MERCEDES BENZ Atego New Service manual

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

Introduction of the New Truck Generation

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The New Atego (Model 967)

Introduction into Service Manual

Preface 3

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Overview 4

New features/modifications 4

Overall vehicle 6

Distribution haulage 6
Construction vehicle 7
Equipment 8

Drive 10

Engines 10
Engine power take-off 15
Exhaust system 16
Fuel system 17

Transmission 18

Clutch 18
Manual and automated transmission 21
Transmission modes 24
Automatic transmission 25
Power take-off 26
Transfer case 29

Chassis 31

Frame 31
Axles 34
Suspension 36
Brakes 37
Permanent magnet retarder 39
Wheels and tires 40

Body 41

Cab 41

Networking 49

Overall network 49

1Introduction of the New Truck Generation | The New Atego (Model 967)

Lights 58

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Exterior lights

Special tools

58

59

Transmission 59
Transfer case
Axles

63

Annex

Abbreviations

62

64

64
Index 66
Information and copyright 67

2 Introduction of the New Truck Generation | The New Atego (Model 967)

Dear Reader,

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This Introduction into Service Manual presents the new Atego
(model 967).

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 February 2013 and may
therefore differ from the current production configuration.

Preface

We will publish 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)
February 2013

Note

b

All of the displays and messages of the multifunction
display are shown in German because the correspon­ding versions in other languages were not available at
the copy deadline.

Note

b

Information about the vehicles and about operating
the vehicle functions can also be found in the interac­tive owner‘s manual on the Internet.

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

3Introduction of the New Truck Generation | The New Atego (Model 967)

New features/modifications

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Overview

General

With the introduction of the new Atego (model 967) in May
2013, the new generation of trucks in the area of light com­mercial vehicles of up to 18 t in the segments of distribution
haulage, code V1D (Atego distribution haulage, new) and
construction vehicles, code V1G (Atego construction vehicle,
new) is complete.

The new light model series benefits from the modular system
of the Actros/Antos (model 963) and the Arocs (model 964).
It has the following advantages:

• Uniform electronic architecture

• Same cab configuration for all model series

• Uniform drive configuration

• Uniform range of special equipment (SA)

The model designation logic for the new Atego is also the
same as for the model series 963/964. The wheelbase is not
part of the model designation any more, but represented in a
code.

Wheelbases can be selected in 300-mm increments, as was
the case until now. For more than 12 t, the wheelbases are
shorter by 60 mm due to larger tires; the front axle is shied
toward the rear by 60 mm.

The range of models of the new Atego comprises 42 different
model designations, e.g.

• Dumper vehicle

• Platform vehicle

• Semitrailer tractor

• Fire-fighting vehicle

• Municipal vehicle

The new Atego (model 967)

4

W00.01-1032-00

Introduction of the New Truck Generation | The New Atego (Model 967)

New features/modifications

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Innovations

• New engines OM 934 (4-cylinder) and OM 936 (6-cylin­der) as standard with Euro VI in seven output stages from
115 to 220 kW

• Nine different transmissions that are optimized for the
intended application

• Shi-by-wire with power-assisted gear shiing

• Automated gearshi, Mercedes PowerShi 3 with the

transmission functions crawling mode and EcoRoll, and
transmission modes that can be individually selected

• Permanent magnet retarder

• New model designation (967.603) for fire-fighting vehic-

les 9.8 t, steel suspension, in two wheelbases

• Separate model designation for municipal vehicles (use of
sweeper body)

• Short/extended/long cab and crew cabin, available in
two roof variants ClassicSpace and BigSpace

• New 4-point cab suspension (mechanical/hydraulic)

• Electronic air-processing unit as on Actros/Antos/Arocs

• Driver seat and front passenger seat with armrests (SA),

with flat-weave fabric (standard) and in velour (SA)

• Electronic Stability Program (ESP®) as standard (not
available for all-wheel drive vehicles)

• Modified rear axle guide

• New steering for better vehicle dynamics

• Multifunction steering wheel

• Instrument cluster in two variants with FleetBoard® Eco

Support

• Broader range of light alloy rims from Daewoo and Alcoa

• Headlamps in new design with halogen or LED daytime

running lamps, stone impact protection, folding (SA for
construction vehicles)

• New transfer case (VG 1000)

• Permanent or shi-on-the-fly four wheel drive

• Wide selection of engine power take-offs at front, for ex-

ample, for the operation of Frigo alternator

Overview

W46.10-1040-00

Multifunction steering wheel

W26.10-1169-00

Shi-by-wire switching unit

Introduction of the New Truck Generation | The New Atego (Model 967)

Rear axle guide

W35.10-1063-00

5

Overall vehicle

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Distribution haulage/ Construction vehicle

Overview of model designations

Model

designation

967.000 Platform vehicle 4 x 2 6, 5 t Steel

967.001 Platform vehicle 4 x 2 7,49 t Steel

967.002 Platform vehicle 4 x 2 7,99 t Steel

967.003 Platform vehicle 4 x 2 9,5 t Steel

967.004 Platform vehicle 4 x 2 10,5 t Steel

967.005 Platform vehicle 4 x 2 11,99 t Steel

967.006 Platform vehicle 4 x 2 13,5 t Steel

967.007 Platform vehicle 4 x 2 15,0 t Steel

Vehicle type Wheel configuration Permissible gross

vehicle weight

(max. GVW)

Suspension

967.008 Platform vehicle 4 x 2 11,99 t Steel

967.020 Platform vehicle 4 x 2 6,5 t Air

967.021 Platform vehicle 4 x 2 7,49 t Air

967.023 Platform vehicle 4 x 2 9,5 t Air

967.024 Platform vehicle 4 x 2 10,5 t Air

967.025 Platform vehicle 4 x 2 11,99 t Air

967.026 Platform vehicle 4 x 2 13,5 t Air

967.027 Platform vehicle 4 x 2 15,0 t Air

967.028 Platform vehicle 4 x 2 11,99 t Air

967.034 Platform vehicle 4 x 4 10,5 t Steel

967.036 Platform vehicle 4 x 4 13,5 t Steel

967.037 Platform vehicle 4 x 4 15,0 t Steel

967.201 Dumper vehicle 4 x 2 7,49 t Steel

967.202 Dumper vehicle 4 x 2 7,99 t Steel

967.203 Dumper vehicle 4 x 2 9,5 t Steel

967.204 Dumper vehicle 4 x 2 10,5 t Steel

967.205 Dumper vehicle 4 x 2 11,99 t Steel

967.206 Dumper vehicle 4 x 2 13,5 t Steel

967.207 Dumper vehicle 4 x 2 15,0 t Steel

967.234 Dumper vehicle 4 x 4 10,5 t Steel

967.236 Dumper vehicle 4 x 4 13,5 t Steel

967.237 Kipper 4 x 4 15,0 t Stahl

6 Introduction of the New Truck Generation | The New Atego (Model 967)

Distribution haulage/ Construction vehicle

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Overview of model designations

Model

designation

Vehicle type Wheel configuration Permissible gross

vehicle weight

(max. GVW)

967.426 Semitrailer tractor 4 x 2 13,5 t Air

967.504 Municipal vehicle 4 x 2 10,5 t Steel

967.526 Municipal vehicle 4 x 2 13,5 t Air

967.603 Fire-fighting vehicle 4 x 2 9,8 t Steel

967.605 Fire-fighting vehicle 4 x 2 11,99 t Steel

967.606 Fire-fighting vehicle 4 x 2 13,5 t Steel

967.607 Fire-fighting vehicle 4 x 2 15,0 t Steel

967.633 Fire-fighting vehicle 4 x 4 9,5 t Steel

Suspension

Overall vehicle

967.635 Fire-fighting vehicle 4 x 4 11,99 t Steel

967.636 Fire-fighting vehicle 4 x 4 13,5 t Steel

967.637 Fire-fighting vehicle 4 x 4 15,0 t Steel

Atego distribution haulage, new (V1D)

Introduction of the New Truck Generation | The New Atego (Model 967)

W00.10-1223-00

7

Equipment

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Equipment packages

Overall vehicle

In addition to the basic equipment and the various standard
equipment packages installed according to the vehicle mo­del/intended use, a number of additional safety and comfort
features are also available. These are bundled in packages
that are coded at the factory, such as:

• Cold Climate Pack Basic (Z0U)

• Cold Climate Pack Classic (Z0V)

• Cargo ligate package (P0L)

• LED light package in the front, with turn signal glasses,

white (L1Y)

W68.20-1032-00

Stowage box/tray above windshield, 2 compartments (D7M)

Stowage box/tray, high, on engine tunnel (D7Q)

Engine version Euro VI (M5Z)

W68.20-1031-00

W00.01-1036-00

8

Introduction of the New Truck Generation | The New Atego (Model 967)

Cockpit

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The cockpit is available in three variants depending on the
requirements based on the application:

• Classic cockpit (D4B), standard

• Standard cockpit (D4A), special equipment, standard for

center seat, with seat belt (D1Z)

• Comfort cockpit (D4C), special equipment

Equipment

Overall vehicle

Multifunction steering wheel for comfort cockpit (D4C)

W46.10-1041-00

Classic cockpit (D4B)

Introduction of the New Truck Generation | The New Atego (Model 967)

W68.10-1107-00

9

Engines

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Drive

In terms of design, the 4-cylinder engine OM 934 builds on
the 6-cylinder engine OM 936.

Features of engine OM 934:

• Common rail injection system

• One-stage charging (115 kW and 130 kW engine)

• Two-stage charging (155 kW and 170 kW engine)

• Newly developed engine braking system (decompression

brake) with higher braking power

• Sturdy construction for high output

• Compliance with Euro VI emissions standard with Selec-

tive Catalytic Reduction (SCR), cooled and regulated ex­haust gas recirculation (EGR) and diesel particulate filters

• Electrically controlled viscous coupling

The engines are available in the following output categories:

• OM 934, R4, 5,1 l, 115 kW (156 PS), 650 Nm (M1H)

• OM 934, R4, 5,1 l, 130 kW (177 PS), 750 Nm (M1I)

• OM 934, R4, 5,1 l, 155 kW (211 PS), 850 Nm (M1J)

• OM 934, R4, 5,1 l, 170 kW (231 PS), 900 Nm (M1K)

• OM 936, R6, 7,7 l, 175 kW (238 PS), 1000 Nm (M2A)

• OM 936, R6, 7,7 l, 200 kW (272 PS), 1100 Nm (M2C)

• OM 936, R6, 7,7 l, 220 kW (299 PS), 1200 Nm (M2D)

Note

b

The Introduction into Service Manual for the engine
OM 936 is available in digital form in SDmedia.

Engine OM 934

10

W01.10-1171-00

Introduction of the New Truck Generation | The New Atego (Model 967)

Engines

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Drive

Overview of engine OM 934

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 Fuel system high pressure pump

8 Exhaust gas recirculation cooler

9 Oil/coolant module

Introduction of the New Truck Generation | The New Atego (Model 967)

W01.10-1172-00

10 Turbocharger

11 Coolant manifold

12 Low-pressure stage turbocharger

13 High-pressure stage turbocharger

G2 Alternator

M1 Starter

Y636 boost pressure regulator

A OM 934.911 with one-stage charging

B OM 934.913 with two-stage charging

11

Engines

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Drive

Technical data

Unit OM 934 OM 936

Displacement cm³ 5132 7698

Cylinder number/arrangement 4/inline 6/inline

Valve timing DOHC DOHC

Number of valves per cylinder inlet/outlet 2/2 2/2

Idle speed 1/min 600 600

Output kW 115 (M1H)

130 (M1I)
155 (M1J)

175 (M2A)
200 (M2C)
220 (M2D)

170 (M1K)

Torque Nm 650 (M1H)

750 (M1I)
850 (M1J)

1000 (M2A)
1100 (M2C)
1200 (M2D)

900 (M1K)

Compression ratio e

17,0 17,0

Stroke mm 135 135

Cylinder bore mm 110 110

Total piston height mm 110 110

Connecting rod length mm 215 215

Cylinder spacing mm 128 128

Rail pressure (max.) bar 2400 2400

Braking power
Engine brake, standard system (M5U)
Engine brake, high-performance system (M5V)

kW
kW

120
160

233
302

Weight (DIN-GZ) kg 510

1

at maximum output

Note

b

It is mandatory that the engine brake for high-perfor­mance system (M5V) is installed on vehicles carrying
dangerous goods (ADR code E5T, E5U, E5V, E5W,
E5X, E9E) with OM 934.

12 Introduction of the New Truck Generation | The New Atego (Model 967)

1

651

1

Performance graphs

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Engines

Drive

a OM 934, 115 kW/650 Nm (M1H)
b OM 934, 130 kW/750 Nm (M1I)

M Torque [Nm]
P Output [kW]
n Engine speed [rpm]

W01.00-1119-00 W01.00-1120-00

c OM 934, 155 kW/850 Nm (M1J)
d OM 934, 170 kW/900 Nm (M1K)

Introduction of the New Truck Generation | The New Atego (Model 967)

13

Engines

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Drive

Performance graphs

a OM 936, 175 kW/1000 Nm (M2A)
b OM 936, 200 kW/1100 Nm (M2C)

M Torque [Nm]
P Output [kW]
n Engine speed [rpm]

W01.00-1121-00 W01.00-1122-00

c OM 936, 220 kW/1200 Nm (M2D)

14

Introduction of the New Truck Generation | The New Atego (Model 967)

Front engine power take-off

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Code Name

N7C Front engine power take-off, oil pan changed

N7E Front engine power take-off, with tandem pump

N7F Front engine power take-off, Frigo alternator preinstallation AW 15

N7G Front engine power take-off, Frigo alternator preinstallation AW 22.5

N7H Front engine power take-off, Frigo alternator preinstallation AW 30

N7V Front engine power take-off, tandem pump preinstallation

N7W Front engine power take-off, TK 315 preinstallation

Rear engine power take-off

Engine power take-off

Drive

Code Name

N7K Rear engine power take-off, c, hydraulic pump SAE A

N7M Rear engine power take-off, c, hydraulic pump ISO 7653D

N7N Rear engine power take-off, c, hydraulic pump SAE B, 200 Nm

N7P Rear engine power take-off, b, flange, 600 Nm

Engine power take-off, Frigo alternator AW 22,5

Introduction of the New Truck Generation | The New Atego (Model 967)

W23.10-0001-00

15

Exhaust system

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Drive

Overview of exhaust systems

Code Name

K7A Exhaust system, end pipe upwards

K7H Exhaust system, fire brigade

K7I Exhaust system, on the frame at right, end pipe inward

K7K Exhaust system, positioned horizontally behind cab

K7L Exhaust system, end pipe toward center of traveled way

Exhaust aertreatment

In order to achieve the applicable exhaust limits, an exhaust
aertreatment unit is installed in addition to the EGR inside
the engine. It consists of a diesel oxidation catalytic conver­ter, a diesel particulate filter (DPF) and an SCR catalytic con­verter (Selective Catalytic Reduction). All the components are
in the exhaust aertreatment unit (EATU).

Diesel particulate filter regeneration

Normally, the active regeneration runs automatically approx.
every 8000 km. The exact point of time is determined by the
exhaust aertreatment control module (ACM). Furthermore,
manual activation of regeneration by the driver is possible as
soon as the message that regeneration is required is shown
on the multifunction display.

Exhaust aertreatment unit, engine OM 934

1 Diesel oxidation catalytic converter
2 Diesel Particulate Filter

16

W49.20-1101-00

3 SCR catalytic converter

Introduction of the New Truck Generation | The New Atego (Model 967)

Fuel system

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Drive

Fuel tank

The fuel tanks are made of LMDPE (Linear Medium Density
Polyethylene). The capacity of the standard tank has been

AdBlue® tank

The AdBlue® tank has a capacity of 25 liters; however, a

35-liter tank can be ordered as special equipment.
increased to 120 liters. A fuel tank (K0I) with a capacity of
80 liters has been newly introduced in order to maximize the
payload of the vehicle.

On municipal vehicles, an AdBlue® tank with a capacity of

8 liters (K3R) is installed in the equipment bridge behind the

cab. On fire-fighting vehicles, the AdBlue® tank is located

behind the EATU on the right side of the frame.

Overview

Code Designation Allocation

K0I Plastic tank 80 l, le Special equipment for platform vehicle

K0E Plastic tank 120 l, le Standard on platform vehicle, dumper vehicle,

semitrailer tractor

K0G Plastic tank 180 l, le Special equipment for platform vehicle and dumper

vehicle

K0P Additional plastic tank 100 l, le Special equipment for platform vehicle with K0G

K0Q Additional plastic tanks 2 x 100 l, le Special equipment for platform vehicle with K0G

K0F Plastic tank 130 l, fire-fighting vehicle Special equipment for fire-fighting vehicle

K0H Plastic tank 125 l, at frame end Standard on municipal vehicle

K5V Shunt tank 20 l, tank system from body

manufacturer

Special equipment for all, standard on fire-fighting
vehicle

Introduction of the New Truck Generation | The New Atego (Model 967)

Plastic tank 180 l, le (K0G)

W47.10-1056-00

17

Clutch

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Clutch plate

Transmission

In order to allow greater mileages with the same contact
force of the clutch, clutch plates with thicker linings and
pressure plates with integrated automatic self adjustment are
installed.

The self adjustment mechanism of the clutch pressure plate
compensates for the wear travel of the clutch linings and
keeps the contact force constant during 90% of the clutch
service life.

The self adjustment mechanism continuously registers the
decrease in clutch lining thickness and compensates for the
gap by turning an adjusting ring.

Clutch operating system

With manual transmission, the clutch is operated by pressing
it using a clutch release fork and clutch booster.

Note

b

The adjustment mechanism cannot be manually reset.
In case of repair, the clutch pressure plate must al­ways be replaced along with the clutch plate.

In case of automated gearshi Mercedes PowerShi 3 (G5G),
the clutch is pressed using the central clutch operator, as is
the case in heavy vehicles.

The central clutch release bearing is located on the trans­mission input sha of the manual transmission and is rigidly
bolted to the front of the transmission housing.

Actuation of the pneumatic central clutch release bearing is
carried out by the transmission control unit (TCM) and via the
solenoid valves integrated in the transmission positioner.

18 Introduction of the New Truck Generation | The New Atego (Model 967)

Clutch

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Transmission

Clutch for manual gearshi (G5H)

W25.10-1088-00

Clutch for Mercedes PowerShi 3 (G5G)

Introduction of the New Truck Generation | The New Atego (Model 967)

W25.10-1089-00

19

Clutch

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Assignment clutch - transmission - engine

Transmission

Clutch Flange Transmission Engine P/M Remarks

115 kW / 650 Nm

Ø 362 mm SAE 3

G 70-6
G 71-6
G 90-6

Ø 395 mm SAE 2 OM 936

Ø 395 mm SAE 2

Torque

converter

TC 418

iW= 1,98

SAE 2

G 140-8
G 141-9

Allison
3000P
3000PR
3500P

OM 934

OM 936

OM 934

OM 936

130 kW / 750 Nm

155 kW / 850 Nm

175 kW / 1.000 Nm

200 kW / 1.100 Nm

220 kW / 1.200 Nm

175 kW / 1.000 Nm

200 kW / 1.100 Nm

220 kW / 1.200 Nm

130 kW / 750 Nm Oil cooler: oil/air

155 kW / 850 Nm

170 kW / 900 Nm

175 kW / 1.000 Nm

200 kW / 1.100 Nm

220 kW / 1.200 Nm

Only on fire-fighting
vehicles

Oil cooler: oil/water
Except for 967.526: oil/air

Ø 395 mm SAE 2

P = Output [kW]
M =Torque [Nm]

9S-1115 TD
ZF-ECOMID

130 kW / 750 Nm

OM 934

OM 936 175 kW / 1.000 Nm

155 kW / 850 Nm

170 kW / 900 Nm

20 Introduction of the New Truck Generation | The New Atego (Model 967)