Mercedes-Benz Series 405 Reference manual

Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart
Introduction of the New Unimog
Generation
Model Series 405
Introduction into Service Manual
Introduction of the New Unimog Generation · Model Series 405
– This printout will not be recorded by the update service. Status: 03 / 2013 –

1Introduction of the New Unimog Generation |Model Series 405
Preface 3
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 aertreatment 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
– This printout will not be recorded by the update service. Status: 03 / 2013 –

2 Introduction of the New Unimog Generation |Model Series 405
Design 56
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
– This printout will not be recorded by the update service. Status: 03 / 2013 –

3Introduction of the New Unimog Generation |Model Series 405
Preface
b Note
Information about the vehicles and about operating
the vehicle functions can also be found in the interac-
tive 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.
Dear Reader,
This Introduction into Service Manual presents the new Uni-
mog 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 com-
ponents and systems.
All of the data in this brochure correspond to the technical
status as of the copy deadline in March 2013 and may there-
fore differ from the current production configuration.
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
– This printout will not be recorded by the update service. Status: 03 / 2013 –

4
G00.20-3127-00
Introduction of the New Unimog Generation |Model Series 405
Vehicle concept
Overview
General
The product features of the new BlueTec 6 Unimog imple-
ment carrier with Euro VI emissions level have been com-
pletely revised for its market launch. The advantages of this
compact and highly maneuverable implement carrier have
been further improved. The vehicle concept has been weight-
optimized in order to compensate for the additional weight of
the Euro VI components.
The exhaust aertreatment 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 inno-
vation 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 ma-
nual transmission in a practical manner.
The new BlueTec 6 Unimog implement carrier
– This printout will not be recorded by the update service. Status: 03 / 2013 –

5Introduction of the New Unimog Generation |Model Series 405
Model designation system
Overview
The new model designation system is a continuation/exten-
sion of the previous system.
Model designation system
b Note
Model series remains the same, serial number
increases.
Model codes in model designation system
Euro V Euro VI
405 . 101 405 . 104
405 101 405 104
Model series Serial no. Model series Serial no.
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 427 405.110 3.150 11,99/13/13,8 200
U 430 405.110 3.150 11,99/13/13,8 220
U 423 405.125 3.600 11,99/13/13,8 170
U 427 405.125 3.600 11,99/13/13,8 200
U 430 405.125 3.600 11,99/13/13,8 220
U 527 405.202 3.350 11,99/15,5/16,5 200
U 530 405.202 3.350 11,99/15,5/16,5 220
U 527 405.222 3.900 11,99/15,5/16,5 200
U 530 405.222 3.900 11,99/15,5/16,5 220
– This printout will not be recorded by the update service. Status: 03 / 2013 –

6 Introduction of the New Unimog Generation |Model Series 405
Model codes
Overview
Model codes
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.
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)
– This printout will not be recorded by the update service. Status: 03 / 2013 –

7Introduction of the New Unimog Generation |Model Series 405
Code system
Overview
Example
Design of new code system
With the introduction of the new generation of BlueTec 6 Uni-
mog 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.
1st digit
Code group
2nd digit 3rd digit
Capital letter (A...Z) Number (0...9) Capital letters (A...Z)
A 1 W
Axles/suspension Front axle Front axle differential lock
– This printout will not be recorded by the update service. Status: 03 / 2013 –

8 Introduction of the New Unimog Generation |Model Series 405
Code system
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/fih wheel
coupling
E Electrical system R Wheels/spare wheel hol-
der/wheel lis
F Cab exterior S Safety
G Transmission/clutch T Unused
H Hydraulic components U Unused
I Internal code V Unused
J Instruments/
communication
W Weight variants
K Fuel system/exhaust
system
X Miscellaneous
L Lighting system/lamps Y Accessories
M Engine Z Internal system control
code
– This printout will not be recorded by the update service. Status: 03 / 2013 –

9Introduction of the New Unimog Generation |Model Series 405
Innovations
Overall vehicle
b Note
In parallel to the Unimog Euro VI, the U 400.103/123
will still also be produced with Euro III/V engines.
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 availa-
ble. 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 wit-
hout modification.
The holistic rework of the product features of the new Blu-
eTec 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 incre-
ased. 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 wor-
king operations.
• Cleanfix reversible fan with automatic control and high-
speed fan drive as special equipment for dirt-intensive
operations (in preparation).
• Swiveling A/C condenser in combination with a wide-
meshed radiator core and smooth radiator slats for easy
cleaning of the radiator unit.
• Charge air cooler decoupled from the radiator and loca-
ted under the engine hood.
• Greater efficiency of fan hydraulics due to variable dis-
placement pump and demand-based, separate control of
both fans. The benefit results from the reduced energy
requirement and optimized driving and working perfor-
mance, including under extreme conditions.
Integrated exhaust management
With respect to exhaust aertreatment, the new engine ge-
neration uses the BlueTec 6 technology which has already
proven its effectiveness in practical use on mass-produced
heavy duty engines.
The exhaust management system ensures that filter regene-
ration 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.
– This printout will not be recorded by the update service. Status: 03 / 2013 –

10 Introduction of the New Unimog Generation |Model Series 405
Innovations
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 decompres-
sion 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 dis-
placement 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 ad-
justed and can be extended to allow the adjustment of exter-
nal 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 ex-
ternal 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 shiing of
manual vehicle transmission
– This printout will not be recorded by the update service. Status: 03 / 2013 –

11Introduction of the New Unimog Generation |Model Series 405
Innovations
Overall vehicle
Power hydraulics (circuit III and IV)
The power hydraulics allow rotating consumers to be powe-
red (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 intermedi-
ate 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, eit-
her 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 superse-
ded with the launch of the new BlueTec 6 Unimog implement
carrier. The new hydrostatic drive (code G34) allows fully hy-
drostatic 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 gearshiing, 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 "dri-
ving joystick active" mode.
Modified suspension
The capabilities of the suspension have been retained in their
entirety and continue to underline the advantages of the Uni-
mog 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 overcom-
pensated 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 ef-
fective across all areas of usage. The new Unimog generation
will continue to use these standardized interfaces and dimen-
sions. 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 capa-
bility 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
– This printout will not be recorded by the update service. Status: 03 / 2013 –

12 Introduction of the New Unimog Generation |Model Series 405
Innovations
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 steerabi-
lity are maintained in the process, which reduces the risk of
accident.
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 deactiva-
ted on public roads and firm ground.
The 4-channel ABS system is installed on all model desig-
nations 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.
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 im-
plements. Up to three additional cameras can be connec-
ted 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.
– This printout will not be recorded by the update service. Status: 03 / 2013 –

13Introduction of the New Unimog Generation |Model Series 405
Technical data
Drive
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
Output kW 115 (code M1H)
130 (code M1I)
170 (code M1K)
200 (code M2C)
220 (code M2D)
Torque Nm 650
750
900
1100
1200
Compression ratio 17,6/1 17,6/1
Stroke mm 135 135
Cylinder bore mm 110 110
Rail pressure max. bar 2400 2400
– This printout will not be recorded by the update service. Status: 03 / 2013 –

14
G01.10-3133-00
Introduction of the New Unimog Generation |Model Series 405
Engine OM 934
Drive
Engine OM 934.972
The OM 934 is a 4-cylinder inline engine with a displace-
ment 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.
– This printout will not be recorded by the update service. Status: 03 / 2013 –

15
G01.10-3135-00
G01.10-3136-00
Introduction of the New Unimog Generation |Model Series 405
Engine OM 934
Drive
Engine power (kW)
Torque (Nm)
– This printout will not be recorded by the update service. Status: 03 / 2013 –

16
G01.10-3134-00
Introduction of the New Unimog Generation |Model Series 405
Engine OM 936
Drive
Engine OM 936.972
The OM 936 is a 6-cylinder inline engine with a displacement
of 7.7 l with turbocharger and cooled exhaust gas recircu-
lation. The OM 936 is only available in EuroVI and the fol-
lowing 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.
– This printout will not be recorded by the update service. Status: 03 / 2013 –

17
G01.10-3137-00
G01.10-3138-00
Introduction of the New Unimog Generation |Model Series 405
Engine OM 936
Drive
Engine power (kW)
Torque (Nm)
– This printout will not be recorded by the update service. Status: 03 / 2013 –

18 Introduction of the New Unimog Generation |Model Series 405
Model codes
Drive
Vehicle Engine Exhaust box (AGN) Model code Model
designation
Wheelbase (mm)
Model designation
Engine power (kW)
Code Cylinder Charging Model
designation
Length (mm)
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
– This printout will not be recorded by the update service. Status: 03 / 2013 –

19
G26.45-3227-00
Introduction of the New Unimog Generation |Model Series 405
Mechanical power take-offs
Drive
B Important
The power take-off (code N05) is only approved for
powering hydraulic or water pumps. Direct mechani-
cal drive (e.g. mechanical rear power take-off) is not
permissible.
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)
Engine power take-off
The engageable engine power take-off (code N05) (engage-
able 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
– This printout will not be recorded by the update service. Status: 03 / 2013 –