Mercedes-Benz 405 Service Manual
Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart
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Introduction of the New Unimog
Generation
Model Series 405
Introduction into Service Manual
Preface 3
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Overview 4
Vehicle concept 4
Model designation system 5
Model codes 6
Code system 7
Overall vehicle 9
Innovations 9
Drive 13
Technical data 13
Engine OM 934 14
Engine OM 936 16
Model codes 18
Mechanical power take-offs 19
Radiator system 20
Exhaust aertreatment 22
Diesel particulate filter regeneration 27
Transmission 29
Main transmission 29
EAS 31
New hydrostatic drive 33
Overview 33
System components 35
Design 36
Hydraulic components 38
Overview 38
Plug connections 40
Distribution 41
Joystick 42
Work hydraulics 43
2-cell work hydraulics 44
3-cell work hydraulics 45
4-cell work hydraulics 46
Power hydraulics 47
Fan hydraulics 49
Tilting hydraulics 50
Data overview 51
Chassis 52
Overview 52
New axles of U200/U300 53
Mechanical sliding caliper disk brake 54
1Introduction of the New Unimog Generation | Model Series 405
Design 56
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Cab exterior 56
Cab interior 58
Instrument cluster 59
Multifunction steering wheel 60
Center console 61
Networking 62
Overall network 62
Pin assignment of equipment socket 70
Control unit network 71
Central gateway (CGW) 72
Lights 73
Exterior lights 73
Driving assistance systems 75
Tire pressure control system 75
Comfort 76
Heating and climate control 76
Audio and communications 78
Radio unit 78
Tachograph 79
Maintenance 80
Maintenance 80
Operating fluids 85
Diagnosis 86
Special tools 87
Engine OM 934/936 87
Annex 95
Abbreviations 95
Index 98
Information and copyright 100
2 Introduction of the New Unimog Generation | Model Series 405
Dear Reader,
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This Introduction into Service Manual presents the new Unimog generation of model series 405.
This brochure is intended for the use of technical personnel
familiar with service and maintenance. 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 March 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
Mercedes-Benz Global Service & Parts (GSP/ORR)
70546 Stuttgart/Germany
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 at:
www.mercedes-benz.de/betriebsanleitung
This Introduction into Service manual is also available
in digital form as a PDF in SDmedia.
3Introduction of the New Unimog Generation | Model Series 405
Vehicle concept
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Overview
General
The product features of the new BlueTec 6 Unimog implement carrier with Euro VI emissions level have been completely revised for its market launch. The advantages of this
compact and highly maneuverable implement carrier have
been further improved. The vehicle concept has been weightoptimized in order to compensate for the additional weight of
the Euro VI components.
The exhaust aertreatment system with BlueTec 6 is based
on the combination of a closed particulate filter and the
Mercedes-Benz SCR system including AdBlue® injection,
which has been used successfully for many years. This innovation allows nitrogen oxide and particulate emissions to be
reduced by 90 %. The term "BlueEfficiency Power" not only
encompasses the environmentally friendly and cost-efficient
nature of the vehicle, but also the improved power ratings of
the new engine generation.This technological leap in the area
of performance, user-friendliness, traction drive, ergonomics
and safety further underlines the unique selling proposition of
the new Unimog implement carrier compared to trucks and
tractors.
The new hydrostatic drive is revolutionary. It is an intelligent
concept which integrates the hydrostatic drive with the manual transmission in a practical manner.
The new BlueTec 6 Unimog implement carrier
4
G00.20-3127-00
Introduction of the New Unimog Generation | Model Series 405
Model designation system
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The new model designation system is a continuation/extension of the previous system.
Model designation system
Euro V Euro VI
405 . 101 405 . 104
405 101 405 104
Note
b
Model series remains the same, serial number
increases.
Overview
Model series Serial no. Model series Serial no.
Model codes in model designation system
Model code Model designation Wheelbase (mm) Load stages (t) Engine power (kW)
U 216 405.090 2.800 7,5/8,5/10 115
U 218 405.090 2.800 7,5/8,5/10 130
U 318 405.104 3.000 7,5/8,5/10/11 130
U 423 405.105 3.000 11,99/13/13,8 170
U 427
U 430
U 423
405.110 3.150
405.110 3.150
405.125 3.600
11,99/13/13,8 200
11,99/13/13,8 220
11,99/13/13,8 170
U 427
U 430
U 527
U 530
U 527
U 530
405.125 3.600
405.125 3.600
405.202 3.350
405.202 3.350
405.222 3.900
405.222 3.900
11,99/13/13,8 200
11,99/13/13,8 220
11,99/15,5/16,5 200
11,99/15,5/16,5 220
11,99/15,5/16,5 200
11,99/15,5/16,5 220
5Introduction of the New Unimog Generation | Model Series 405
Model codes
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Overview
The new model codes point to a completely revised product
range with the introduction of the "New Unimog Generation"
including new engine technology and allow for differentiation
from the old/existing model series.
Model codes
Old model code New model code
Euro V Euro VI
UNIMOG
Implement carrier Euro V Implement carrier Euro VI
U 400 U 423
Previously without code number for engine power U 4 23
Code number for size class
(same as U 400)
Code number for engine
power (230 hp)
6 Introduction of the New Unimog Generation | Model Series 405
Code system
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With the introduction of the new generation of BlueTec 6 Unimog implement carrier, the codings of the special versions
have been matched to the new codings of the truck model
series. This has necessitated the complete rearrangement
of some letter groups. A third of the codes have stayed
the same, a third of the codes have been matched to the
truck changes and a third have been added due to the new
technology.
The special equipment codes still have three digits but now
have the sequence "letter - number - letter". The codes are
made up of the installation location, function and logical
usage. Codes that belong together have the same number.
For example: all front axles start with A1, rear axles with A2,
etc. The range of numbers "9" in the code groups is reserved
for preinstallations and/or omitted items.
Overview
Design of new code system
1st digit
Code group
Capital letter (A...Z) Number (0...9) Capital letters (A...Z)
Example
A 1 W
Axles/suspension Front axle Front axle differential lock
2nd digit 3rd digit
7Introduction of the New Unimog Generation | Model Series 405
Code system
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Overview
Overview of code groups
A Axles/suspension N Power take-offs
B Brakes O Internal system control
code
C Chassis P Platform/dumper
D Cab interior Q Spring/crossmember/trai-
ler hitch/fih wheel
coupling
E Electrical system R Wheels/spare wheel hol-
der/wheel lis
F Cab exterior S Safety
G Transmission/clutch T Unused
H Hydraulic components U Unused
I Internal code V Unused
J Instruments/
communication
K Fuel system/exhaust
system
W Weight variants
X Miscellaneous
L Lighting system/lamps Y Accessories
M Engine Z Internal system control
8 Introduction of the New Unimog Generation | Model Series 405
code
Innovations
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Numerous optimizations and new features have been phased
into the new Unimog generation. As a result, solutions have
had to be found for the reduction in installation space available. The manoeuvrability and compact dimensions (2.15 m
wide) of the vehicle have nevertheless been retained and
existing implements can therefore still be used almost without modification.
The holistic rework of the product features of the new BlueTec 6 implement carrier is described below under brief
headings:
The cooling system has been adapted to the new technology.
As a result of the uprated engines with cooled exhaust gas
recirculation, cooling power requirements have also increased. The development of the modified cooling system was
based on the aim of retaining the compact vehicle concept
while integrating larger radiators at the same time.
The following concept was therefore put in place:
• Arrangement of radiator and A/C condenser on le-hand
side of vehicle. This reduces radiator soiling during working operations.
• Cleanfix reversible fan with automatic control and highspeed fan drive as special equipment for dirt-intensive
operations (in preparation).
• Swiveling A/C condenser in combination with a widemeshed radiator core and smooth radiator slats for easy
cleaning of the radiator unit.
• Charge air cooler decoupled from the radiator and located under the engine hood.
• Greater efficiency of fan hydraulics due to variable displacement pump and demand-based, separate control of
both fans. The benefit results from the reduced energy
requirement and optimized driving and working performance, including under extreme conditions.
Integrated exhaust management
With respect to exhaust aertreatment, the new engine generation uses the BlueTec 6 technology which has already
proven its effectiveness in practical use on mass-produced
heavy duty engines.
Overall vehicle
Note
b
In parallel to the Unimog Euro VI, the U 400.103/123
will still also be produced with Euro III/V engines.
The exhaust management system ensures that filter regeneration is carried out according to requirements.
• The cooled exhaust gas recirculation system reduces
the proportion of oxygen in the combustion mixture. This
results in the production of less nitrogen oxide during
combustion.
• The camsha adjustment function for increasing the
exhaust temperature supports active regeneration of the
diesel particulate filter during operation.
9Introduction of the New Unimog Generation | Model Series 405
Innovations
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Overall vehicle
High-performance engine brake
The engine brake developed by Mercedes-Benz significantly
reduces the wear on the wheel brake systems and makes a
significant contribution to the cost-efficiency of the vehicle.
The engine brake is designed as a dual-pulsed decompression brake and provides a high level of brake power.
• Each cylinder in the engine has its own engine brake unit.
Fan hydraulics with variable displacement pump
The fan hydraulics are included in the basic scope of all
vehicles.
• Greater efficiency of fan hydraulics due to variable displacement pump and demand-based, separate control of
both fans.
Tilting hydraulics based on fan hydraulics
The tilting hydraulics allow the vehicle tilt cylinder to be adjusted and can be extended to allow the adjustment of external consumers (e.g. rail guide or auxiliary rear axle steering)
(but not permanent consumers).
• Simple tilting hydraulics for the vehicle tilt cylinder (code
HE1)
• Tilting hydraulics with additional connection option for external adjustment operations (code HE2) e.g. trailer with
tilt system.
Working/municipal hydraulics (circuit I and circuit II)
The working hydraulics allow an implement to be adjusted
or a permanent consumer to be supplied. On the 1-circuit
hydraulic system one circuit is available for this, while on
the 2-circuit hydraulic system, two independent circuits are
available, each with its own fixed displacement pump.
This allows adjustment operations to be carried out and a
permanent consumer to be supplied simultaneously. On the
2-circuit hydraulic system, the volumetric flow rates can be
swapped over via the volume switchover function or added
together via flow summation.
Changes compared to the hydraulic system of Euro V
vehicles:
• Fully proportional working hydraulics at connections of
cells 1–4 (connections 1-8)
• Integrated pressure filter
• Control of consumers during adjustment operations via
the vehicle joystick (social distribution) with diagonal
movement of vehicle joystick. Due to the omission of link
motion, two adjustment operations can be carried out
simultaneously. Example: Raise front loader and tilt shovel
simultaneously
• Hydraulic connection possibility on valve block (e.g. for
roll stabilization)
• Electrical interface for actuation of hydraulic valve block
(circuit I) e.g. for external actuation of front and/or rear
power li
• Joystick with rocker switch for forward/reverse shiing of
manual vehicle transmission
10 Introduction of the New Unimog Generation | Model Series 405
Innovations
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Power hydraulics (circuit III and IV)
The power hydraulics allow rotating consumers to be powered (e.g. cutting roller, wood chipper etc.). Both circuits are
designed as open circuits with a maximum pressure of 280
bar. Code HL4 includes one circuit while code HL5 includes
two power hydraulics circuits.
The power hydraulics are located in the platform intermediate frame and can be removed if necessary (e.g. for winter
service operations). They are powered by a propeller sha on
the engine power take-off, code N05. The hydraulic couplings
are located at the vehicle rear above the end crossmember.
Front hydraulic connections are also optionally available, either for one circuit or for both circuits.
System concept of new hydrostatic drive G34:
The new hydrostatic drive system: code G34 combines a
modified hydrostatic drive major assembly concept with the
cruise control operating and control concept. The previous
hydrostatic drive system (code G33) has now been superseded with the launch of the new BlueTec 6 Unimog implement
carrier. The new hydrostatic drive (code G34) allows fully hydrostatic driving at up to 50 km/h and, in combination with
EAS, also allows mixed hydrostatic/transmission-powered
driving and can be controlled with the normal driving controls
(accelerator pedal, brake, gear selector lever, steering wheel
cruise control buttons). In addition, the gearshiing, cruise
control and travel direction functions are supported by a le
additional control lever (code DG1). The vehicle can also be
accelerated and decelerated via the hydraulic joystick in "driving joystick active" mode.
Modified suspension
The capabilities of the suspension have been retained in their
entirety and continue to underline the advantages of the Unimog concept.
• Weight optimization measures: Cutouts in the frame, use
of high-strength steels, greater proportion of light alloys
and plastics
• The portal axles have also been reinforced which means
that the permissible gross vehicle weight is above the
previous level
• The additional major assembly weight has been overcompensated for with additional components
• Pneumatic disk brakes on model series U2xx/U3xx
Standardized mounting points
On the current Euro V model series of the Unimog implement
carrier, mounting points were defined which have proven effective across all areas of usage. The new Unimog generation
will continue to use these standardized interfaces and dimensions. This applies to the front mounting plate, front power
take-off, the ball mounting points on the platform and the
mounting brackets at the rear end.
Improved ergonomics
• Steering column with adjustable height and inclination
(not on vehicles with transferable steering)
• Reduced steering wheel control force and steering capability at standstill
• Multifunction steering wheel
• Improved cab steps
• Transmission control via right multifunction control lever
• EQR operation on hydraulics joystick
• Engine speed adjustment function
• Driving and function controls within primary
(400 mm - 600 mm) area of reach of driver
• Modular positioning of hydraulics joystick
• Hydraulics joystick within optimal reach area
• Improved accessibility of switches of center console
Overall vehicle
11Introduction of the New Unimog Generation | Model Series 405
Innovations
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Overall vehicle
New design of exterior/interior
• Hood
• Roof-mounted wiper system
• Headlamps
• Aluminium rims (optional, code R2T)
• Multifunction steering wheel
• CD radio with Bluetooth® hands-free system
• Instrument cluster
• Controls
• Center console
• Higher output heating/cooling system with improved air
distribution
4-channel ABS
If a wheel is tending towards locking up, the pressure in the
wheel cylinder is corrected depending on the road surface
condition and load condition. This ensures safe handling
characteristics during braking. Driving stability and steerability are maintained in the process, which reduces the risk of
accident.
Further changes and improvements
• Electrical interface EN 16330 for demountable imple-
ments in preparation => code ES6
• Parameterizable special module (PSM) as standard
• Combinations of 0 to 2 trailers are possible without spe-
cial measures for turn signal failure detection.
• Front camera with monitor (available optionally with code
EM3). This improves visibility of the road surface and implements. Up to three additional cameras can be connected via a connecting point in the cab.
• 160 kW instead of 150 kW will now be available at the
front power take-off (limitation of engine torque to 850
Nm instead of 800 Nm previously)
• Increase in permissible load values, particularly on model
series U318 to up to 11000 kg and on U400 to up to
14000 kg
• Due to the optimized frame concept, front skids are
not required for assembly frames for heavy bodies (e.g.
crane). This makes the frames shorter, simpler, lighter
and more cost-effective. It also simplifies assembly.
The ABS can be switched to off-road mode, which allows the
wheels to lock up to a certain extent in order to build up a
wedge of earth. The ABS off-road program must be deactivated on public roads and firm ground.
The 4-channel ABS system is installed on all model designations and has been tested on mass-produced models. It
provides a high level of safety through separate actuation of
each wheel on the front and rear axle.
12 Introduction of the New Unimog Generation | Model Series 405
Technical data
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Unit OM 934 OM 936
Displacement cm3 5100 7700
Cylinder number/arrangement 4/inline 6/inline
Valve timing DOHC DOHC
Number of valves per cylinder (intake/exhaust) 2/2 2/2
Idle speed rpm 720 720
Drive
Output kW 115 (code M1H)
130 (code M1I)
170 (code M1K)
Torque Nm 650
750
900
Compression ratio 17,6/1 17,6/1
Stroke mm 135 135
Cylinder bore mm 110 110
Rail pressure max. bar 2400 2400
200 (code M2C)
220 (code M2D)
1100
1200
13Introduction of the New Unimog Generation | Model Series 405
Engine OM 934
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Drive
The OM 934 is a 4-cylinder inline engine with a displacement of 5.1 l with turbocharger and cooled exhaust gas
recirculation. The OM 934 is available in the following power
categories:
• 115 kW, 650 Nm (code M1H)
• 130 kW, 750 Nm (code M1I)
• 170 kW, 900 Nm (code M1K)
The excellent characteristics of the engines, in particular
their low fuel consumption in relation to their high power,
have been achieved with a range of technical innovations:
• The Common Rail injection system reduces the fuel quan-
tity required for combustion to a minimum.
• The engine brake provides greater performance and is
now designed as a decompression brake which replaces
the constant throttle and exhaust flap brake.
• The engines fulfill the Euro VI emission standard with Se-
lective Catalytic Reduction (SCR), cooled and regulated
exhaust gas recirculation and diesel particulate filters.
Engine OM 934.972
14
G01.10-3133-00
Introduction of the New Unimog Generation | Model Series 405
Engine OM 934
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Drive
Engine power (kW)
G01.10-3135-00
Torque (Nm)
Introduction of the New Unimog Generation | Model Series 405
G01.10-3136-00
15
Engine OM 936
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Drive
The OM 936 is a 6-cylinder inline engine with a displacement
of 7.7 l with turbocharger and cooled exhaust gas recirculation. The OM 936 is only available in EuroVI and the following power categories:
• 200 kW, 1100 Nm (code M2C)
• 220 kW, 1200 Nm (code M2D)
The excellent characteristics of the engines, in particular
their low fuel consumption in relation to their high power,
have been achieved with a range of technical innovations:
• The Common Rail injection system reduces the fuel quan-
tity required for combustion to a minimum.
• The engine brake provides greater performance and is
now designed as a decompression brake which replaces
the constant throttle and exhaust flap brake.
• The engines fulfill the Euro VI emission standard with Se-
lective Catalytic Reduction (SCR), cooled and regulated
exhaust gas recirculation and diesel particulate filters.
Engine OM 936.972
16
G01.10-3134-00
Introduction of the New Unimog Generation | Model Series 405
Engine OM 936
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Drive
Engine power (kW)
G01.10-3137-00
Torque (Nm)
Introduction of the New Unimog Generation | Model Series 405
G01.10-3138-00
17
Model codes
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Drive
Length (mm)
designation
Code Cylinder Charging Model
Engine power
(kW)
Model
designation
Wheelbase
(mm)
designation
Vehicle Engine Exhaust box (AGN)
18 Introduction of the New Unimog Generation | Model Series 405
Model code Model
U 216 405.090 2.800 934.971 115 M1H 4 1-stage 930.728 806
U 218 405.090 2.800 934.971 130 M1I 4 1-stage 930.728 806
U 318 405.104 3.000 934.971 130 M1I 4 1-stage 930.728 806
U 423 405.105 3.000 934.972 170 M1K 4 2-stage 930.728 806
U 427 405.110 3.150 936.971 200 M2C 6 1-stage 930.728 856
U 430 405.110 3.150 936.971 220 M2D 6 1-stage 930.728 856
U 423 405.125 3.600 934.972 170 M1K 4 2-stage 930.728 806
U 427 405.125 3.600 936.971 200 M2C 6 1-stage 930.728 856
U 430 405.125 3.600 936.971 220 M2D 6 1-stage 930.728 856
U 527 405.202 3.350 936.971 200 M2C 6 1-stage 930.728 856
U 530 405.202 3.350 936.971 220 M2D 6 1-stage 930.728 856
U 527 405.222 3.900 936.971 200 M2C 6 1-stage 930.728 856
U 530 405.222 3.900 936.971 220 M2D 6 1-stage 930.728 856
Engine power take-off
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The engageable engine power take-off (code N05) (engageable only with engine off) is driven by the cranksha of the
engine via intermediate gears. The flange output is located
at the rear of the engine and is activated via an engageable
dog clutch. The engine power take-off (code N05) may only
be used in combination with a flexible coupling to insulate it
from engine vibrations.
The essential features of the engine power take-off are:
• Integrated into gear drive of engine
• Drive of power hydraulics (code HL4 or HL5) via a propel-
ler sha (clockwise rotation direction)
Technical data:
• i = 0.933
• Maximum available continuous output 148 kW
• Maximum available torque (continuous) 600 Nm
Mechanical power take-offs
Important
B
The power take-off (code N05) is only approved for
powering hydraulic or water pumps. Direct mechanical drive (e.g. mechanical rear power take-off) is not
permissible.
Drive
OM 936.972 with engine power take-off
1) Fan drive variable displacement pump, engine power take-off additional dumper function (code N05)
2) Engine power take-off (code N05)
Introduction of the New Unimog Generation | Model Series 405
G26.45-3227-00
19
Radiator system
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Drive
The radiator system is located in the frame, behind the cab.
This concept allows space for a windshield which extends far
down towards the engine hood and provides an optimal view
of the working area. The large radiator is designed for high
outside temperatures and slow vehicle speeds to ensure a
high level of operational reliability.
The radiator system can be folded out without the use of
tools, which makes it very accessible for cleaning.
In order to increase the efficiency of the radiator, a radiator
grille is installed to hold back coarse dirt particles.The radiator system is located on the le in the direction of travel and
is thus located in an area which has a low susceptibility to
soiling.
The hydrostatic fan drive provides optimal cooling output
throughout the entire rpm range in any driving situation. It
does so by adjusting the rpm of the fan drive according to
demand and uses as little energy as possible.
Radiator system
20
G20.20-3242-00
Introduction of the New Unimog Generation | Model Series 405
Rapid radiator cleaning system
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The Clean-Fix rapid radiator cleaning system (code M74) provides effective cleaning of a soiled radiator by turning the fan
blades about their own axis and raising the rpm. This ensures
that the optimal cooling output is available in every situation.
Activation of the reversible fan can be performed while driving or working using a button on the center console.
It is also possible to activate an intermittent switching function (automatic start-up every 10 min).
Radiator system
Note
b
On vehicles with code M74, a safety insert is also
installed in the air filter housing in addition to the air
filter. This must also be replaced with every third air
filter replacement.
Drive
Safety insert in air filter housing
G09.10-3152-00
Clean-Fix fan (code M74)
1) Cooling
2) Switchover
3) Cleaning
Introduction of the New Unimog Generation | Model Series 405
G20.20-3249-00
21
Exhaust aertreatment
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Drive
Due to the stricter Euro VI emissions regulations, additional
system components for exhaust aertreatment are required
to meet the emissions regulations.
Overview
Model Euro III model designation Euro IV/V model
U200 405.090
As a result of the technical implementation of Euro VI, a
modified arrangement of the components on the chassis
was necessary. This is known as the "Euro VI packaging".
The Euro VI vehicle package differs fundamentally from the
package of Euro III and Euro IV/V vehicles and new model
designations have been assigned.
Euro VI model
designation
designation
U300k 405.100 (production up to
11/2006)
U300l 405.120 (production up to
11/2006)
U400k 405.102 405.103 405.105
U400 405.110
U400l 405.122 405.123 405.125
U500k 405.200 (production up to
11/2006)
405.101 405.104
405.121 Discontinued
405.201 405.202
U500l 405.220 (production up to
11/2006)
22 Introduction of the New Unimog Generation | Model Series 405
405.221 405.222
Exhaust aertreatment
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Drive
Euro 6 technology and vehicle packaging
In order to meet the requirements of the Euro VI legislation
and customer demands for minimal fuel consumption, new
engines and a new exhaust aertreatment system were
developed. The engines feature Common Rail injection and
exhaust gas recirculation and are designed for minimal consumption. The new exhaust aertreatment system removes
particulates and nitrogen oxides.
The exhaust aertreatment system consists mainly of:
• Oxidation catalytic converter (DOC)
• Diesel particulate filter (DPF)
• SCR catalytic converter
• Slip catalytic converter
The system also includes the AdBlue® metering unit with various sensors, the ACM electronic unit (Aertreatment Control Module) and the fuel (HC) metering system. Low-sulfur
fuel is required. The fuel may contain up to 7% biodiesel.
Function description:
• The exhaust first flows through the oxidation catalytic
converter. This converts the hydrocarbons and carbon
monoxide present into carbon dioxide and water. Furthermore, part of the nitric oxide (NO) is oxidized to nitrogen
dioxide (NO2).
• The particles are separated through adhesion and collected in the porous filter structure of the diesel particulate
filter (DPF). In the particulate filter, the NO2 reacts with
the stored soot to produce NO und CO2. The deposits
are broken down and the system regenerates itself: "passive regeneration". In order to achieve complete filter
regeneration, the "passive regeneration" is coupled with
"active regeneration". In the case of active regeneration,
a reaction takes place between O2 and soot at temperatures above the passive regeneration range. In order
to reach the temperatures required for this, the exhaust
temperatures are increased by injecting HC in the form of
diesel fuel. The HC reacts exothermically in the oxidation
catalytic converter and increases the temperature of the
exhaust.
• SCR catalytic converter: The BlueTec diesel technology
reduces the proportion of nitrogen oxide in the exhaust
through the addition of AdBlue® (aqueous urea solution).
The aqueous AdBlue® solution is injected into the hot
exhaust via a metering valve.
23Introduction of the New Unimog Generation | Model Series 405
Exhaust aertreatment
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Drive
Exhaust gas recirculation Diesel particulate filter Selective Catalytic Reduction
(AGR) (DPF) (SCR)
Mode of operation of Euro 6
1) Charge air cooler
2) Exhaust gas recirculation cooler
3) Turbocharger
4) Temperature sensor
5) Fuel injection
G49.20-3104-00
6) Pressure sensor
7) NOx sensor
8) Exhaust
9) AdBlue® metering
10) AdBlue® tank
24
Introduction of the New Unimog Generation | Model Series 405
The AdBlue® tank is always located on the right-hand side of
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the vehicle ahead of the exhaust box (except on model series
U200). On the U200, the AdBlue® tank is located on the lehand side of the vehicle ahead of the fuel tank.
Two variants of the exhaust system are available:
• Exhaust system, upward tailpipe (code K7A) - standard
• Exhaust system, downward outlet (code K7Q) - SA
Exhaust aertreatment
Note
b
On all predecessor vehicles, the upward exhaust
(code C87) was special equipment. Exhaust tailpipe
positioned between the axles (code K7Q).
Drive
Standard exhaust system (upward exhaust)
Introduction of the New Unimog Generation | Model Series 405
G49.10-3191-00
25
Exhaust aertreatment
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Drive
AdBlue® supply
The AdBlue® is supplied via a heated tank. The AdBlue® is
supplied via the intake line to the supply unit and from there
to the metering unit on the exhaust system via the pressure
line. AdBlue® can be diverted from the metering unit directly
back to the AdBlue® tank via the return line. A special tank
fitting with reduced diameter prevents the AdBlue® tank
from being filled incorrectly with diesel fuel. The tank size is
18 l for the U200 and 25 l for all U300/U400/U500 models.
The AdBlue® intake line between the AdBlue® tank and
pump module and the AdBlue® pressure line between the
pump module and metering unit are heated electrically by the
heating elements integrated in the line sections.
Rear muffler with integrated oxidation catalytic
converter, diesel particulate filter and SCR catalytic
converter
A corresponding catalytic converter volume is required depending on the vehicle's engine. Only the following AGN boxes (exhaust aertreatment boxes) are installed ex factory:
• 806 mm long on engine OM 934
• 856 mm long on engine OM 936
Exhaust box without cover
26
G14.00-3313-00
Introduction of the New Unimog Generation | Model Series 405
Diesel particulate filter regeneration
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Drive
Regeneration
Soot from diesel combustion and engine oil ash is continuously stored in the closed diesel particulate filter. In order
to allow longer filter change intervals and a long filter service
life, regular regeneration of the diesel particulate filter is
required.
High exhaust temperatures pack the soot and engine oil ash
and store it in compressed form at the end of the filter. This
keeps the required exhaust back pressure within the permissible limits. Since the exhaust temperatures are not sufficient
for passive regeneration in every driving situation, active
regeneration may be carried out depending on the driving
situation.
The system initiates regeneration automatically once a certain quantity of soot or ash is stored.
Passive regeneration
• Continuously, at exhaust temperatures > 250 °C
• Without additional diesel injection
• Initiated automatically, no action required from driver
Active regeneration
• Is required if the exhaust temperature is too low e.g. vehicle at standstill or slow driving
• Additional diesel injection to increase exhaust
temperature
• Can be stopped at any time using the inhibit switch to suit
the type and location of vehicle operation
• Initiated automatically, no action required from driver
Introduction of the New Unimog Generation | Model Series 405
1) Information field for regeneration messagesInhibit switch
G54.30-3843-00G54.25-3464-00
27
Diesel particulate filter regeneration
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Drive
Diesel particulate filter regeneration
Message What must be done?
those with wide open throttle, at the exhaust pipes. Do not interrupt regeneration if possible.
"DPF regeneration" No action required: Active regeneration in progress. Pay attention to high exhaust temperatures, comparable to
trip using significant engine power (freeway, mountain route etc.) or perform manual regeneration. (Duration
"High particulate filter fill level" Action required within the next hours depending on fuel consumption and driving profile: Perform an extended
approx. 30 minutes)
engine power (freeway, mountain route etc.) or perform manual regeneration at standstill. (Duration approx. 30
minutes)
"Particulate filter full" Action required depending on fuel consumption and driving profile: Perform an extended trip using significant
Immediate action required: Perform manual regeneration at standstill. (Duration approx. 30 minutes)
+
"Particulate filter full"
"Output reduction"
Immediate action required: Visit a workshop and have the DPF filter replaced. It is only possible to drive to the
next workshop under reduced power. Regeneration is no longer possible.
+
"Particulate filter full"
"Service Required"
28 Introduction of the New Unimog Generation | Model Series 405
The manual transmission is equipped with double-cone syn-
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chronization for all main gears and the reversing group and
features a new transmission control system with 8 forward
and 6 reverse gears to ensure optimal vehicle speeds for
working deployments and transport journeys. Due to the fine
graduations of the lower gears, it is possible to individually
adjust the vehicle speed during working deployments.
The synchronized reversing group (EQR), for direct shiing
between forward and reverse gears, enables quick reversing
and can be used to rock the vehicle free.
Depending on the requirements, the transmission can be extended with a working group or crawler group and thus offers
optimal gear-ratio steps for any usage profile.
The transmission model of the Euro IV/V vehicles has not
changed for the
Euro VI vehicles. The technical differences of the transmissions are controlled via the engine code.
Main transmission
Note
b
Pay attention to the engine code for replacement part
orders.
Transmission
29Introduction of the New Unimog Generation | Model Series 405
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