Mercedes-Benz Special Trucks and Mörtlbauer Present Hydrogen-Powered Prototypes

Key Highlights:

• Mercedes-Benz and Mörtlbauer showcased hydrogen combustion engine prototypes.
• The project was funded by Germany's Federal Ministry for Economic Affairs and Climate Action.
• The Unimog and crawler passed various tests successfully.
• Both vehicles can be refuelled with hydrogen and have low emissions.
• The "WaVe" project aimed to replace diesel engines with hydrogen engines for special vehicles.

Mercedes-Benz Special Trucks and Mörtlbauer Baumaschinen Vertriebs GmbH have unveiled two new prototypes as part of the "WaVe" development project, which seeks to investigate hydrogen combustion engines for special-purpose vehicles. The Unimog test truck and crawler demonstrated their ability in both driving and working activities at the Mörtlbauer factory.

The demonstration concluded the project, which was supported by Germany's Federal Ministry of Economic Affairs and Climate Action. Over the past three years, Mercedes-Benz Special Trucks and Mörtlbauer, along with 16 other consortium partners, have collaborated to develop these hydrogen combustion engines.

The Unimog implement carrier has been undergoing numerous tests for over a year, and the dump truck crawler, which has been operational since the spring of 2024, has also performed well in first application-specific testing.

Franziska Cusumano, Head of Mercedes-Benz Special Trucks, stated, "The final event held with our partner Mörtlbauer on their premises once again demonstrated that both vehicles have reached a development status that we can be very satisfied with, even though this project has only been running for three years. After several test deployments, emission measurements, and technological fine-tuning, we are confident that hydrogen combustion for work machines with large power requirements, both for driving and powering auxiliary drives, is worthwhile, practicable, and very low in emissions."

Armin Mörtlbauer, Managing Director of Mörtlbauer Baumaschinen Vertriebs GmbH, stated, "The fact that our crawler and the Mercedes-Benz Special Trucks Unimog can be easily refuelled with gaseous hydrogen and that these vehicles work reliably when using implements is the result of the outstanding cooperation in this research partnership. We conducted research and gained an understanding of this technology. We now have the relevant experience and data. However, in order to implement these in serial production, we must go much further down this path. If the government and society decide to move forward with hydrogen combustion engines, we are prepared."

During the occasion, the Unimog U 430 implement carrier drove the crawler with a low loader and displayed the refueling procedure at a mobile hydrogen refueling station. The Unimog also demonstrated implement operation with a front-mounted Schmidt sweeper.

Hydrogen combustion

The prototypes are powered by medium-duty engines that have been specially adapted to run on hydrogen. Customized pistons, a hydrogen-compatible intake system, and an optimized ignition system were employed. The hydrogen combustion process in these engines creates water, which is then ejected as hot steam through the exhaust system.

The Unimog's four TÜV-certified, 700-bar high-pressure tanks carry roughly 13 kg of gaseous hydrogen and provide approximately 290 horsepower / 1000 Nm, similar to a 300 hp diesel engine. The crawler has a similar engine output and fuel capacity, holding 14.5 kilos of hydrogen at 700 bar, a payload capacity of 30 metric tonnes, and versatility due to its dozer blade and 360-degree rotating body.

"WaVe" Development Project

The "WaVe" initiative, which began in July 2021 and is supported by Germany's Federal Ministry for Economic Affairs and Climate Action, brings together 18 corporate and scientific partners. The goal was to create a hydrogen-powered drive system for working machines, which might potentially replace traditional diesel engines. 

The study established that hydrogen-powered vehicles and machines could be operated in the same way as contemporary diesel engines, with only modest drivetrain adjustments.

These developments demonstrate the potential of hydrogen combustion engines to reduce emissions and improve the efficiency of special-purpose vehicles, paving the path for more sustainable industrial uses.

Also Read: IndianOil Delivers Green Hydrogen Fuel Cell Bus to Indian Navy

CMV360 Says

The successful development of hydrogen-powered prototypes by Mercedes-Benz and Mörtlbauer represents a significant step toward sustainable industrial applications. The project highlights the potential of hydrogen combustion engines to reduce emissions and improve efficiency in special-purpose vehicles, paving the way for a greener future in the industrial sector.