MERCEDES BENZ Zetros New Service Manual

The New Zetros

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Introduction into Service Manual for Model Series 949

Mercedes-Benz Service

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The New Zetros

Introduction into Service Manual

for Model Series 949

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

Information and copyright

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Ordering workshop information

All printed workshop information from GSP/OI, such as Introduction into
Service Manuals, System Descriptions, Function Descriptions, Technology
Guides, Technical Data Manuals and adhesive labels, can be ordered as
follows:

In Germany

Through our GSP/OI Shop on the Internet
Link: http://gsp-ti-shop.de

or alternatively

Phone: [phone]
Fax: [phone]

Outside Germany

Please get in touch with the contact person responsible for your market.

Product portfolio

You can also find comprehensive information on our complete product port­folio in our Internet portal.
Link: http://aftersales.mercedes-benz.com

E-mail: [e-mail]

Questions and suggestions

If you have any questions or suggestions concerning this product, please write
to us.
E-mail: [e-mail]
Fax: [phone]

or alternatively
Address: Daimler AG

GSP/OIS
HPC R822, W002
D-70546 Stuttgart

© 2008 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/OIS, 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: W00.01-1009-00
Order no. of this publication: 6517 1253 02

08/08

Contents

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Preface 5

Overview

Models and major assemblies 6

Brief description 7

Overall vehicle

Technical design 8

Product features 9

Cab concept 10

Engine hood 11

Interior compartment 12

Technical data 13

Dimensions 14

Transport by air and rail 16

Body variants 17

Drive

Overall concept 18

Engine OM 926 LA 19

Power curves 20

Engine data 21

Manual transmission G 131-9 22

Transfer case VG 1700-3W 23

The New Zetros, Introduction into Service Manual for Model Series 949

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Contents

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Chassis

Frame 24

Suspension 25

Front axle 26

Rear axle 27

Tires 28

Steering 29

Body

Cab 30

Electrical system 31

Heating/climate control 36

Seats 37

Special tools

Transmission/engine 38

Workshop equipment

Tools 39

Abbreviations 40

Index 41

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The New Zetros, Introduction into Service Manual for Model Series 949

Dear Reader,

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Preface

This Introduction into Service Manual presents the
new Zetros, model series 949.

The purpose of this brochure is to acquaint you with
the technical highlights of these vehicles in advance of
their market launch. This brochure is intended to
provide information for people employed in service,
maintenance and repair as well as for aftersales staff.
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.

This Introduction into Service Manual is not intended
as an aid for repairs or for the diagnosis of technical
problems. For such needs, more extensive information
is available in the Workshop Information System (WIS)
and in the Diagnosis Assistance System (DAS).

WIS is updated monthly. Therefore, the information
available there reflects the latest technical status of
our vehicles.

This Introduction into Service Manual presents initial
information relating to the new Zetros in model series
949 and, as such, is not stored in WIS. The contents of
this brochure are not updated. No provision is made
for supplements.

We will publicize modifications and new features in the
relevant WIS documents. The information presented in
this Introduction into Service Manual may therefore
differ from the more up-to-date information found in
WIS.

All information relating to specifications, equipment
and options is valid as of the copy deadline in August
2008 and may therefore differ from the series produc­tion configuration.

Daimler AG

Technical Information
and Workshop Equipment (GSP/OI)

The New Zetros, Introduction into Service Manual for Model Series 949

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Models and major assemblies

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Overview

Model series 949.016 949.066

Type of drive 4x4 6x6

Engine OM 926 LA

9-speed manual transmission G131-9
with hydraulic-pneumatic power shift (HPS)

Transfer case
VG 1700-3W

Clutch Single-plate clutch dia. 395 mm

Front axle

Zetros 1833A 2733A

926.935

926.947

1)

2)

926.935

926.947

715.570

750.861

AL7/56 DS-9

730.115

1)

2)

1st rear axle

HL7/56 DS-13

HD7/56 DS-13

748.270

2nd rear axle –

Steering

LS 8 BK

HL7/56 DS-13

765.821

Brakes Drum brakes

Wheel suspension Leaf springs

Tires/rims 14.00 R20/10.00 V20

1)

Euro 3 emissions standard

2)

Euro 5 emissions standard

748.271

748.270

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The New Zetros, Introduction into Service Manual for Model Series 949

Brief description

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Cab-behind-engine vehicles with all-wheel drive

With the Zetros, Mercedes-Benz is continuing its
tradition of cab-behind-engine vehicles with all­wheel drive.

The new cab-behind-engine vehicles with all-wheel
drive from Mercedes-Benz are designed to meet the
following requirements of a modern special­purpose vehicle:

• Reliable handling characteristics on all types of
road and off-road

• Safe and ergonomic controls

• Suitable for special deployments and
specialized transport tasks

• Suitable for worldwide deployment in all climate
zones

• Occupant protection

• Tactical and strategic mobility

• Large ground clearance with a large ramp
breakover angle and large approach/departure
angles for excellent off-road capability

Overview

As the first example of the new generation of cab­behind-engine vehicles with all-wheel drive, the
Zetros naturally benefits from all of the other advan­tages of the cab-behind-engine vehicle concept:

• Well-balanced load distribution for optimal
handling characteristics and steering ability

• Low overall height to facilitate transport by rail
or air, provide a low clearance height and allow
easy entry/exit by occupants

• Easy access to engine and ancillary assemblies
for maintenance and repair

• On military version, optimized distribution of
weight of armor over front and rear axles to
maintain maneuverability and load reserves for
best possible protection

The New Zetros, Introduction into Service Manual for Model Series 949

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Technical design

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The new Zetros meets the specific requirements of
the current market and is based on tried-and-tested
mass-production technology.

Overall vehicle

Proven components from the Actros, Atego and
Axor model series have been used on this vehicle to
ensure that general customer requirements for
quality, cost-efficiency and worldwide support can
be met.

The new vehicle concept, particularly the rede­signed cab, allows the vehicle to meet the specific
requirements placed on a modern special-purpose
vehicle.

Zetros 1833A Front view

W00.10-1048-00

Zetros 1833A Rear view

Zetros 1833A Side view

W00.10-1049-00

W00.10-1050-00

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The New Zetros, Introduction into Service Manual for Model Series 949

Overview of the most important product features

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Product features

1 Low vehicle height
2 Low entry/exit height
3 Cab-behind-engine concept
4 Medium-long cab
5 Full-size three-seater with unhindered

movement between seats (no engine tunnel)

6 Fuel tank with 300 l capacity
7 Underride guard for radiator

8 Planetary front axle

with differential lock

9 Reinforced frame
a 2-speed transfer case with permanent all-

wheel drive

b Planetary rear axle

with differential lock

Overall vehicle

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Cab concept

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The cab has been developed with particular atten­tion paid to ergonomics and safe and uncompli­cated use/operation. The main features are:

Overall vehicle

• Fixed cab with "3-point mounting"

• Engine hood and roof (optional) can be walked
on

• Easy and safe entry/exit

• Modern adjustable seats

• Ergonomic positioning and design of controls
and displays/indicators

• Spacious cab design for three persons with
stowage space for equipment

• Good visibility and overall view

• Low-noise interior

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The New Zetros, Introduction into Service Manual for Model Series 949

W60.80-1135-00

The engine hood can be tilted forwards to allow direct

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access to the engine and all maintenance items. All of
the maintenance items are located under the hood
and are easily accessible. This has the following
advantages:

• Rapid and simple access to engine and ancillary
assemblies

• Cab unloading is not necessary

• Occupants can remain in the cab

• Radio and weapons systems can be used without
limitation

Engine hood

Overall vehicle

The New Zetros, Introduction into Service Manual for Model Series 949

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Interior compartment

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The spacious interior compartment is equipped with
three full-size adjustable individual seats with enough
room for a 3-man crew and their equipment.
The dashboard has been taken over from the

Overall vehicle

Atego/Axor with its tried-and-tested ergonomic posi­tioning of controls and displays/indicators.

W68.00-1009-00

W68.00-1010-00

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The New Zetros, Introduction into Service Manual for Model Series 949

W68.00-1008-00