 744 mm

964.233 8x8/4 41 t Steel 744 mm

Concrete mixers

964.324 6x4 26 t Air 834 mm

964.330 8x4/4 32 t Air 834 mm

964.338 8x4/4 32 t Air 834 mm

964.341 8x4 ENA 32 t Air 834 mm

964.326 6x4 33 t Air 834 mm

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New features/modifications

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Overview

Semitrailer tractors

Platform trucks

Concrete mixers

Vehicles launched in December 2013

Model Wheel

configuration

963.422 6x2/4 VLA 22.5'' 25 t Air 834 mm

964.422 6x2/4 VLA 22.5'' 25 t Air 834 mm

963.022 6x2/4 VLA 22.5'' 25 t Air 834 mm

964.022 6x2/4 VLA 22.5'' 25 t Air 834 mm

Vehicles launched in January 2014

Model Wheel

configuration

Permissible gross

vehicle weight

Permissible gross

vehicle weight

Rear suspension Frame width

Rear suspension Frame width

964.338 8x4/4 41 t Steel 834 mm

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

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Product group: Grounder (V1Z)

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The new Arocs will see the introduction of the
product group (PG) Grounder (V1Z). Grounders are
vehicles with maximum load rating, robustness and
offroad capability for customers in the construction
business.

Product groups

Overall vehicle

The main features of the Grounder PG with the example of a dumper

1Strengthened frame
2 Strengthened steel suspension
3 Planetary hub reduction axles
4 Stabilizer bar
5Steel rims
6Large tires

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Product groups

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Product group: Loader (V1Y)

The product group (PG) Loader (V1Y), first intro-

Overall vehicle

duced with the Antos, is also available for the Arocs
model 964.

Customers in the construction industry are offered
a payload-optimized semitrailer tractor (964.403),
e.g. for dumper semitrailers, as well as extremely
payload-efficient concrete mixers (964.330/338).

Equipment packages for the Loader PG with the example of a concrete mixer

Loader standard equipment, not deselectable

1 Compressed air reservoir, aluminum (B4L)
2 Omission of guard plate under bumper (M9V)

Loader standard equipment, selectable/deselectable

3 Omission of front passenger seat (D9Z)
4 Bumper, center section with towing eyes (F7C)

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W00.01-1027-00

Loader standard equipment, exclusive, not
deselectable

5 Windshield, weight-optimized (F6G)
6 Floor covering, weight-optimized (D5V)
7 Aluminum battery lines (Z7J)
8 Omission of engine suspension lugs

Loader standard equipment, exclusive,
selectable/deselectable

9 Rear axle, ring gear 390, hypoid, 9.5 t, single (A2O)
10 Tubeless tires, 385/65 R 22.5 on rear axle (I2Q)
11 Batteries 2 x 12 V/140 Ah, low-maintenance (E1F)
12 Omission of roof hatch/roof vent flap (D9T)

Product groups

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Models in the Grounder product group

Model Axle configuration Version Max. GVW

964.001 4x2 Platform 20 t

964.008 4x4 Platform 20 t

964.016 6x4 Platform 33 t

964.018 6x6 Platform 33 t

964.031 8x4/4 Platform 41 t

964.201 4x2 Dumper 20 t

964.208 4x4 Dumper 20 t

964.216 6x4 Dumper 33 t

964.218 6x6 Dumper 33 t

964.231 8x4/4 Dumper 41 t

964.232 8x6/4 Dumper 41 t

964.233 8x8/4 Dumper 41 t

964.316 6x4 Concrete mixer 33 t

Overall vehicle

964.331 8x4/4 Concrete mixer 41 t

964.401 4x2 Semitrailer tractor 20 t

964.408 4x4 Semitrailer tractor 20 t

964.416 6x4 Semitrailer tractor 33 t

964.418 6x6 Semitrailer tractor 33 t

Models in the Loader product group

Model Axle configuration Version Max. GVW

964.330 8x4/4 Concrete mixer 33 t

964.338 8x4/4 Concrete mixer 41 t

964.403 4x2 Semitrailer tractor 18 t

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Increased gross combination weights

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Gross combination weights above 44 t

Increased gross combination weights (GCW) can

Overall vehicle

now be selected by code for the first time. The code
covers all the components necessary to achieve the
desired GCW. The vehicle can then be licensed with
the required GCW.

Codes for increased gross combination weights

Code G0A G0B G0C G0D

GCW up to 68 t up to 80 t up to 120 t above 120 t

At gross combination weights above 120 t the turbo
retarder coupling (G3Y) is recommended. Further­more, on 2-axle vehicle of 44 t GCW and above, a
parking brake on the front axle (B2Z) is necessary.

Drive one driven axle at least 2 driven axles

Clutch 1-plate 2-plate 2-plate, also turbo retarder coupling

G 260-16 (G1J) G 260-16 (G1J) G 260-16 (G1J)

G 280-16 (G2D) G 280-16 (G2D) G 280-16 (G2D)

Transmission

G 281-12 (G2E) G 330-12 (G2F)

G 330-12 (G2F)

Planetary hub

reduction rear axle

Rear axle

with ring gear 300

(A2G) or hypoid rear

axle with ring gear

485 (A2I)

Planetary hub reduction rear axle with ring gear 300 (A2G) or (A2H)

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General

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Equipment

In addition to the basic equipment and the various
standard equipment packages installed according
to the vehicle model/product group, a number of
additional safety and comfort features are also
available. These are bundled in packages that are
coded at the factory, such as the Safety Pack or the
Comfort Pack. The scope of these packages is
already described in the Introduction into Service
manuals for the new Actros and Antos.

Code

K5R Guard plate for tank

L4Z Stone impact protection, metal, for headlamps

L1Q Rear lamps for construction vehicles, in metal surround with mesh

A new package specifically for the Arocs is the
Protection Pack (Z9E).

The Protection Pack comprises a number of items
of protective equipment for construction site oper­ations.

The Protection Pack is only available for left-hand
drive vehicles (Z5X) and not for semitrailer tractors
(964.4xx) or the models 964.211 and 964.013.

Scope of Protection Pack (Z9E)

Overall vehicle

F7Z Step, with handrail on roof

Step, with handrail on roof (F7Z)

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Equipment

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Axle load compensation

8x6 and 8x8 vehicles are equipped with axle load

Overall vehicle

compensation as standard.

The axle load compensation system distributes the
load almost equally between the two front axles
when the vehicle is driven over bumps and obsta­cles. This prevents damage due to overloading and
reduces wear on the axle suspension, steering and
tires.

Axle load compensation

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W33.00-1035-00

Engines

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Drive

The engines OM 936, OM 470 and OM 471 that
are already available for the Actros and Antos
(model 963) are also offered for the Arocs
(model 964).

OM 936

• 175 kW (238 hp), 1000 Nm (M2A)

• 200 kW (272 hp), 1100 Nm (M2C)

• 220 kW (299 hp), 1200 Nm (M2D)

• 235 kW (320 hp), 1300 Nm (M2E)

• 260 kW (354 hp), 1400 Nm (M2F)

OM 470

• 240 kW (326 hp), 1700 Nm (M2N)

• 265 kW (360 hp), 1800 Nm (M2P)

• 290 kW (394 hp), 1900 Nm (M2Q)

• 315 kW (428 hp), 2100 Nm (M2R)

OM 471

• 310 kW (421 hp), 2100 Nm (M3A)

• 330 kW (449 hp), 2200 Nm (M3B)

• 350 kW (476 hp), 2300 Nm (M3C)

• 375 kW (510 hp), 2500 Nm (M3D)

A new addition for the models 963 and 964 is the
OM 473, a 6-cylinder inline engine with a displace­ment of 15.6 l, which is available in 3 power catego­ries.

OM 473

• 380 kW (517 hp), 2600 Nm (M3N)

• 425 kW (578 hp), 2800 Nm (M3P)

• 460 kW (625 hp), 3000 Nm (M3V)

i Note

Engine OM 473 will be available as of December
2013 and March 2014 (all-wheel drive vehicles).

Engine OM 473 Euro VI

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Drive

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Engine OM 473

The OM 473 is technically based on the engines
OM 470 and OM 471 that have already been
introduced, but also features a turbocompound.

Overview of engine OM 473

1Rail
2 Diesel fuel metering unit (for regeneration of diesel

particulate filter)
3 Compressor
4 Fuel filter module
5 Oil/coolant module with coolant pump
6 Exhaust gas recirculation cooler
7 Refrigerant compressor

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W01.10-1143-00

8Turbocharger
9Turbocompound

10 Power steering pump

G2 Alternator
M1 Starter

A Left ("cold") side of engine
BRight ("hot") side of engine

Turbocompound

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The turbocompound is a power turbine that is
installed downstream of the turbocharger in the
exhaust stream and which converts the energy of
the exhaust gas into kinetic energy. The kinetic
energy is delivered directly to the crankshaft of the
engine via a 2-gear train with an intermediate
hydrodynamic coupling. This means that up to
35 kW more power can be delivered with simulta­neous reductions in fuel consumption and
CO

emissions.

2

Engine OM 473

Drive

Turbocompound

1Turbocharger
2 Turbocompound turbine wheel
3 Primary reduction gear

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4 Hydrodynamic coupling
5 Secondary reduction gear
6 Crankshaft gear

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Drive

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Technical data

Unit OM 936 OM 470 OM 471 OM 473

Displacement cm

3

7698 10677 12809 15569

Cylinder number/arrangement 6/inline 6/inline 6/inline 6/inline

Valve timing DOHC DOHC DOHC DOHC

Number of valves per cylinder

2/2 2/2 2/2 2/2

(intake/exhaust)

Idle speed rpm 600 500 560 500

Power kW 175 (M2A)

200 (M2C)
220 (M2D)
235 (M2E)

240 (M2N)
265 (M2P)
290 (M2Q)
315 (M2R)

310 (M3A)
330 (M3B)
350 (M3C)
375 (M3D)

380 (M3N)
425 (M3P)
460 (M3V)

260 (M2F)

Torque Nm 1000 (M2A)

1100 (M2C)
1200 (M2D)
1300 (M2E)

1700 (M2N)
1800 (M2P)
1900 (M2Q)
2100 (M2R)

2100 (M3A)
2200 (M3B)
2300 (M3C)
2500 (M3D)

2600 (M3N)
2800 (M3P)
3000 (M3V)

1400 (M2F)

Compression ratio ε 17.0 17.6 17.3 17.3

Stroke mm 135 145 156 171

Bore mm 110 125 132 139

Total piston height mm 110 105 113.5 119.5

Connecting rod length mm 215 245.5 268 274

Cylinder spacing mm 128 155 165 173

Rail pressure (max.) bar 2400 900 900 900

Weight (DIN-GZ) kg 666

1

with max. power

1

951

1

1092

1

1243

1

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Performance graph: OM 473

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Technical data

Drive

a OM 473, 380 kW/2600 Nm (M3N)

b OM 473, 425 kW/2800 Nm (M3P)

c OM 473, 460 kW/3000 Nm (M3V)

MTorque
PPower
nRpm

W01.00-1113-00

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Drive

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Engine air intake

Cyclone prefilter for coarse dust (M8L)

A cyclone prefilter for coarse dust (M8L) is available
for all model 963 and model 964 vehicles.
The cyclone prefilter protects the paper air filter
from coarse dust and sand. The cyclone prefilter
can be cleaned easily by pressing the rubber lips on
the two dust expulsion valves.

The cyclone prefilter is only available in conjunction
with the optional air intake, behind cab, top
mounted (M8B) or air intake from front (M8A), but
with the air intake from the front only in combina­tion with the body floor height of 420 mm,
OM 936 and steel-sprung cab mounting.

Cyclone prefilter for coarse dust (M8L)

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

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W09.00-1018-00

Exhaust system

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

The following exhaust systems are now available to meet the needs of construction site operations:

Code Description

K7A Exhaust system, end pipe upwards

K7E Exhaust system, end pipe upwards, outlet variable

K7F Exhaust system, offset, with large tires

K7G Exhaust system, with connection for dumper bucket heater

Drive

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

Code Description

K7R Exhaust pipe, straight, over second axle

K7S Exhaust pipe, curved, over second axle

K7T Exhaust pipe, over fender, second axle

From the exhaust aftertreatment unit it runs under
the frame and back over the 2nd axle towards the
front again to the upright end pipe behind the cab.

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

25i

Drive

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

Exhaust system

W49.00-1007.00

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

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

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