Mercedes-Benz Unimog BlueTec 6 User manual

Extreme off-road Unimog BlueTec 6
Technical Manual
August 2014 issue

Part A
Concept and sales reasoning
Part B
Technical data
Technical Manual for extreme off-road Unimog BlueTec 6
The present Technical Manual serves Unimog Sales as an advisory
document. In addition to the basic vehicle version, special equipment is
also covered. Regarding the availability of standard and special equipment,
please refer to the applicable price lists. Subject to technical modifications
without notice. All rights reserved. Reprinting or reproduction in electronic
form, including excerpts, is prohibited and requires the approval of
Mercedes-Benz Special Trucks.
The latest changes and additions are available through our updates on
the Extranet at:
www.specialtrucks-extranet.com
Daimler AG
Mercedes-Benz Special Trucks
Sales & Marketing
August 2014 issue
Technical Manual
Mercedes-Benz Special Trucks 1

Contents – Part A
Overview of models and components ................................ 6
Product concept ................................................................... 7
Unimog model series in comparison .................................. 7
Extreme off-road capability ................................................ 8
The Unimog concept for extreme torsional flexibility ......... 9
Angle of approach / departure and ramp breakover angle10
Fording capability............................................................. 11
Optional equipment – fording capability .......................... 12
Frame...................................................................................13
Frame concept ................................................................. 13
Optional equipment – frame ............................................ 15
Engine ..................................................................................17
Engine concept ................................................................ 17
Drive clutch...................................................................... 19
High-performance engine brake....................................... 20
Engine control.................................................................. 20
Exhaust gas aftertreatment – BlueTec 6 .......................... 21
Exhaust emissions – limiting values ................................. 23
Regeneration.................................................................... 24
Radiator system .............................................................. 25
Optional equipment – engine ........................................... 26
Transmission.......................................................................27
Main transmission............................................................ 27
Overview .......................................................................... 28
Engine management ........................................................ 29
Electronic Quick Reverse (EQR) ....................................... 30
Optional equipment – transmission ................................. 31
Axles ....................................................................................33
Portal axles ...................................................................... 33
Axle suspension ............................................................... 35
Torque tube technology.................................................... 36
Drive system .................................................................... 37
Single tyres ...................................................................... 38
Optional equipment – axles.............................................. 39
Brakes..................................................................................43
Dual-circuit braking system.............................................. 43
4-channel ABS.................................................................. 44
Optional equipment – brakes ........................................... 45
Steering ...............................................................................46
Power steering ................................................................. 46
Optional equipment – steering......................................... 47
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2
Contents

Cab exterior.........................................................................48
Cab concept..................................................................... 48
Doors ............................................................................... 49
Safety............................................................................... 50
Optional equipment – cab exterior................................... 51
Cab interior .........................................................................54
Spaciousness................................................................... 54
Controls ........................................................................... 55
Steering and gear-changing ............................................. 56
Instrumentation ............................................................... 57
Standard controls ............................................................ 58
Air conditioning, heating and ventilation system.............. 59
Optional equipment – cab interior.................................... 60
Auxiliary drives ...................................................................64
Location ........................................................................... 64
Optional equipment – power take-offs ............................. 65
Hydraulics ...........................................................................68
Overview of hydraulic system........................................... 68
Optional equipment – hydraulic system ........................... 69
Electrical system ................................................................71
Electronic networking ...................................................... 71
Optional equipment – electrical system........................... 72
Attachment and mounting areas ......................................77
Locations of attachment and mounting areas.................. 77
Mounting areas ................................................................ 78
Optional equipment – mounting areas ............................. 79
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Contents

Contents – Part B
Engine ..................................................................................86
Engine data – OM934 ..................................................... 86
Engine diagram – OM934 ................................................ 87
Filling capacities .............................................................. 88
Engine brake .................................................................... 88
Compressed air generation.............................................. 89
Transmission.......................................................................90
Main transmission............................................................ 90
Clutch .............................................................................. 90
Vehicle speeds – U 4023 / U 5023 ................................. 91
Vehicle speed conversion factor ...................................... 92
Axles ....................................................................................93
Suspension ...................................................................... 93
Technical data on axles .................................................... 93
Technical data on U 4023 rims ........................................ 94
Technical data on U 5023 rims ........................................ 95
Brakes..................................................................................96
Braking system ................................................................ 96
Cab exterior.........................................................................97
Exterior ............................................................................ 97
Cab interior .........................................................................98
Interior ............................................................................. 98
Auxiliary drives ...................................................................99
[N05] Engine PTO to rear, with flange .............................. 99
[N13]/[N16]/[N19] Transmission PTO........................... 100
Hydraulics .........................................................................101
Technical data on single hydraulic system ..................... 101
Electrical system ..............................................................102
On-board electrical system ............................................ 102
Lights ............................................................................. 102
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4
Contents

Weights..............................................................................103
Permissible load values.................................................. 103
Trailer operation ...............................................................104
Pin-type trailer hitch....................................................... 104
Hook-type trailer hitch (not for civilian use) ................... 104
Towing capacities – U 4023, model designation
437.427, 170 kW........................................................... 105
Towing capacity U 5023, model designation
437.437, 170kW........................................................... 106
Wheels/tyres ....................................................................107
Tyre availability............................................................... 107
Tyres (technical data) ..................................................... 108
Tyre load capacity .......................................................... 109
Speed allocations........................................................... 110
MPT (multi-purpose tyres).............................................. 112
AS tyres ......................................................................... 114
Dimensions .......................................................................115
Technical drawing for U 4023 BlueTec 6,
model designation 437.427 ........................................... 115
Technical drawing for U 5023 BlueTec 6,
model designation 437.437 ........................................... 116
General information .........................................................117
Vehicle climbing resistance............................................ 117
Trailer climbing resistance ............................................. 117
Tractive force diagram – U 4023 (8.8 t) ......................... 118
Tractive force diagram – U 4023 (10.3 t) ....................... 118
Tractive force diagram – U 5023 (14.1 t) ....................... 119
Tractive force diagram – U 5023 (14.5 t) ....................... 119
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Mercedes-Benz Special Trucks 5
Contents

Overview of models and components
Model name Model designation Wheelbase
(mm)
Engine Output
(kW/hp)
No. of
cylinders
Permissible gross vehicle
weight: Variants (t)
U 4023 437.427 3850 OM934 170/231 4 7.5 / 8.0 / 8.8 / 9.8 / 10.3
U 5023 437.437 3850 OM934 170/231 4 12.5 / 12.7 / 13.0 / 14.1 / 14.5
Overview of models and components Technical Manual
Mercedes-Benz Special Trucks
6

Unimog Implement Carrier BlueTec 6 Extreme off-road Unimog BlueTec 6
Unimog model series in comparison
Unimog Implement Carrier BlueTec 6
• Compact all-terrain Unimog implement carrier
• Vehicle type: tractor unit/truck
• Vehicle width: from 2.15 m
• Wheelbases: 2800 mm – 3900 mm
• Straight, dimensionally stable and weight-optimised
ladder-type frame
• Panoramic cab with large windscreen and
low instrument support
• 4+3 implement mounting areas
• Extensive hydraulics package
• Mechanical engine and transmission PTOs
• Permanent all-wheel drive, differential locks engageable
Extreme off-road Unimog BlueTec 6
• Extreme off-road Unimog chassis
• Vehicle type: truck chassis
• Vehicle width: from 2.3 m
• Wheelbase: 3850 mm
• Dropped, flexible and torsionally flexible frame
• Cab-behind-engine truck with raised windscreen
• Long body length for greater load volume
• Integrated hydraulics system available
• Mechanical engine and transmission PTOs
• Rear axle drive, all-wheel drive and differential locks engageable
Product concept
Technical Manual
Mercedes-Benz Special Trucks 7
Product concept

Extreme off-road capability
Feature
• Heavy-duty, torsionally flexible frame
• Portal axle with asymmetric differential arrangement
• Axle location via torque tube technology, coil springs and
transverse control arms
• Fording capability
• Atmospheric pressure equalisation of components
• Short frame overhangs at front and rear
• Low vehicle centre of gravity
• All-wheel drive and differential locks engageable and disengageable
via dog clutch while on the move
Advantage
• Good flexibility off-road on steep inclines and rough surfaces
• Large ground clearance when driving over obstacles
• Extreme diagonal torsional flexibility
• Central load application and bracing on gearbox
• Protection for drive shafts
• Enables fording of water to a depth of 80 cm (standard) /
120 cm [Z16]
• No excess pressure in components
• Large angle of approach/departure and ramp breakover angle
• High climbing and tipping angle
• High tractive power available at all times
• 100 % locking effect
• No interruption in tractive power, no stopping
U 4023 U 5023
a) Ground clearance (mm) 410 460
b) Angle of approach (°) 42 46
c) Ramp breakover angle (°) 32 36
d) Angle of departure (°) 46 50
e) Tipping angle (°) 38 38
ed b
a
c
i
Angle not dependent on load condition or tyres.
Product concept Technical Manual
8Mercedes-Benz Special Trucks

30°30°
The Unimog concept for extreme torsional flexibility
Driving over obstacles optimised by asymmetric arrangement of the axle differentials Major axle articulation made possible by torque tube concept and coil springs
Driving over sharp crests possible thanks to large ramp breakover angle and
angle of approach/departure
3-point mounting of engine, gearbox and cab. Double 3-point body mounting
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Mercedes-Benz Special Trucks 9
Product concept

36°
38°
45°
50° 46°
46°
Angle of approach / departure and ramp breakover angle
Figures shown are static values for the chassis of a U5023.
Ramp breakover angle
Tipping angle
Fording capability, approach angle
Angle of approach and departure
Slope angle
i
For the angles of the individual
vehicle models, please refer to the
dimensioned drawings in Section B.
Illustrations show 365/85 R20 tyres.
i
The permissible roll angle is 38 degrees
in static state (vehicle functional);
the dynamic limit is 16.5 degrees
(corresponding to 30 %).
Approach
Product concept Technical Manual
Mercedes-Benz Special Trucks
10

Fording capability
Feature
• Torque tube technology
• Air intake pipe at level of cab roof
• Large ground clearance
• Fan with electronic viscous clutch, mechanically driven via
propeller shaft, raised
• Key components and electrical devices protected against
splashing water
Advantage
• Enables standard fording capability to 80 cm
• No permanent drive, fan remains operational
• No damage resulting from exposure to water
• No sagging of a V-belt
Standard fording capability to 80 cm
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Mercedes-Benz Special Trucks 11
Product concept

Advantage
• Enable fording capability to 120 cm
• Atmospheric pressure compensation with vent lines from the
components prevents entry of water and fine sand
• No reduction in fording capability with optional auxiliary heater
Optional equipment – fording capability
Feature
[Z16] Special parts, fording capability
• Raised pressure compensating lines for axles, gearbox,
working gear range, torque tube, fuel tank, air drier,
solenoid valves, brake system, etc.
• Waterproof main headlights with central, raised ventilation
• New position for auxiliary heater [D6N]
Special equipment, special parts for fording capability to
120cm [Z16]
i
Recommended special equipment:
• Double sealing of wheel hubs, for
operations in muddy conditions
[A27]
Product concept Technical Manual
12 Mercedes-Benz Special Trucks

Frame
Frame concept
Feature
• 2 U-section longitudinal frame members with welded tubular
cross-members and reinforcements in the frame profile
• Offset design, no components protruding downwards
• Robust steel bumper
• Special torsionally flexible connection flange
Advantage
• Heavy-duty, flexible and torsionally flexible frame offering
high elasticity
• No permanent deformation even after extreme diagonal torsion
• Enables all four wheels to remain permanently in contact with the
ground in all driving situations
• Safe and controlled off-road driving
• Installation of drive units at lowest possible point:
low centre of gravity, high ground clearance
• Protection of components in off-road terrain
• Robust protection from mechanical influences in collisions
• Transmission of high torsional forces between longitudinal and
transverse members
Frame with attachment fixtures for non-MB bodies [CD5], front mounting
brackets [CA2], front mounting plate [CP3], cable winch brackets (CH5)
Special torsionally flexible connection flange
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Mercedes-Benz Special Trucks 13
Frame

Feature
• Integrated attachment points
• 3-point mounting of cab, engine and gearbox
• Double 3-point mounting for bodies and attached equipment
Advantage
• Suitable for attaching heavy front- and rear-mounted implements
with defined transmission of forces
• Torsion and stress-free mounting of components and bodies
• No restriction of off-road capabilities
• Equipment, attachments and bodies can be mounted in the ideal
positions with regard to torsion and centre of gravity
• Transmission of trust, tensile and weight forces to the intended
points in the frame
• Safe, secure and simple attachment and mounting of equipment
3-point mounting of engine and gearbox
Even with extreme
axle articulation (30°)
there is only a limited
amount of twist
between cab and
body (12°)
Frame Technical Manual
14 Mercedes-Benz Special Trucks

Optional equipment – frame
Feature
[Q32] End cross-member, for increased towing capacity
• Reinforced end cross-member
[Q35] Additional towing jaw at front, lowered
• Additional trailer hitch at front
Advantage
• Enables use of draw-bar trailers
up to 15.4 t (U 4023) and 19.9t (U 5023)
• Enables use of rigid draw-bar trailers and centre-axle trailers up to
9 t (U 4023 / U 5023)
• Facilitates manoeuvring
• Towing possible, e.g. with towing bar
End cross-member, for increased towing capacity [Q32]
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Mercedes-Benz Special Trucks 15
Frame

Feature
[Q06] Trailer coupling, larger jaw, annual spring, pin 38.5
• Jaw size 280 x 170 mm
• Make, type: Ringfeder 86 G 110
• Drawbar load: 500 kg
• Pin diam.: 38.5 mm
• Swivelling coupling pin
[Q86] Trailer hitch, small jaw, Rockinger, increased load
• Jaw size 200 x 100 mm
• Make, type: Rockinger 225 G 110
• Drawbar load: 700 kg / 1500kg*
• Pin diam.: 38.0 mm
[Q88] Trailer hitch, small jaw, Rockinger
• Jaw size 200 x 100 mm
• Make, type: Rockinger 227 G 110 J
• Drawbar load: 500 kg / 1250 kg*
• Pin diam.: 38.5 mm
[Q97] Trailer hitch, large jaw, Rockinger
• Jaw size 360 x 215 mm
• Make, type: Rockinger 4040 G 135, version A
• Drawbar load: 700 kg / 1000 kg*
• Bolt Ø: 38.5 mm for 40-mm eyelets
• Swivelling coupling pin
Advantage
• For trailer operation with 40 mm towing lug
• For trailer operation with 40 mm towing lug
• High trailer loads possible
• For trailer operation with 40 mm towing lug
• Minimal installation space required
• For trailer operation with 40 mm towing lug
• One-hand operation optimised
• Optimisation of locking and bearing points on coupling body
• 30 – 40 % longer lifespan
* Only in conjunction with [Q32].
Frame Technical Manual
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16

Engine
Engine concept
Feature
• Newly developed Mercedes-Benz 4-cylinder OM934 engine
rated at 170 kW/231hp and 5.1 l displacement
• Common rail direct injection with high injection pressures
(up to 2400 bar)
• Multistage injection
• Twin-stage turbocharger
• Mercedes-Benz BlueTec 6 technology, Euro VI compliant:
combined SCR technology with particulate filter and cooled exhaust
gas recirculation (EGR)
Advantage
• Proven engines of the Mercedes-Benz volume series
• High power reserves
• Efficient and clean combustion
• Optimised fuel consumption
• Smooth running
• High torque even at low engine speeds
• Reduced NOxemissions
• Reduced particulate emissions
OM934 4-cylinder engine
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Mercedes-Benz Special Trucks 17
Engine

Engine power [kW] Torque [Nm]
600 1000 1400 1800 2200
170 kW900 Nm
2600
1500 300
1000 200
500
100
200 0
Engine speed (rpm)
Feature
• Optimised choice of materials and manufacturing process
• Extended maintenance intervals – 1400 operating hours
• High torque, max. 900 Nm
• Optimised in-engine combustion
• Air intake on right of cab at roof level
Advantage
• Service life extended by 20 %
• Extended use period, low service requirements, reduced
operating costs
• High pulling power and holding ability of torque
• High adaptability on very rough off-road terrain with steep gradients
• Significantly reduced AdBlue®consumption
• Intake of combustion air from area with low dust content
• No entry of water into the intake during fording
• Reduced soiling and extended service life for the air filter
Output and torque
diagram for
OM934, 170 kW,
900 Nm
Engine Technical Manual
18 Mercedes-Benz Special Trucks

Drive clutch
Feature
• 395mm single-plate dry clutch
• Hydraulic central clutch release bearing
• Pneumatic clutch pressure booster
• Position sensor
• Wear compensation
• Aluminium clutch housing
• Organic, asbestos-free clutch linings
Advantage
• Easy to regulate, long service life
• No lubrication of moving parts necessary
• Low pedal force (approx. 150 N)
• Wear detectable without disassembly
• Secure frictional connection
• Weight optimisation
• Environmentally compatible
Clutch plate Clutch pressure plate Clutch housing
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Mercedes-Benz Special Trucks 19
Engine