Genuine Remanufactured Engines and Transmissions from Mercedes-Benz. Your key to more flexibility.

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1 Genuine Remanufactured Engines and Transmissions from Mercedes-Benz. Your key to more flexibility.

2 ADVANTAGES Your advantages at a glance. Outstanding price/performance ratio From the smallest repair kit right up to a complete assembly our flexible packages have the right solution for every requirement. In one delivery, including transport costs to your Mercedes-Benz Service Partner. Giving the old parts in part-exchange enables you to save even more costs. All complete assemblies are delivered with the latest wiring, control units and updated software. H ow to keep your Mercedes the real thing even with high mileage and a tight budget. Guaranteed Mercedes-Benz quality All wear parts are replaced by Mercedes-Benz GenuineParts. Genuine Remanufactured assemblies are tested to the highest Mercedes-Benz standards. The latest technological developments and quality-related improvements are incorporated into the remanufacturing process. This means that the performance of all delivered Genuine Remanufactured assemblies is improved thanks to updated software. We offer a manufacturer s warranty of up to 2 years for our assemblies.* Mercedes-Benz Genuine Remanufactured Engines and Transmissions are a very convincing proposition. They are the particularly cost-effective and flexible repair solution for many Mercedes-Benz trucks. From repair kits to complete, remanufactured units, we are able to offer a complete portfolio for all repair requirements. All Genuine Remanufactured assemblies have this in common: they lower costs without compromising tried-and-tested Mercedes-Benz quality. Mercedes-Benz Genuine Remanufactured assemblies are completely overhauled to high standards, updated with Mercedes-Benz GenuineParts and subsequently checked on in-house test stands. This allows us to quickly get your vehicle back on the road saving both time and money. See for yourself by specifically asking your Mercedes-Benz Service Partner for Mercedes-Benz Genuine Remanufactured assemblies for your truck. Availability assured The comprehensive Mercedes-Benz Service Network offers a wide product portfolio: over 1500 Mercedes-Benz Genuine Remanufactured assemblies are already available now. The high level of parts availability ensures shorter repair times. Which means gratifyingly short vehicle downtimes. Conservation of resources during manufacture Mercedes-Benz Genuine Remanufactured Parts not only save money, but also large amounts of energy and raw materials. * Available in selected markets. 2 3

3 REMANUFACTURING PROCESS W e keep the best and replace the rest. Remanufacturing. In a multi-stage process using our exclusive know-how as the manufacturer, the assemblies are professionally dismantled, cleaned and remanufactured to high standards. Both engines and transmissions undergo this process. Wear parts are always replaced by Mercedes-Benz GenuineParts. All the assemblies are then subjected to stringent quality control according to Mercedes-Benz test criteria. To ensure the consistently high quality of the remanufacturing processes, we have had them audited and certified by an external service provider, and we carry out continuous quality assurance. Which means that you receive a Mercedes-Benz assembly that performs in every respect: in terms of price, technology and quality. The remanufacturing process quality based on manufacturer expertise Disassembly The assembly is first professionally stripped down to its individual parts, then the valuable materials are systematically segregated and fed into the recycling process where appropriate. This protects the environment: The manufacture of Mercedes-Benz Genuine Remanufactured Parts re quires far less energy and raw materials compared to new parts. Only 1 % of old parts is waste, for example. Cleaning Various cleaning procedures are used in a complex cleaning process that is suited to the part(s) in question e.g. special washing processes and solvent baths for cleaning large surfaces, and sand or glass blasting for detailed areas. But there is nothing to beat the final hand-finishing that ensures perfect cleanliness. Testing All parts are required to meet the highest test criteria. To this end, each part is given a detailed visual and functional examination during which any damage is immediately detected. Sophisticated measuring procedures check for dimensional accuracy and faults that are not easy to recognize such as hairline cracks and leaks. If parts fail to meet the test criteria they are rejected. Remanufacturing All reusable parts are remanufactured using the latest processes, and therefore fully meet Mercedes-Benz specifications in every respect. These processes use manufacturing engineering which only we as the manufacturer of the original assembly can ensure. The remanufacturing of Mercedes-Benz Genuine Remanufactured Parts saves considerable energy and raw materials. Reassembly All tested parts are put together to form a complete Mercedes-Benz Genuine Remanufactured assembly in accordance with the stringent Mercedes-Benz standards. Qualityrelated changes are automa tically incorporated in the process. Quality control Before being dispatched, each assembly is tested on Mercedes-Benz test stands according to the strict criteria for series production of new assemblies for the highest quality, functionality and durability. Installation poses no problems thanks to inte grated and updated control units. 4 5

4 OVERVIEW ENGINES The choice is yours: our range of Mercedes-Benz Genuine Remanufactured Engines. Repair kits Application: for minor or medium damage, or for a general overhaul of engines with a low residual value. Basic repair kit Super repair kit Complete repair kit 40 % cost saving compared to purchasing the individual parts. All parts are a precise fit, and can be ordered with the click of a mouse. 3 variants available depending on the requirement. As individual as your repair needs: Genuine Remanufactured Components and Engines. Reduced downtimes and favorable repair costs: With our extensive and rapidly available portfolio of Genuine Remanufactured Parts, you will find the perfect solution for any engine repairs needed from a repair kit or long block engine right up to a Genuine Remanufactured or factory overhauled, complete engine. You can choose the most suitable repair solution, depending on whether you want the vehicle ready for use as soon as possible or the repair to be particularly low in price. Your engine remains the genuine article thanks to the outstanding know-how of our personnel, standardized processes with testing according to Mercedes-Benz specifications and Genuine Remanufactured Parts in manufacturer quality. You can place your confidence in a Genuine Remanufactured Part in every respect: it meets the high Mercedes-Benz standards, is technologically up-to-date and is configured for a long operating life. Our parts are designed for a second lease of life from the start: highly durable parts such as a crankshaft can even be remanufactured up to 4 times. Valuable raw materials are conserved, as even the materials of old parts that are no longer usable are segregated and recycled. There is a further cost advantage: transport costs to the Mercedes-Benz Service Partner are already included in the quoted price. More information can be found on pages 8 to 10. Long block engine Application: for more severe damage, e.g. crack in the crankcase but detachable parts in good condition. Cost saving thanks to the reuse of detachable parts. Highly effective with little repair effort. More information can be found on page 11. Complete engine Application: for very quick engine replacement, including as-new detachable parts, if the vehicle is to be back on the road as soon as possible. Allround package to reduce downtimes. A worthwhile investment if the vehicle is to deliver maximum availability for a long time to come. Also available as a factory overhauled and Genuine Remanufactured engine priced according to damage. More information can be found on pages 12 and

5 ENGINES Basic repair kit the low-cost alternative. For minor engine rectification work, e.g. increase in oil consumption. Rapidly available: ordered with one mouse click. Up to 40 % price advantage compared to purchase of the individual parts. Super repair kit the fast replacement option. For a major engine overhaul including cylinder heads. Rapidly available: ordered with one mouse click. Up to 40 % price advantage compared to purchase of the individual parts. The Basic repair kit contains the following parts: Bolts, shaft seals, sealing rings and other small parts Cylinder head covers with gaskets and bolts Cylinder head gaskets Fuel filter Oil filter Oil pump Pistons with cylinder liners Reduction of downtimes thanks to rapid availability: The Basic repair kit can be ordered with just one mouse click. This avoids errors when ordering, and makes the laborious entry of individual item numbers unnecessary. The kit is delivered directly to the Mercedes-Benz Service Partner. Up to 40 % cost saving compared to purchasing the individual parts. Actros with V6 and V8 engines with emission standard Euro II to Euro V Axor with in-line 6-cylinder engine with emission standard Euro III to Euro V and EEV New parts or new part standards fitness program for your engine Outstanding functionality, longevity and smooth running thanks to perfectly coordinated components such as e.g. pistons and cylinder liners. The Super repair kit contains the following parts: Bolts, shaft seals, sealing rings and other small parts Cylinder head covers with gaskets and bolts Cylinder head gaskets Cylinder heads with valves and constant throttle Fuel filter Oil filter Oil pump Pistons with cylinder liners Reduction of downtimes thanks to rapid availability: The Super repair kit can be ordered with one mouse click. This avoids errors when ordering, and makes the laborious entry of individual item numbers unnecessary. The kit is delivered directly to the Mercedes-Benz Service Partner. Less repair effort, as e.g. the cylinder heads are already prefitted with valves. Actros with V6 and V8 engines with emission standard Euro II to Euro V Axor with in-line 6-cylinder engine with emission standard Euro IV and Euro V and EEV New parts or new part standards fitness program for your engine Outstanding functionality, longevity and smooth running thanks to perfectly coordinated components such as e.g. pistons and cylinder liners. Long operating life and less wear thanks to hardened cylinder heads. Enhanced vehicle performance as the parts are designed for the severe stresses of heavy-duty operation. Up to 40 % cost saving compared to purchasing the individual parts. 8 9

6 ENGINES Complete repair kit flexible replacement. Long block engine the golden mean. For a complete engine overhaul including crankshaft. Rapidly available: ordered with one mouse click. Up to 40 % price advantage compared to purchase of the individual parts. Reduced downtimes as the engine does not need to be assembled from individual parts. High potential savings as still functioning detachable parts are reused. The Complete repair kit contains the following parts: Bolts, shaft seals, sealing rings and other small parts Crankshaft with bearing shells Cylinder head covers with gaskets and bolts Cylinder head gaskets Cylinder heads with valves and constant throttle Fuel filter Oil filter Oil pump Pistons with cylinder liners Reduction of downtimes thanks to rapid availability: The Complete repair kit can be ordered with one mouse click. This avoids errors when ordering, and makes the laborious entry of individual item numbers unnecessary. The kit is delivered directly to the Mercedes-Benz Service Partner. Less repair effort, as e.g. the cylinder heads are already prefitted with valves. Up to 40 % cost saving compared to purchasing the individual parts. Cost saving thanks to combined and coordinated sets of crankshafts and bearing shells. Actros with V6 and V8 engines with emission standard Euro II to Euro V Axor with in-line 6-cylinder engine with emission standard Euro IV and Euro V and EEV New parts or new part standards fitness program for your engine Outstanding functionality, longevity and smooth running thanks to perfectly coordinated components such as e.g. pistons and cylinder liners. Long operating life and less wear thanks to hardened cylinder heads. Enhanced vehicle performance as the parts are designed for the severe stresses of heavy-duty operation. Genuine Remanufactured long block engine, consisting of: Camshaft Connecting rods Crankshaft Crankcase housing Cylinder head covers (for OM457 and OM500) Cylinder head gaskets Cylinder heads Cylinder liners Nozzle holders (for OM457 and OM500) Oil pump Oil spray nozzles Pistons Timing case Various small parts Drastically reduced downtimes as the engine does not need to be assembled from individual parts. Rapid installation thanks to delivery in a well protected wooden crate, with prefitted valves in the cylinder heads. 60 % lower costs compared to a Genuine Remanufactured engine, as still functioning detachable parts such as the turbocharger, starter and air compressor are reused. Atego, Axor, Actros, Econic, Zetros, Unimog Engine series: 300, 400, 457, 500 and 900 Cleaning and examination carefully cleaned and tested All functional surfaces are carefully cleaned using eco-friendly cleaning agents. This also reveals any hidden damage. Components that are particularly hard to clean, e.g. the crankcase, are cleaned in a multi-stage industrial process and inspected. This is to prevent consequential damage such as bearing seizure caused by residual soiling. Highly sensitive test procedures to remain within series production tolerances of a few micrometers. When reprocessing crankshafts, for example, it is necessary to achieve a spherical accuracy between 2 and 4 μm at the main and conrod bearings. New parts or new part standards fitness program for your engine Very smooth running as all rotating parts such as the crankshaft are finely balanced to the current technical standard of new parts. Great reliability and durability as all wear parts and small parts are replaced with Mercedes-Benz GenuineParts, e.g. lines and bearing shells subject to pressure loads. The hardened outer skin of cylinder heads is restored to the original condition by induction hardening. Compliance with emissions regulations and improved durability, e.g. rigorous replacement of valve guides and reworking of valve seat rings to new part dimensions

7 ENGINES/FACTORY OVERHAUL Complete engine the all-round package. Plug-and-play to reduce downtimes. A worthwhile investment if the vehicle is to deliver maximum availability for a long time to come. For maximum and longest vehicle availability. Genuine Remanufactured complete engine, consisting of: Air compressor Control unit with updated software Engine wiring harness Exhaust manifold Flywheel Power steering pump Starter (for OM457 and OM500) Turbocharger Vibration damper Water pump Plug-and-play: Extensive package contents with preassembled components and optimum dimensional accuracy ensure short downtimes: It is only necessary to remove the old engine and install the new one. Reduced downtime costs as the vehicle is ready for use as quickly as possible. Potential savings in fuel consumption and other operating fluids as the engine operates more efficiently thanks to the control unit with updated software. Prefilling of oil saves money after engine replacement: the break-in engine oil is a prefilled, special Mercedes-Benz mixture. The high rate of reuse for old parts helps to keep the price of Genuine Remanufactured Parts attractive, for example the twin-wire arc spray coating process which restores the crankcase to its original dimensions. New parts or new part standards fitness program for your engine Very smooth running as all rotating parts such as the flywheel and crankshaft are precisely balanced to the current technical standard of new parts. The flywheel and camshafts are of the highest quality as these components are reworked in new parts production and already have sufficient allowance for wear for a second lease of life. Great reliability and durability as all wear parts and small parts are replaced with Mercedes-Benz GenuineParts, e.g. lines and bearing shells subject to pressure loads. The hardened outer skin of cylinder heads is restored to the original condition by induction hardening. Atego, Axor, Antos, Arocs, Actros, Econic, Zetros, Unimog, industrial engines Engine series: OM457, OM500, OM900, OM93X, OM47X Warranty Up to 2 years warranty (only in selected markets). Compliance with emissions regulations and improved durability, e.g. rigorous replacement of valve guides and reworking of valve seat rings to new part dimensions. Full functionality and durability are ensured, and consequential damage is prevented, as obviously functioning parts such as vibration dampers are always subjected to function and dimensional checks, and if necessary replaced with new parts. Cleaning and examination carefully cleaned and tested All functional surfaces are carefully cleaned using eco-friendly cleaning agents. This also reveals any hidden damage. Components that are particularly hard to clean, e.g. the crankcase, are cleaned in a multi-stage industrial process and inspected. This is to prevent consequential damage such as bearing seizure caused by residual soiling. Gentle cleaning processes protect the parts and increase their operating life, e.g. parts with sensitive electrical contacts such as control units and sensors are cleaned with dry ice. Highly sensitive test procedures to remain within series production tolerances of a few micrometers. When reprocessing crankshafts, for example, it is necessary to achieve a spherical accuracy between 2 and 4 μm at the main and conrod bearings. Optimum break-in for the engine to ensure a long operating life by a pressurized oil filling before the engine test run. This ensures that all components receive optimum lubrication right from the first crankshaft revolution. Compliance with statutory emission levels and fuel efficiency are assured, as the engines are optimally tested and adjusted for output, torque, fuel consumption and emission levels on high-tech in-house test rigs. Improved long-term corrosion protection and greater perceived value thanks to a complete paint finish after the engine test run. Factory engine overhaul the economical alternative. A factory overhaul is the economical alternative to a Genuine Remanufactured engine, and is above all worthwhile for older vehicles. Your truck engine will come back from the factory fully overhauled and renewed naturally in unrivaled Mercedes-Benz quality and with the same level of care as a Genuine Remanufactured engine. In some markets the costs of a factory overhaul can be set on the basis of the damage, resulting in a particularly favorable price. There are 3 alternatives depending on the urgency and the extent of required repairs. Individual factory overhaul The most economical solution for price-conscious customers. Your engine is individually overhauled by the manufacturing plant. Standard factory overhaul The most suitable solution for most customers. Advance delivery of an already overhauled engine specifically for your vehicle. Delivery time: 6 to 10 working days. Express factory overhaul The particularly quick solution for customers in a hurry. Advance delivery of an already overhauled engine within 24 hours. Express service at an attractive price

8 OVERVIEW TRANSMISSIONS Our attractive transmission remanufacturing packages. Transfer case All-wheel drive vehicles are quickly repaired. Application: for complete replacement of the transfer case. Sensors and transmitters installed. 100 % operating reliability thanks to test rig run and simulation of different driving situations. More information can be found on page 16. Range-change group The economical, needs-based solution. Application: partial overhaul of the transmission by replacement of an assembly. In the right gear for transmission repairs: Genuine Remanufactured Components and Transmissions. Every powertrain is only as efficient as the transmission that transfers its power. When the worst happens a Mercedes-Benz Genuine Remanufactured transmission therefore comes highly recommended, thanks to its well-proven standard of quality and great economic efficiency. Fast repair, short downtimes: Over 6500 customer variants for numerous models are usually immediately available from Mercedes-Benz Service Partners. Great cost-effectiveness thanks to a wide portfolio with damage-based pricing. High-quality remanufacturing process: transmissions are disassembled into individual parts, cleaned and examined. Worn or outdated parts are completely replaced with Mercedes-Benz GenuineParts. Tried-and-tested longevity as current improvements are incorporated during reprocessing. Full functioning ability is verified by a report following a test rig run. Low fuel consumption and optimum shift comfort thanks to up-to-date software for the transmission control unit. Environmentally friendly and favorably priced: 98 % of old transmission components are recycled. This is both active environmental protection and a cost advantage which we pass directly on to you. Including the required electronic transmitters. Safety-related bolted flange connections tightened and recorded to the technical standard. More information can be found on page 17. Complete transmission When things are particularly urgent. Application: for complete replacement of the transmission. All external shift components are installed. Wiring and sensors are installed. Transmission control unit has up-to-date software. All tapered roller bearings are replaced with new parts. 100 % operating reliability thanks to test rig run under load and simulation of different driving situations. Also available as a factory overhauled or Genuine Remanufactured transmission with price based on damage level. More information can be found on pages 18 and

9 TRANSMISSIONS Transfer case quickly restores power to all the wheels. Short downtimes thanks to less time-consuming repair. Reduced downtime costs thanks to quick delivery. Range-change group new impetus for your transmission. Short downtimes thanks to complete replacement of the range-change group. Price advantage thanks to the option of replacing the range-change group separately. Warranty Warranty Genuine Remanufactured transfer case, consisting of: Sensors Transmitters Actros, Axor, Arocs, Antos, Atego, Zetros Up to 2 years for private and 1 year for commercial customers without mileage limitation (only in selected markets). Genuine Remanufactured range-change group, consisting of: Electronic transmitters Flange Oil pump Shift cylinders Actros, Axor, Arocs, Antos, Atego, Zetros For 9, 12 and 16-speed transmissions 1 year without mileage limitation. Reduced downtimes as components are already installed and tested. Reduced downtime costs thanks to quick delivery: A wide range of transfer cases is always in stock, and can be delivered promptly. Price advantage thanks to the reuse of parts and inclusion of transport costs to the Mercedes-Benz Service Partner. New parts or new part standards fitness program for your transmission Great reliability and longevity as all wear parts and small parts are replaced with Mercedes-Benz GenuineParts, e.g. shift pistons, tapered roller bearings and seals. High product safety as bolted flange connections are tightened and recorded to the series production standard. High-quality corrosion protection thanks to surface treatment that prevents rust. Cleaning and examination carefully cleaned and tested Perfect operation thanks to measurement of all bearing seats in the transmission housings. Worn housings are replaced with new parts. Thorough cleaning for perfect operation and a long service life: careful cleaning of all housing components, plus an additional rinsing procedure, ensure that no foreign bodies are deposited in areas that are difficult to access. High functional reliability thanks to the same high standards during test rig operation that new parts also have to absolve. Reduced downtimes thanks to low repair effort, as the range-change group is completely replaced. Considerably less expensive than a complete transmission depending on the extent of the damage, replacing the range-change group makes the vehicle fit for further operation. Price advantage thanks to the use of Mercedes-Benz production facilities for low-cost components, including transport costs to the Mercedes-Benz Service Partner. New parts or new part standards fitness program for your transmission Great reliability and longevity as all wear parts are replaced with Mercedes-Benz GenuineParts, e.g. shift pistons and electronic transmitters. The range-change group also benefits from the production processes for new parts, for example the carbon coating for the synchronizer cones is replaced using the process for new parts. High product safety as bolted flange connections are tightened and recorded to the series production standard. Cleaning and examination carefully cleaned and tested Sophisticated tests are able to detect the slightest damage, for example the fluorescent magnetic powder crack detection system which can make even microscopic damage to the planet carrier visible. Optimum shift quality thanks to concentricity tested synchronizer cones

10 TRANSMISSIONS/FACTORY OVERHAUL Complete transmission the rapid all-round solution. Shorts downtimes thanks to quick delivery. Reduced repair effort thanks to extensive preassembly. Genuine Remanufactured complete transmission, consisting of: Electronic transmitters and sensors External shift components such as gear and gate modules Transmission control unit with updated software Wiring Actros, Axor, Arocs, Antos, Atego, Zetros, Unimog For 6, 8, 9, 12 and 16-speed transmissions Reduced downtimes as all external parts such as shift components, wiring, sensors and transmitters are already installed and tested as a system. This reduces the repair effort for the Mercedes-Benz Service Partner. Reduced downtime costs thanks to rapid delivery: A wide range of over 1000 transmissions is always in stock, and can be delivered promptly. New parts or new part standards fitness program for your transmission Great reliability and longevity as all wear parts and small parts are replaced with Mercedes-Benz GenuineParts, e.g. shift pistons and tapered roller bearings, the vanes of the countershaft brake and seals. The Genuine Remanufactured complete transmission also benefits from the production processes for new parts, for example the carbon coating for the synchronizer cones is replaced using the process for new parts. High product safety as bolted flange connections are tightened and recorded to the series production standard. Improved shift strategy and shift comfort thanks to updated software for the transmission control unit. Warranty Up to 2 years for private and 1 year for commercial customers without mileage limitation (only in selected markets). Cleaning and examination carefully cleaned and tested Sophisticated tests are able to detect the slightest damage, for example the fluorescent magnetic powder crack detection system which can make even microscopic damage to the planet carrier visible. Optimum shift quality and perfect operation without gear-jumping, thanks to tested concentricity of the synchronizer cones and measurement of all bearing seats in the transmission housings. Worn housings are replaced with new parts. Thorough cleaning for perfect operation and a long service life: Thorough cleaning of all housing components, plus an additional rinsing procedure, ensure that no foreign bodies are deposited in areas that are difficult to access. Shifts the gears like on day 1, as operating reliability is verified by a test rig run under load and simulation of different driving situations. Factory overhauled transmissions with the know-how of professionals. A factory overhaul of the transmission is the economical alternative to replacement, as the overhaul takes current value into account. Only those parts are replaced which are worn or damaged. We work with the same care and according to the same stringent quality criteria as with Genuine Remanufactured transmissions. The overhaul takes all technological and quality-related improvements into account. Parts whose function or operating life is optimized by quality-related product improvements are replaced, resulting in a positive effect on the value retention of your vehicle. You benefit from shorter downtimes thanks to rapid availability. Almost all variants are available immediately. Simply place an order with your Mercedes-Benz company-owned sales and service outlet or an authorized Mercedes-Benz Service Partner. So many advantages are worth warranting: 1 year for commercial and 2 years for private use in both cases with no mileage limitation. In some markets the costs of a factory overhaul can be set on the basis of the damage. There are 3 alternatives depending on the urgency and the extent of required repairs: Individual factory overhaul The most economical solution for price-conscious customers. Your transmission is individually overhauled by the manufacturing plant. Standard factory overhaul The most suitable solution for most customers. Advance delivery of an already overhauled transmission specifically for your vehicle. Delivery time: 2 to 5 working days. Express factory overhaul The particularly quick solution for customers in a hurry. Advance delivery of an already overhauled transmission within 24 hours. Express service at an attractive price

11 Notes on the information in this publication: Changes may have been made to products since this publication went to press in 09/2016. The manufacturer reserves the right to make changes to the design, form, color and specification during the delivery period, provided these changes, while taking into account the interests of the vendor, can be deemed reasonable with respect to the purchaser. Should a Genuine Remanufactured Part be unavailable, a genuine new part may be delivered instead. Where the vendor or the manufacturer uses symbols or numbers to describe an order or the subject of an order, no rights may be derived solely from these. Colors may differ slightly from those shown in the brochure, owing to the limitations of the printing process. This brochure is distributed internationally. Information given regarding statutory regulations, legal requirements and taxation applies only to the Federal Republic of Germany at the time of going to press. Please consult your Mercedes-Benz Dealer for the latest details and for information about legal requirements which apply in other countries. Daimler AG, Mercedesstrasse 137, Stuttgart, GSP/RMM, /0916, Printed in Germany