Sprinter 906 Series Body Builder Information Manual – PDF DOWNLOAD

Description

Sprinter 906 Series Body Builder Information Manual – PDF DOWNLOAD

FILE DETAILS:

Sprinter 906 Series Body Builder Information Manual – PDF DOWNLOAD

Language : English
Pages : 81
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Sprinter 906 Series Body Builder Information Manual – PDF DOWNLOAD

Table of Contents
Alterations 1
Revised 1
1 Introduction 2
1 1 The aim of the Body Builder Information
Book 2
1 2 Vehicle Safety 3
1 3 Operating Safety 3
1 4 Regulatory Requirements: 4
1 5 Definitions 5
1 6 Warranty and Vehicle Safe Operation: 5
2 General 6
2 1 Emissions and safety information 6
2 1 1 Vehicle noise emission control information
6
2 1 2 Exhaust emission control information 7
2 2 Vehicle safety standards information 8
2 2 1 FMVSS 101/CMVSS 101 8
2 2 2 FMVSS 102/CMVSS 102 8
2 2 3 FMVSS 103/CMVSS 103 8
2 2 4 FMVSS 104/CMVSS 104 8
2 2 5 FMVSS 105/CMVSS 105 8
2 2 6 FMVSS 106/CMVSS 106 8
2 2 7 FMVSS 108/CMVSS 108 8
2 2 8 FMVSS 110/CMCSS 110 8
2 2 9 FMVSS 111/CMVSS 111 9
2 2 10 FMVSS 113/CMVSS 113 9
2 2 11 FMVSS 114/CMVSS 114 9
2 2 12 FMVSS 116/CMVSS 116 9
2 2 13 FMVSS 118/CMVSS 118 9
2 2 14 FMVSS 119/CMVSS 119 9
2 2 15 FMVSS 120/CMVSS 120 9
2 2 16 FMVSS 124/CMVSS 124 9
2 2 17 FMVSS 201/CMVSS 201 9
2 2 18 FMVSS 202/CMVSS 202 9
2 2 19 FMVSS 203/CMVSS 203 10
2 2 20 FMVSS 204/ CMVSS 204 10
2 2 21 FMVSS 205/ CMVSS 205 10
2 2 22 FMVSS 206/ CMVSS 206 10
2 2 23 FMVSS 207/CMVSS 207 10
2 2 24 FMVSS 208/ CMVSS 208 10
2 2 25 FMVSS 209/ CMVSS 209 10
2 2 26 FMVSS 210/ CMVSS 210 10
2 2 27 FMVSS 212/ CMVSS 212 10
2 2 28 FMVSS 214/CMVSS 214 10
2 2 29 FMVSS 219/ CMVSS 219 11
2 2 30 FMVSS 220/ CMVSS 220 11
2 2 31 FMVSS 301/ CMVSS 301 11
2 2 32 FMVSS 302/CMVSS 302 11
2 3 Vehicle and model designations 12
2 4 Vehicle and model designation 13
2 5 Vehicle Identification Number (VIN)
Coding Summary 15
2 6 Labels 17
2 7 Granting of body technical assistance 19
2 8 Body builder responsibilities 19
2 9 Vehicle rollover stability information 20
3 Planning of Bodies 21
3 1 Selecting the chassis 21
3 1 1 Selecting the suspension package 21
3 2 Vehicle modifications 22
3 3 Dimensions and weights 23
3 4 Vehicle type identification date 24
3 5 Tires 25
3 6 Bolted and welded connections 26
3 6 1 Bolted connections 26
3 6 2 Welded connections 26
3 7 Noise Insulation 29
3 8 Maintenance and repairs 29
3 8 1 Storing the vehicle 30
3 8 2 Battery maintenance and storage 30
3 8 3 Work before delivering the modified
vehicle 31
3 9 Optional Equipment 31
4 Technical limiting values for planning 32
4 1 Limiting values of the basic vehicle 32
4 1 1 Maneuverability 32
4 1 2 Extreme permissible positions of center of
gravity 32
4 1 3 Center of gravity Chassis Cab 32
4 1 4 Vehicle dimensions Chassis Cab 32
4 2 Chassis limiting values 33
4 2 1 Permissible axle loads 33
4 2 2 Approved tire sizes 33
4 2 3 Diameter of turning circle 33
4 2 4 Modifications to the Axles 33
4 2 5 Modifications to the steering system 33
4 2 6 Modifications to the brake system 33
4 2 7 Modifications to springs, spring
mountings/shock absorbers 33
4 2 8 Wheel alignment 33
4 3 Body shell limiting values 34
4 3 1 Modifications to the body shell 34
4 3 2 Limiting values of the vehicle frame 34
4 3 3 Vehicle overhang 34
4 3 4 Attachment points on the frame 34
4 3 5 Vehicle roof/roof load 34
4 4 Modifications of engine peripherals / drive
train 35
4 4 1 Fuel system 35
4 4 2 Modifications to the engine/drive train
components 35
4 4 3 Engine cooling system 35
4 5 Modification to the interior 35
Body Builder Information Book for SPRINTER model series 906 as of May 3rd, 2011
Only print out complete sections from the current version
I-3
4 5 1 Modifications to airbags and belt tensions
35
4 5 2 Modifications to seats 35
4 6 Limits to Electrics / Electronics 36
4 6 1 Vehicle Marker and Clearance lamps 36
4 6 2 Retrofitting electrical equipment 36
4 6 3 Mobile communication systems 36
4 6 4 CAN bus 36
4 6 5 Electronic Stability Program 36
4 7 Design Limits for additional equipment 36
4 8 Design Limits for attachments 36
4 9 Design Limits for the body 37
4 9 1 Design Limits of the mounting frame 37
5 Damage prevention 38
5 1 Brake hoses / cables and lines 38
5 2 Welding Work 38
5 3 Corrosion protection 40
5 4 Painting work 42
5 5 Towing 42
5 6 Storing and delivery of the vehicle 42
6 Electrics/Electronics 43
6 1 General Information 43
6 2 Electromagnetic compatibility (EMC) 43
6 3 Battery 44
6 3 1 Auxiliary battery retrofit guidelines 45
6 3 2 Retrofitting an additional battery 49
6 3 3 Battery maintenance and storage 49
6 3 4 Alternator 49
6 4 Interfaces 51
6 4 1 CAN bus and networking 51
6 4 2 Electric wiring/fuses 52
6 4 3 Additional power circuits 52
6 4 4 Control Switches 52
6 4 5 Retrofitting electrical equipment 53
6 4 6 Retrofitting an alternator 53
6 4 7 Power supply 54
6 4 8 Power supply Aux Battery 55
6 4 9 Speed Signal 56
6 4 10 Ground Connections 56
Location of Chassis Cab Ground Terminal 57
6 5 Lighting 58
6 5 1 Adjusting the Headlamps 58
6 5 2 Tail lamps 58
6 5 3 Marker Lamps 59
6 5 4 Exterior lamps 59
6 5 5 Interior Lamps 60
6 5 6 Rain-light sensor 60
6 5 7 Aftermarket tail light installation 60
6 6 Mobile communication systems 62
6 6 1 Equipment 62
6 6 2 Connecting and routing the wiring for the
radio antenna 62
6 6 3 Radio 63
6 7 Electronic ignition switch (EZS) 65
6 7 1 General Information 65
6 7 2 Central locking/rescue vehicle 65
6 8 Windows and doors 66
6 8 1 Power windows/window hinges 66
6 8 2 Load compartment sliding door 66
6 8 3 Sliding sunroof 67
6 8 4 Windscreen wipers 67
6 8 5 Exterior mirrors 67
6 8 6 Windscreen heating/rear window heating
67
6 9 Electronic Stability Program (ESP) 67
6 10 Signal acquisition and actuation module
(SAM) 68
6 11 Parametric special module (PSM) 69
6 11 1 Inputs/Outputs 70
6 11 2 Parameterization with Logic Blocks 70
6 11 3 Contacts and pin allocation 71
6 11 4 PSM signals 72
6 12 Tire pressure monitoring system 74
6 13 Parktronic 75
6 14 Lifting platform connection 75
6 15 Rain / light sensor 76
7 Modifications to the basic vehicle 77
7 1 1 General information on the suspension 77
7 1 2 Springs/shock absorbers/anti-roll bars 78
7 1 3 Brake system 79
7 1 4 Wheels and tires 80
7 1 5 Spare wheel 80
7 2 Body shell / Body 81
7 2 1 General information on the body
shell/body 81
7 2 2 Attachment to the frame 84
7 2 3 Chassis frame material 88
7 2 4 Overhang extension 88
7 2 5 Side wall, windows, doors and flaps 91
7 2 6 End frame cross member 92
7 2 7 Roof structure 92
7 2 8 Tire Clearance Chassis-Cab 93
7 2 9 Wheel well Cargo-Van 93
7 2 10 Cutting the cab roof and b-pillar roof arch
94
7 3 Engine peripherals/drive train 96
7 3 1 Fuel system 96
7 3 2 SCR system and DEF Tank location 99
7 3 3 Exhaust system 101
7 3 4 Engine cooling system 102
7 3 5 Engine air intake 102
7 3 6 Clearance for assemblies 103
7 3 7 Engine speed regulation 103
7 4 Interior 104
7 4 1 General Information 104
7 4 2 Safety equipment 105
7 4 3 B-Pillar cover removal & reinstallation 110
Body Builder Information Book for SPRINTER model series 906 as of May 3rd, 2011
Only print out complete sections from the current version
I-3
7 4 4 Reducing noise in the vehicle interior 111
7 4 5 Ventilation 112
7 5 Additional equipment 113
7 5 1 Retrofitting an air-conditioning system 113
7 5 2 Auxiliary heating 113
7 5 3 Power take-offs 114
7 6 Attachments 115
7 6 1 Wind deflectors 115
7 6 2 Attachment above cab 115
7 6 3 Roof racks 115
7 6 4 Fitted shelving/installations 116
7 6 5 Loading cranes 119
7 6 6 Loading tailgate (lifting platform) 120
7 6 7 Trailer hitch 121
7 6 8 Underride guard 122
8 Design of bodies 123
8 1 Mounting frame 123
8 1 1 Material quality 123
8 1 2 Design 123
8 1 3 Section dimensions / dimensioning 124
8 1 4 Attachment to the frame 125
8 1 5 Mounting frame as floor assembly 128
8 2 Self-supporting bodies 128
8 3 Modifications to the interior 129
8 3 1 Retrofitting additional rear seats 129
8 4 Modifications to Cargo vans 129
8 5 Platform bodies 130
8 6 Cargo vans 130
8 7 Refrigerated vehicles 130
8 8 Dump bodies 130
8 9 Rescue vehicles 131
8 10 Torsional rigidity of body types 131
8 11 RV Conversion 132
8 12 Integrated Bodies 133
8 13 Bodies on chassis with lowered roof 135
8 13 1 Mounting the auxiliary roof frame 135
8 13 2 Mounting the body on the auxiliary roof
frame 135
9 Calculating the center of gravity 137

DESCRIPTION:

Sprinter 906 Series Body Builder Information Manual – PDF DOWNLOAD

Introduction:

• This is the Body Builders Information Book for Mercedes-Benz USA LLC (MBUSA) and Mercedes- Benz Canada (MBCAN) and Daimler Vans USA LLC (DVUSA) Mercedes-Benz SPRINTER & Freightliner SPRINTER Vans and Chassis Cabs.
• This publication provides Body Builders who modify or install equipment in Mercedes-Benz Sprinters & Freightliner Sprinters (“SPRINTER”) Engineering specifications and assists them with their regulatory responsibilities.
• The specifications and descriptions contained in this book, including regulatory information, are believed to be accurate at time of publication.
• Nevertheless Body Builders should consult with legal counsel to ensure compliance of pertinent laws and regulations.
• Periodically, this book will be updated as new products are introduced and additional information regarding these products become available.
• Upon written requests MBUSA, MBCAN and DVUSA designee set forth below will provide certain additional technical data.
• SPRINTER ENGINEERING USA/Canada Contact information see page 19. Prior to making any modifications to or installing any equipment in or on a SPRINTER, read this Information Book, and if necessary consult with SPRINTER ENGINEERING USA/Canada.

General:

Emissions and safety information:

• A complete SPRINTER Van “As Delivered” or a Chassis Cab, i.e. an incomplete vehicle, delivered by MBUSA, MBCAN & DVUSA to Dealers or Body Builders is certified for by Daimler AG for compliance with the U.S. and Canadian emissions and safety standards at the time of manufacture.
• If this vehicle is altered, after delivery by MBUSA, MBCAN & DVUSA, Body Builders and/or Dealers assume the regulatory responsibility for certification This section provides general information concerning applicable emissions and safety standards at the time of the vehicle manufacture.
• This section is written to assist Body Builders in understanding the U.S. EPA and the CARB exhaust emission and noise standards, Federal Motor Vehicle Safety Standards (FMVSS) and Canadian Motor Vehicle Safety Standards (CMVSS). SPRINTER ENGINEERING neither approves nor recommends any modifications or additions to the SPRINTER vehicle, which may cause noncompliance with any EPA or FMVSS or CMVSS standards, or render the vehicle unsafe

G.B 07/04/25