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Mercedes-Benz Series 405, Introduction Into Service Manual

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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

Intr

oduction of t

he N

ew U

nimog Gener

ation · Model Ser

ies 405

– This printout will not be recorded by the update service. Status: 03 / 2013 –

Summary of Contents for Series 405

Page 1: ...nformation and Workshop Equipment GSP OR D 70546 Stuttgart Introduction of the New Unimog Generation Model Series 405 Introduction into Service Manual This printout will not be recorded by the update...

Page 2: ...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 Distribu...

Page 3: ...etwork 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...

Page 4: ...t 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 p...

Page 5: ...ue 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...

Page 6: ...signation 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...

Page 7: ...luding 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 4...

Page 8: ...es 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 lo...

Page 9: ...rai ler hitch fifth wheel coupling E Electrical system R Wheels spare wheel hol der wheel lifts F Cab exterior S Safety G Transmission clutch T Unused H Hydraulic components U Unused I Internal code V...

Page 10: ...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...

Page 11: ...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 circui...

Page 12: ...de 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 thei...

Page 13: ...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 i...

Page 14: ...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...

Page 15: ...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...

Page 16: ...1 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...

Page 17: ...articular 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 c...

Page 18: ...1 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...

Page 19: ...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...

Page 20: ...off code N05 engage able only with engine off is driven by the crankshaft of the engine via intermediate gears The flange output is located at the rear of the engine and is activated via an engageable...

Page 21: ...iator 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 coar...

Page 22: ...ures that the optimal cooling output is available in every situation Activation of the reversible fan can be performed while dri ving or working using a button on the center console It is also possibl...

Page 23: ...o 11 2006 405 201 405 202 U500l 405 220 production up to 11 2006 405 221 405 222 Due to the stricter Euro VI emissions regulations additional system components for exhaust aftertreatment are required...

Page 24: ...onoxide present into carbon dioxide and water Further more part of the nitric oxide NO is oxidized to nitrogen dioxide NO2 The particles are separated through adhesion and collec ted in the porous fil...

Page 25: ...e air cooler 2 Exhaust gas recirculation cooler 3 Turbocharger 4 Temperature sensor 5 Fuel injection 6 Pressure sensor 7 NOx sensor 8 Exhaust 9 AdBlue metering 10 AdBlue tank Exhaust gas recirculation...

Page 26: ...st system upward exhaust The AdBlue tank is always located on the right hand side of the vehicle ahead of the exhaust box except on model series U200 On the U200 the AdBlue tank is located on the left...

Page 27: ...ly 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 pu...

Page 28: ...s sible 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 syste...

Page 29: ...ower freeway mountain route etc or perform manual regeneration Duration approx 30 minutes Particulate filter full Action required depending on fuel consumption and driving profile Perform an extended...

Page 30: ...f the lower gears it is possible to individually adjust the vehicle speed during working deployments The synchronized reversing group EQR for direct shifting between forward and reverse gears enables...

Page 31: ...g work is carried out by pneumatic cylinders promote relaxed and concentrated driving The neutral switch with catch position in the multifunction control lever allows direct shifting to neutral from a...

Page 32: ...ronic automated gearshift EAS system code G48 for Unimog Euro VI vehicles The technology of the automated clutch system has been fully reworked but its operation is largely identical to that of the pr...

Page 33: ...osis The values of both travel sensors can be accessed on the instrument cluster for diagnosis All compressed air connections of the PCA and pressure booster are now connected to the auxiliary consume...

Page 34: ...ting cruise control and travel direction functions The vehicle can also be accelerated and decelerated via the hydraulic joystick in driving joystick active mode Using proportional valves and pressure...

Page 35: ...for Drive is engaged with the vehicle at a standstill Changing between the new hydrostatic drive and transmission The new hydrostatic drive can be deactivated while driving by pressing the system but...

Page 36: ...s engaged A variable gear ratio for rpm and torque is produced by adjusting the volumes in the pump and motor As a result of mechanical and volumetric losses the resulting efficiency levels are lower...

Page 37: ...grated feed pump of the hydro stat pump The motor displacement is varied in a pressure range of 4 16 bar from 0 cm to 75 cm The actuating pressure is controlled on a linear basis with a 24 V proportio...

Page 38: ...able and flashable which allows troubleshooting using Star Diagnosis in the workshop An operating hours counter can be accessed on the Instrument A control joystick can be installed on the center cons...

Page 39: ...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...

Page 40: ...with a maximum volumetric flow rate of 125 l min each at a maximum of 280 bar Code HL4 includes one circuit while code HL5 includes two power hyd raulics circuits The power hydraulics are located in t...

Page 41: ...integrated in the platform intermediate frame All of the connections are loca ted at the vehicle rear above the end crossmember Special hydraulic equipment at rear Hydraulic plug connection rear 4 con...

Page 42: ...tional code HN7 Hydraulic system 2 circuit 4 cell fully proportional snowplow relief code HN8 Center connections of work hydraulics circuit II only The hydraulic connections of circuit II for the cent...

Page 43: ...he hydraulics for the tilt mechanism Joystick 1 Rocker switch Perform EQR function 2 Rocker switch Regulate working speed 3 Button free for assignment by body manufacturers allows actuation of a 3rd p...

Page 44: ...ersa It is also possible to combine the flow rates of circuits I and II known as flow summation This means that the flow rate of the other circuit is additionally made available to a consumer Circuit...

Page 45: ...ic system A Intake line B Pressure line general C Working line cell 1 D Working line cell 2 G Return line general Z1 Cell 1 Z2 Cell 2 1 Hydraulic oil reservoir 1a Filter unit 2 Radiator 3 Pressure fil...

Page 46: ...line general H Pressure line circuit II J Load signal line KR II Circuit II SR Separate return line Z1 Cell 1 Z2 Cell 2 Z3 Cell 3 1 Hydraulic oil tank 1a Filter unit 2 Flow control valve 3 Pressure li...

Page 47: ...eturn line general H Pressure line circuit II J Load signal line KR II Circuit II SR Separate return line Z1 Cell 1 Z2 Cell 2 Z3 Cell 3 Z4 Cell 4 1 Hydraulic oil tank 1a Filter unit 2 Flow control val...

Page 48: ...circuit IV code HL5 H93 H94 Volumetric flow rates of power hydraulics A constant delivery rate is often necessary to operate a per manent consumer As a result both circuits of the power hydraulics ci...

Page 49: ...neral K Pressure line circuit III M Pressure line circuit IV L Leak oil line KR III Circuit III KR IV Circuit IV SR Separate return line 1 Drive shaft 2 Variable displacement pump circuit III 3 Variab...

Page 50: ...e displacement pump 3 Pressure filter 4 Valve block dumper flatbed 5 Tilt cylinder 6 Oil motor 7 Left radiator 8 Valve block fan 9 Oil motor charge air cooler oil cooler 10 Front radiator The fan hydr...

Page 51: ...ng hydraulics code HE2 incl hy draulic connection for auxiliary consumers rail guide and auxiliary rear axle steering Tilt cylinder actuation On vehicles without work hydraulics the tilt cylinder is a...

Page 52: ...pump Variable displace ment pump Fixed displace ment pump Fixed displace ment pump Fixed displace ment pump Variable displace ment pump Variable displace ment pump Drive Power take off on engine i 1...

Page 53: ...3 000 737 583 747 583 747 584 U 400 k U 427 405 110 3 150 737 583 747 583 747 584 U 400 k U 430 405 110 3 150 737 583 747 583 747 584 U 400 l U 423 405 125 3 600 737 583 747 583 747 584 U 400 l U 427...

Page 54: ...ion Model Series 405 New axles of U200 U300 Chassis View of front axle model designation 737 572 with air powered disk brakes View of rear axle model designation 747 572 with air powered disk brakes T...

Page 55: ...ially on the guide pins of the brake carrier The brake pads are held and supported in the brake carrier so that they can move axially The brake pads are held in place by a retaining bracket and by hol...

Page 56: ...em Designation Dimension A Total thickness of brake disk new 25 mm B Wear dimension limit 21 mm C Total thickness of brake pad new 19 mm D Brake pad carrier 7 mm E Minimum thickness of brake pad 2 mm...

Page 57: ...ng angle of almost 90 allows the driver to enter and exit the vehicle safely and conveniently using 3 steps Roof mounted wiper system A newly developed roof mounted wiper system wipes snow to the side...

Page 58: ...h describe environmentally compatible disposal The all round heat insulating glass significantly reduces the tendency of the interior compartment to heat up while the windshield is made of laminated g...

Page 59: ...ater variants are available in the LHD models Control and display concept In addition to the redesigned instrument panel a new control and display concept has also been implemented which offers greate...

Page 60: ...rrespon ding symbol disks On the instrument cluster an internal speaker generates noises such as the turn signal noise and warning tones The instrument cluster is connected to the chassis CAN via an 1...

Page 61: ...e height and inclination of the multifunction steering wheel can be adjusted to suit the individual seat position Many functions can be controlled conveniently via the button groups on the left and ri...

Page 62: ...nal stowage space An equipment socket code E87 equipped with C3 signals for equipment operation is also integrated in the cab Cable holes sealed with plugs simplify the connection of equipment The fol...

Page 63: ...62 G00 19 3173 00 Introduction of the New Unimog Generation Model Series 405 Overall network Networking Network diagram This printout will not be recorded by the update service Status 03 2013...

Page 64: ...l unit 3 control unit network MUX3 A305 Special Trucks Control Unit STCU A305 a1 Implement Carrier Module ICM control unit A305 a2 Tire pressure control sys tem TPC control unit A306 Hydraulics operat...

Page 65: ...ingly In the new Unimog there are 3 LIN data buses alone to connect the various control units switches and other electronic components to each other On the other hand the number of CAN data buses has...

Page 66: ...Immobilizer with transponder JV2 Preinstallation for mobile radio cell phone 12 V J2A CD radio J2B Bluetooth CD radio J9H Preinstallation for 12V trunked radio system JV5 Preinstallation wiring antenn...

Page 67: ...ply Power is supplied via two maintenance free 12 V batteries each with a rating of 140 Ah The following three phase alternators are available Three phase alternator 24 V 100 A standard Three phase al...

Page 68: ...uration Brake light Right turn signal left turn signal Activate rotating beacon from vehicle Horn actuation CAN interface for hydraulic control PSM parameteriz able special module Rpm control request...

Page 69: ...e of construction and standard EN 15431 for its pin assignment b b Note Pin 4 of the socket is assigned to terminal 30 24 V continuous positive In addition pin 7 is not used This means that the pin as...

Page 70: ...the left hand side in the direction of travel and incorporates various functions ranging from supplying power to the body and controlling the engine remotely through to operating indicator lamps on t...

Page 71: ...e body 15 Switch power take off N13 N16 N19 on off 16 Signal power take off N13 N16 N19 switched on 17 Signal parking brake activated 18 Start off fixed speed 19 Increase engine speed 20 Reduce engine...

Page 72: ...ated overload protection function for each output also makes the use of external fuses unnecessary The control unit network is mainly used to implement the basic electrical functions of the vehicle e...

Page 73: ...following functions It routes messages and signals between various CAN bu ses function gateway It can route messages and signals from an entire SUB CAN for diagnosis purposes This function is called...

Page 74: ...Rear foglamp backup lamps and brake lights Daytime running lights Additional headlamps code L47 Additional headlamps which are mounted higher on the ve hicle are available under code L47 for the opera...

Page 75: ...d in the rear lamps to perform the functions of the taillight rear fog lamp backup lamps brake lamps turn signals and position lamps Backup warning system An acoustic backup warning system code E6Z in...

Page 76: ...e driving In the event of tire damage the vehicle can drive to the nearest workshop by means of the pressure loss compen sation function The tire pressure can be adjusted individually at the front and...

Page 77: ...produces an immediate response and accurate adjustability The air distribution system of the heating ventilation and cli mate control system includes Defroster vents positioned along the windshield F...

Page 78: ...rol the climate of the inte rior compartment The multistage blower allows the windows to be quickly deiced A hot water heater with residual heat utilization saves fuel and protects the environment The...

Page 79: ...tion phone book only in combination with code J2B Source change Selection of CD track In the Audio menu item the multifunction display shows plain text about the selected radio station or USB CD acti...

Page 80: ...ph EC rpm ADR code J1R Tachograph 1 day 2 driver modular code J1K The digital tachograph code J1R is available from the sup pliers VDO code J1S or Stoneridge code J1T A calibration system code G5Z is...

Page 81: ...r clutch TWIN DISC the maintenance scopes at 50 Bh and 600 Bh are not required The time of the first maintenance service is unchanged at 200 Bh The maintenance intervals of the power take off transmis...

Page 82: ...tification number must be entered in the maintenance booklet and in VeDoc Before replacing a DPF this identification number must be checked against the entry in the maintenance booklet VeDoc If the nu...

Page 83: ...nts by dirty hydraulic fluid appropriate oil filters have been installed Basic scope of fan hydraulics tilting hydraulics work hy draulics one high pressure filter one filter in circuit I and one retu...

Page 84: ...Bh 12 600 Bh etc C Maintenance at 2800 Bh 5600 Bh 8400 Bh 11 200 Bh 14 000 Bh etc The additional operations are combined accordingly on the maintenance sheet and separated by corresponding hea dings V...

Page 85: ...e usage of the Uni mog an additional workshop visit may be necessary for main tenance operations on the additional drive systems However the main advantage is a significant extension of the oil change...

Page 86: ...on board computer 0 0 05 sulfur content factor 1 0 05 0 1 sulfur content factor 0 5 0 1 sulfur content factor 0 3 Roughly 2 weeks before a service is due the driver is infor med about this via a pop u...

Page 87: ...units is interrupted in order to free up the CAN line This shortens the flashing time from approx 30 min to approx 3 min Faults which occur can also be read out on the inst rument cluster The advanta...

Page 88: ...ck Basic Operation Note Sleeve Use For installing the front crankshaft radial sealing ring in the oil pump cover MB number W 936 589 00 14 00 FG 03 Set B Category Mercedes Benz Truck Basic Operation N...

Page 89: ...For fixing the high pressure fuel pump and compressor in place when disassembling and assembling the drive gear MB number W 936 589 00 31 00 FG 07 Set B Category Mercedes Benz Truck Special Operation...

Page 90: ...ck Special Operation Note Available as of March 2013 Adapter Use For filling flushing and bleeding the oil circuit at the oil fil ter module MB number W 936 589 00 63 00 FG 18 Set B Category Mercedes...

Page 91: ...03 Set C Category Mercedes Benz Truck Basic Operation Note Mounting tool Use For pulling O rings onto injectors MB number W 936 589 01 33 00 FG 07 Set B Category Mercedes Benz Truck Special Operation...

Page 92: ...Puller Use For pulling off main bearing bridges MB number W 936 589 02 33 00 FG 03 Set C Category Mercedes Benz Truck Special Operation Note Available as of March 2013 in combination with puller W 47...

Page 93: ...B Category Mercedes Benz Truck Basic Operation Note Extraction tool Use For pulling out the seals of the pressure pipe connections on the injector line MB number W 936 589 04 33 00 FG 07 Set B Catego...

Page 94: ...Note In combination with test adapter W 470 589 02 21 00 Collet Use For mounting pistons in cylinder barrel MB number W 936 589 00 37 00 FG 03 Set B Category Mercedes Benz Truck Basic Operation Note...

Page 95: ...alling the diesel particulate filter DPF MB number W 470 589 01 62 00 FG 14 Set B Category Mercedes Benz Truck Basic Operation Note Mount Use Mount for adapting the DPF mount to a standard forklift MB...

Page 96: ...Interface Kommunikationsschnittstelle CPC Common Powertrain Controller drive control control unit DIN Deutsches Institut f r Normung German Standards Institute DOC Oxidation catalytic converter DOHC D...

Page 97: ...N Local Interconnect Network MCM Motor Control Module engine management control unit MIL Malfunction Indicator Lamp MS Maintenance System MSF Modular switch panel NA Power take off PTO OBD On Board Di...

Page 98: ...e STCU Special Trucks Control Unit TCC Truck Control Center TCM Transmission Control Module TFT Thin Film Transistor TPC Tire Pressure Control system UVV Accident prevention regulations USB Universal...

Page 99: ...e filter 14 16 23 24 26 27 28 81 95 Disk brake 54 Dog clutch 19 33 35 36 Drive transmission mode 34 Dual master cylinder 31 32 E EAS 11 31 32 33 34 95 Emissions regulations 22 Engine brake 10 14 16 92...

Page 100: ...9 40 42 47 48 51 80 82 84 Power supply 66 Pressure sensor 24 R Radiator system 20 Radio unit 78 Rapid radiator cleaning system 21 Rear axle 12 52 53 54 75 Rear lamps 74 Regeneration messages 27 Regene...

Page 101: ...er com Fax 49 0 18 05 0 10 79 78 2013 by Daimler AG This document including all its parts is protected by copyright Any further processing or use requires the previous written consent of Daimler AG De...

Page 102: ...101 Introduction of the New Unimog Generation Model Series 405 Space for notes This printout will not be recorded by the update service Status 03 2013...

Page 103: ...102 Introduction of the New Unimog Generation Model Series 405 This printout will not be recorded by the update service Status 03 2013...

Page 104: ...Daimler AG GSP OR D 70546 Stuttgart Order No HLI 000 000 12 24 Printed in Germany 09 2013 This printout will not be recorded by the update service Status 03 2013...

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