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Unimog Body and Implement Mounting Guidelines
Unimog Body and Implement Mounting Guidelines
MOUNTING GUIDELINES
N O R T H A M E R I C A
Body and Implement Mounting Guidelines U500 North America
This is the 2005 Body and Implement Mounting Guideline for the Unimog New standards and amendments issued by the National Highway Traffic
U500 North America. Safety Administration will appear in the Federal Registry from time to time.
You may obtain the Federal Register through the Superintendent of Docu-
Request additional copies through your local dealer or via email:
ments, U.S. Government Printing Office, Washington, D.C. 20502
Unimoginfo@Freightliner.com (www.access.gpo.gov).
Similarly, changes in the Canadian Motor Vehicle Safety Standards are
published in the Canada Gazette (http://canadagazette.gc.ca/index-e.html).
The specifications and descriptions contained in this guide are believed to
be accurate at the time of publication. In a continuing effort toward product The final stage manufacturer is solely responsible for the final certification
improvement, changes affecting this data may be made without notice. of the vehicle and for compliance with Emission Control Standards and Mo-
tor Vehicle Safety Standards. The following recommendations are furnished
for the final stage manufacturer’s information and guidance.
Important Information Freightliner LLC neither approves nor disapproves and does not warrant
This document is provided as an aid to intermediate and final stage manu- vehicle component or chassis modifications or equipment installations ar-
facturers in determining conformity to applicable U.S. and California Emis- ranged by dealers or customers and performed by entities other than
sion Control standards, and U.S./Canadian Motor Vehicle Safety Standards Freightliner LLC, since Freightliner LLC has no control over the work being
and other applicable standards. This document is not a substitute for performed by the various vehicle body equipment builders.
knowledge of the requirements of these standards. Final stage manufactur- If dealers or customers have any vehicle modifications or equipment instal-
ers should maintain familiarity with all current Emissions Control and lations performed, to the extent these modifications or equipment installa-
U.S./Canadian Motor Vehicle Safety Standards and be aware of their spe- tions adversely affect other vehicle components or vehicle performance,
cific responsibility in regard to each standard. Freightliner LLC's shall not accept any product liability or claims under
The U.S. and Canadian Governments have established Motor Vehicle terms of the vehicle warranty. These claims become the sole responsibility
Safety Standards for various categories of motor vehicles and motor vehicle of the person performing the modifications or equipment installations.
equipment under the provisions of the National Traffic and Motor Vehicle If additional technical information or explanation concerning the contents of
Safety Act (United States) and the Canadian Motor Vehicle Safety Act this vocational reference guide is required, contact the Unimog Implement
(Canada). The Acts impose important legal responsibilities on manufactur- Manager:
ers, dealers, body builders, and others engaged in the manufacturing and
marketing of motor vehicles and motor vehicle equipment. Unimog North America, Phone: 1-877-701-3000
Unimoginfo@Freightliner.com
Questions dealing with the specific application of these Acts or the stan-
dards to your business should be discussed with your legal counsel. This is (c) 2005 Freightliner LLC
particularly so because the standards and other requirements or interpreta-
All rights reserved. Reproduction or translation in whole or in part is not
tions are subject to change by government agencies in charge, the National
permitted without written authorization from the publisher.
Highway Traffic Safety Administration (United States) (www.nhtsa.dot.gov)
or Transport Canada (www.tc.gc.ca). Fourth edition: January, 2005
Body and Implement Mounting Guidelines U500 North America Table of Contents
1.8 Accident prevention .......................................................17 2.10 Aerial devices (man lifts) ............................................... 34
1.11 Damage prevention and safety regulations ...................19 2.13 Front end loaders .......................................................... 37
1.11.3 Prevention of accidents on the vehicle ..........................19 2.16 Water tanks ................................................................... 40
1.11.4 Plastic compressed-air, fuel and brake lines .................19 2.17 Front mounted 3-point hitches ....................................... 41
1.11.5 Welding operations ........................................................20 2.18 Rear mounted 3-point hitches ....................................... 42
1.11.9 Electrical system ............................................................21 2.22 Wood chipper (front mounted) ....................................... 46
5.9 Power take-off shaft drive (code N08) .........................171 6.1.4 Oil heating ................................................................... 193
5.9.2 Usable power output of the power take-off shaft .........172 6.2.1 Information on the basic hydraulic system................... 195
5.9.3 Technical data of power take-off shaft drive N08.........173 6.2.2 Information to the basic hydraulic systems.................. 198
5.9.4 Power take-off shaft profile (according to SAE J499a) 173 6.2.3 Shut-off valve............................................................... 202
5.9.5 Position of PTO shaft ...................................................174 6.2.4 Volume flows of the Unimog basic hydraulic systems . 202
5.9.6 Calculation of the PTO shaft height above ground ......175 6.2.5 Dealer for hydraulic couplings in the USA ................... 205
5.10 Auxiliary power take-off drives (code N16/N19) ..........177 6.2.6 Tema parts list for Unimog hydraulic connectors......... 205
5.10.1 General notes on auxiliary PTO’s (code N16/N19)......177 6.3 Information to the power hydraulic systems ................ 206
5.10.2 Technical data on auxiliary PTO’s (code N16 / N19) ...177 6.3.1 Power hydraulic flow rates........................................... 206
5.10.3 Hydraulic pumps for N16 auxiliary power take-off .......180 6.3.2 Drawings of the power hydraulics................................ 207
5.10.4 Direct flange mounting on auxiliary PTO N16..............183 6.3.3 Front power hydraulic connections, code H94............. 209
5.11 Drive shafts for implements .........................................184 6.3.4 Center power hydraulic connections............................ 209
6.3.5 Volume flows of the Unimog power hydraulic systems 210
• The Unimog technical data book with all technical data and im- • Unimog Weight Calculator and Axle Load Calculations
portant additional information • Center of Gravity Calculation
• Body and Implement Mounting Guidelines including all informa- The Unimog Resource CD can be requested from the Unimog Im-
tion on mounting implements and the Freightliner LLC require- plement Manager.
ments for implement mounting.
Instructions regarding vehicle safety
These documents form the basis for the development, modification
We recommend the following:
and review of bodies, implements and equipment of all types,
which are temporarily or permanently mounted on and operated with Only use genuine Mercedes-Benz service parts and conversion
the Unimog. The development and review of implements or bodies parts and accessories, which have been explicitly approved by
for the Unimog does not, in principle, entitle claims for costs or dam- Freightliner for use with your vehicle model. Such parts have been
ages to be made against Freightliner LLC. This also applies with re- specially tested for safety, reliability and suitability.
gard to compliance with road traffic law and accident prevention as
Freightliner can give no guarantee with regard to reliability, safety
specified in the national and international regulations on road traffic
and suitability in the following cases:
and technical equipment.
• If original parts or approved conversion parts or accesso-
Particular reference is made to the responsibility of the implement
ries have been exchanged for other parts or other changes
manufacturer for his scope of delivery and to the rules of safety to
have been made to the vehicle.
be complied with in respect of the vehicle/implement interface.
The instructions given must be observed exactly to maintain the op- • If bodies are not manufactured or mounted according to
erating and road traffic safety of the chassis and to maintain war- the valid Body and Implement Mounting Guidelines or if, in
ranty rights. the event of deviations, the approval of Freightliner is not
sought.
Illustrations and drawings are examples only and serve to explain
the texts and tables. Official acceptance by public testing bodies or official approval
does not rule out safety hazards.
References to regulations, standards, directives, etc. are partially
given in key words and serve only as information. Please contact the Unimog Implement Manager listed at the be-
ginning of this guideline for further general technical data of the
A CD-ROM called “Unimog Resource CD” is available with the fol- Unimog, which is not contained in this Body and Implement
lowing documents: Mounting Guideline.
• Body and Implement Mounting Guidelines Confidential. All rights reserved. Reproduction or translation
in whole or in part is not permitted without written authoriza-
tion from the publisher.
This vehicle will conform to FMVSS / CMVSS No. 125, Warning De- FMVSS 210 / CMVSS 210
vices, if no alterations are made to any components or items of the This vehicle will conform to FMVSS / CMVSS No. 210, Seat Belt
warning devices and no obstructions are installed which limit visibility or Assembly Anchorages, if no additional occupant seats or seat belt
usage of any item. assembly anchorages are added and if no alterations are made
FMVSS 205 / CMVSS 205 which affect the function, physical, or mechanical properties, envi-
ronmental or vital clearance of the components, assemblies or
This vehicle will conform to FMVSS / CMVSS No. 205, Glazing Materi- systems of any components of the seat belt assembly anchor-
als, if no alterations are made in the glazing material installed in the ages.
windshield and windows of the cab.
FMVSS 302 / CMVSS 302
This vehicle will conform to FMVSS / CMVSS No. 302, Flammabil-
ity of Interior Materials, if no alterations are made to the materials,
• The batteries must be checked for capacity and condition and 1.8 Accident prevention
must be serviced in accordance with the manufacturer's specifi-
cations. The body and implement manufacturer is responsible for damage:
• If a wheel has been removed or changed, the wheel nuts must • Resulting from insufficient reliability or safety of the
be retightened to the tightening torque specified in the mainte- body/implement or components supplied,
nance instructions.
• Resulting from errors or omissions in the Operating In-
• Operating Instructions and directives for maintenance operations structions for the body/implement or supplied components.
on installed components or devices must be provided with the
The body and the attached or mounted implement must comply
vehicle.
with relevant laws, industrial safety or accident prevention regula-
• Instructions regarding road traffic and operating safety of the ve- tions and the safety regulations of public insurance institutions. All
hicle equipped with implement or body units are especially im- technical possibilities for the avoidance of operating risks must be
portant. exploited.
• If components have been removed and re-installed by the im- National laws and regulations must be observed.
plement or body manufacturer, the mounting must be checked to The body and equipment manufacturer is responsible for compli-
ensure that it has been fitted correctly. In the case of compo- ance with these laws and regulations.
nents, which contain liquids (coolant, lubricant, etc.), the fill lev-
els must be checked and, if necessary, topped off using the All accident prevention regulations listed in the operating instruc-
specified fluids. tions must be adhered to.
The driving speed must be appropriate to the prevailing road, traf-
fic and terrain conditions. The influence of the implement/body on
1.7 Corrosion protection measures braking, cornering, driving on a slippery road surface or unfirm
ground, on side slopes, on inclines or declines, etc. must be taken
If the original corrosion protection of the chassis has been affected by into consideration. Always drive in a defensive manner.
work carried out after the vehicle has been dispatched from the factory,
it has to be repaired according to our directives. The body manufacturer must ensure that the vehicle
owner/customer is trained and familiarized with the theory and
The following points must be observed: practice of operating the implement or the vehicle in conjunction
• Avoid welding operations close to inaccessible cavities, with the implement.
• Remove drilling and grinding swarf,
• De-burr edges,
• Remove burnt paint,
• Prime and paint all bare parts with zinc-rich paint,
• Preserve cavities with wax preservative.
• Preferably use materials, which allow the implementation of ma- • Consequential damage which occurs due to fitting, installa-
terial recycling and closed material loops. tion or conversion work carried out by the body manufac-
turer
• Select material and manufacturing procedure so that only slight
volumes of waste, which can easily be recycled, are incurred. • Consequential damage which occurs due to retrofitting of
electronic systems
• In the case of plastics, particularly compound materials use mu-
tually compatible materials from one material family. • Consequential damage due to any influence on the exist-
ing vehicle electrical system
• In the case of recycling-relevant components, keep the number
of different plastics used as low as possible. • The functional safety and the free movement of all moving
parts of the chassis (e.g. axles, springs, propeller shafts,
• Check whether a component can be manufactured from recycled steering, engine control, shift linkage, brake components,
material or with recycled additives. etc.) even in the event of full axle articulation or diagonal
torsion of the chassis frame
• Ensure that recyclable components can be removed easily, e.g.
via snap connections, nominal break points, good accessibility. The body manufacturer must indemnify Freightliner LLC
against all liability for damage occurring due to
• Ensure that the removal of service fluids is simple and environ-
mentally compatible via the provision of drain plugs, etc. • Non-compliance with the Body and Implement Mounting
Guidelines
• Avoid painting and coating components wherever possible, use
colored plastic parts. • Use of the vehicle or the vehicle/implement combination
not in compliance with the regulations, particularly with re-
• Design components in areas, which are subject to accidents to
gard to the application of implements
be damage-tolerant, repairable and easily replaceable.
• Deficient design, manufacture or installation
• Only use plastics in places where they provide cost, functional or
weight advantages. • Failure to observe the appropriate basic principles in any
other regard
• Inadequate operating instructions of the implements / bod-
ies
The surface and corrosion protection of the springs must not be dam-
aged when they are fitted. Caution: If the instructions given in the Driver’s Manual
are not observed, damage may be caused to the
The protective measures described in Section 1.11.5 Welding opera- drive train.
tions, page 20 must be applied during welding operations.
1.11.7 Painting procedures 1.11.9 Electrical system
In order to avoid color variations on painted bodies, information regard- • Never start the engine unless the battery terminals are
ing the primer coats and cover coats used in manufacturing may be re- firmly connected.
quested by the Unimog Implement Manager listed at the beginning of • Incorrect supply voltage polarity may destroy the control
this guideline. units.
Before painting, cover the following areas: • Do not undo or disconnect the battery terminals while the
• Bearing surfaces between the wheel and wheel hub engine is running.
• Bearing surfaces of the wheel nuts • If the batteries are flat, the engine can be jump-started us-
ing jump leads and the battery of another vehicle running
• All bearing surfaces of high tensile threaded connections (e.g. on the same voltage. Observe the Driver’s Manual and the
engine mounting system, rear cross member, etc) Maintenance Manual. (12 V only)
• Coupling flanges of drive shafts, power take-off shafts and power • Jump-starting with a rapid charger (over voltage) is not
take-offs permitted.
• Hydraulic cylinder piston rods (platform tipping cylinder, cab tilt- • Only tow-start the vehicle with the battery connected.
ing hydraulics, etc.)
• Only charge the battery with a rapid charger if it has been
• All compressed air and hydraulic system control valves and the disconnected from the vehicle’s electrical system. The
interfaces of these components positive and negative terminals of the battery must be dis-
• Breather pipes in transmission, axles, etc. connected. Observe the Maintenance Manual.
• Cables routed near exhaust systems must be protected against radio manufacturer to certify the electromagnetic compatibility of
high temperatures. the appliance.
• Cables must not be routed near the exhaust manifold or turbo- Antennas:
charger. Code E54 (preparation of two-way radio including antenna) is re-
• Install the cables in such a way that there are no chafe or shear quired for mounting two-way radio devices. Please observe the
points (in vehicle torsion and relative movement between vehicle manufacturer’s instructions and the installation guidelines of the
and implement or body parts), particularly at crossing points and devices.
sharp edges and use cable channels or conduit if necessary. 1.11.11 Electromagnetic compatibility (EMC)
• Do not attach electric cables to brake lines. The electric and electronic components of the UNIMOG are tested
• Do not carry out measurements at connector contact points us- in the factory with regard to their electromagnetic compatibility in
ing unsuitable media (test probes, wire ends, etc.). This may the vehicle.
lead to contact problems as a result of the formation of contact If additional implement or body components, which affect the elec-
resistance. Use suitable test leads. tromagnetic compatibility of the vehicle components, are fitted, the
• The ground terminal of the welding unit must be connected di- implement or body manufacturer must ensure that the operating
rectly to the part to be welded and as close as possible to the safety of the entire vehicle/implement combination is guaranteed.
welding point. A further EMC test may be necessary.
2 Applications
2.1 Front mounted mowers
2.3 Spreaders
Overview of the related sections:
Hydraulic connector
Drive: - at the side (H68) → Chapter 6, page 189
- at the rear (H58/H59) → Chapter 6, page 189
Figure 2.5: Spreader mounted on ballpoints Axle loads → Section 4.4, page 62
Notes: Wheel loads → Section 4.5, page 63
Center of gravity → Section 4.8, page 67
Electrical
Code E45 → Section 7.4.2, page 219
connection:
Figure 2.10: Front mounted sweeper
2.9 Winches
Overview of the related sections:
Notes: Cable passage into the cab → Section 9.3, page 243
Front
2.15 Sewer cleaning devices - front mounting plate D12 → Section 4.13, page 81
Center
Mounting: - on platform P27 / P40 → Section 4.14.2, page 92
- on ballpoints P60 → Section 4.14.3, page 105
- directly on the chassis → Section 4.14.4, page 119
Front
- PTO (code N08) → Section 5.9, page 171
Center
Drive: - Engine-PTO (code N05) → Section 5.8, page 168
or
- gearbox-PTO (code N19) → Section 5.10, page 177
Electrical
Not necessary
connection:
Electrical
Not necessary
connection:
< 1t:
Implement mounting → Section 4.15, page 162
bracket rear (code D50)
+ undercarriage load → Section 4.14.8.1, pg. 160
bar under the rear axle → Section 4.14.8, pg. 156
2.24 Digger
Hydraulic connector
Drive: - at the side (H68) → Chapter 6, page 189
- at the rear (H58/H59) → Chapter 6, page 189
Electrical
Trailer socket (7 pin) → Section 7.4.4, page 222
connection:
Figure 2.28: Rear mounted crane < 3.5 mt
3 Vehicle Information
Transmission
This body and implement guideline covers the following vehicles: Type BM: G 718.840
All synchromesh MB 8-speed EPS-manual gearbox
Unimog model / Wheelbase Output With integrated permanent front wheel drive (all wheel drive).
Model
sales designation [in] [mm] [hp] [kW] Torque distribution front/rear axle 50:50
1-6 gears can be driven in reverse
U500 NA 405.210 131.89 3,350 260 193.88
(G03) 7-8 reversing gears open for rail-road application
Working gears (G20) / Working and crawler gears (G21)
U500 NA 405.230 153.54 3,900 260 193.88
Model UG 100-8 / 9,57-0,74 GPA, EPS
Table 3.1: Vehicle and model designations Overall gear Gear Forward Reverse
ratios: 1 9.570 14.569
2 6.635 10.101
3 4.375 6.660
3.1 General Technical Data 4 3.219 4.900
5 2.188 3.330
Engine 6 1.517 2.309
Emission class EPA 04 LEV 7 1.000 1.522
Manufacturer Mercedes-Benz 8 0.736 1.120
Type (LA = Turbocharger with intercooler) OM 906 LA Axles
Model 902.912 Type:
Number and arrangement of cylinders 6 (upright inline) Portal axles on trailing arm and transverse control struts
260 hp / 193.88 kW Hub reductions – identical design front and rear
Output (at rated speed)
(at 2,200 rpm) All wheel drive (Standard) with interaxle differential lock
Maximum torque (at speed) 700 lb⋅ft / 949 Nm Differential locks rear (Standard), front (optional A 52)
(at 1,200 – 1,600 rpm) Model front axle 737.591
Idle speed 600 rpm Model rear axle 747.591
Cold start ability with options M89 and All differential locks:
-22°F / -30°C
Z43 Pneumatically engage able and disengage able
Fuel tank capacity 60 gal / 227 l While in motion without traction force interruption
Width flange to flange 84.65 in / 2150 mm
Pitch circle diameter of wheel
13.19 in / 335 mm
studs
Number of wheel studs 10
Axle ratio i =5.92
*
*
*
* *
*
Note:
Dimensions marked with a * vary by
tires and/or vehicle (axle) loads.
* * *
Dimensions without brackets are in
[mm]. Dimensions in brackets are in [in].
Note:
* Dimensions marked with a * vary by
tires and/or vehicle (axle) loads.
*
Dimensions without brackets are in
* [mm]. Dimensions in brackets are in [in].
*
*
*
* *
* Note:
Dimensions marked with a * vary by
tires and/or vehicle (axle) loads.
* Note:
Dimensions marked with a * vary by
* tires and/or vehicle (axle) loads.
Before starting work with implements and bodies, a review must be The free movement and functional safety of all parts of the chassis,
carried out to see whether the selected chassis is suitable for the especially moving parts such as wheels, axles, pan hard rods,
planned implement or body. Also check that the chassis model and springs, propeller shafts, steering, etc. must also be guaranteed fol-
its equipment correspond with the intended application. Vehicle lowing the fitting of the implements or the bodies, even at maximum
drawings, technical data and other information are available on the axle articulation, maximum and minimum axle loads and maxi-
Unimog Resource CD or may be requested from the Unimog Im- mum steering angles (left and right).
plement Manager listed at the beginning of this guideline. The inspection for free movement and sufficient clearance at the
The Unimog chassis provides various possibilities for implement wheels and axles at full suspension travel, max steering angles and
and body mounting, see section 4.12 on page 80. axle articulation can best be carried out after removing the springs.
Verification must be provided through testing. To do this, the
diagonally opposing wheels of the front and rear axles must be
raised in such a way (min. 11.81 in / 300 mm) that the other two
wheels are only just touching the ground, see Figure 4.1.
If snow chains are to be used, the free movement tests must be car-
ried out with the chains fitted.
Caution:
Ensure that the vehicle is po-
sitioned securely before car-
rying out a chassis frame tor-
sion test. If approach ramps
are used, these must be se-
cured against slipping and
tipping. On lift platforms, the
tire contact surfaces must be
moistened to reduce drag.
Figure 4.1: Chassis frame torsion
Figure 4.4: Sketch of the upper edge frame level over the
wheel center
z
4.7 Coordinate systems z
RAW = W fr + GVWempty + Wmi + Wre − FAW Equation 4.3 Note: For FAW use the result of Equation 4.2
hf
Block springs of cab and fill the tank completely
• Place the vehicle-implement/body-combination in a horizon- Scale
tal and level position with one axle on the scale
QRAW
Warning: Use wheel chocks to prevent vehicle from rolling.
• Lift the other axle at least 1/3 of the wheelbase
• Weigh the existing axle load (RAW with lifted front axle or Figure 4.10: Determining the height of the center of gravity
FAW with lifted rear axle)
• Measure the exact lifting height (hf) of the front or rear axle. QFAW Front axle load by lifted rear axle
As an alternative to the lifting height, you also can determine QRAW Rear axle load by lifted front axle (see Figure 4.10)
the angle between the wheel centers to the horizontal. hf Lifting height of the raised axle
• Calculate the height of the center of gravity by using the hcog Center of gravity height above the wheel center
Equation 4.4 to Equation 4.9 hs Center of gravity above the road surface
rstat Statically loaded tire radius (see also Table 4.3)
• For confirming the height of the center of gravity, raise the α Angle between the wheel centers to the horizontal
lifted axle by further (e.g.) 4 in or 100 mm. Measure the axle
Table 4.2: Symbol definitions
load and the lifting height again and calculate the c.o.g.
height a second time.
If the vehicle suspension can’t be blocked it’s necessary to do sev-
eral calculation with different lifting heights, e.g. hf1 = 1/3 of the
wheelbase, hf2 = hf1 + 4 in, hf3 = hf2 + 4 in, hf4 = hf3 + 4 in. You can
limit the measurement errors by using the average value of all cal-
culated c.o.g. heights. Deviations of the c.o.g. height of more than
2 in or 50 mm point to measurement and/or calculation errors.
⎛ n mass n * c.o.g. height of the massn above the road ⎞ Seal off
hs = ⎜⎜ ∑ ⎟⎟ − x Spring danger zone!
⎝ i =1 GVW with implement / body ⎠
Equation 4.10
hk
α
Counterweight
(max. 1.5 t)
bolted front locking device
Center mounting
Platform mounting F see chapter 4.14.2
Ball points mounting F see chapter 4.14.3
Direct mounted body F see chapter 4.14.4
Mounting frame for
implements with outriggers F see chapter 4.14.6
Dimensions in [mm]
and dimensions in
brackets in [in]
Figure 4.19: Front mounting plate (code D12, part-no. A 405 550 12 38)
For implement mounting to the front mounting plate, suitable Listing of the Schmidt mounting kit for implement mounting to the
claws that are aligned with the pocket of the front mounting Unimog front mounting plate
plate, should be used, see Figure 4.20. These compatible and
screwable claws for front mounting plates, size 5 (code D12), are Schmidt
Description: Quantity:
manufactured by SCHMIDT®. Part No.:
Claw size A (compatible to Unimog
Order address 0150 026-3 2
Joe Zaloga plate)
Saddle River Road 7222
Monsey, NY 10952 0151 252-4 Block (40 mmx20 mmx140 mm) 2
Phone: +1-845-323-9231
Email: Mbilunimog@aol.com 0208 209-7 Hexagon bolt M16x70 mm 10.9 4
Hexagon socket countersunk flat
0222 075-4 4
®
The SCHMIDT identification head screw M16x70 mm 10.9
number of the zinc-plated claws 0205 474-0 Hexagon nut M16 8
is: 150 026-3 GGG 40
0150 722-7 Bolt 24 mmx315 mm 2
We recommend ordering the
complete mounting kit, listed in 0168 437-2 Washer 46 mmx25 mmx12 mm 2
Table 4.8 for implement mount-
ing to the front mounting plate 0204 710-8 Washer B 25 mmx44 mmx4 mm 2
of the Unimog.
0206 598-5 Split pin 6.3 mmx40 mm 2
Figure 4.21: Compatible claw for front mounting plate from SCHMIDT®
Figure 4.23: Angle between front mounting plate and the vehicle
frame (optional mounting position of the front mounting plate)
Note: Loosen the bolt at the steering gearbox and retorque! A 405 524 13 40 Bumper Bracket 1
For further information about removing the front mounting plate and
retrofitting of the cross member please contact the Unimog Imple-
ment Manager listed at the beginning of this guideline.
implement c.o.g.:
max. 1,500kg / 3,307lbs
implement c.o.g.:
max. 2,000kg / 4,409lbs
Figure 4.34: Overview of the platform and subframe mounting parts at the U500 with a short wheelbase
Figure 4.35: Overview of the platform and subframe mounting parts at the U500 with a long wheelbase
Every platform has eight fastening points and four additional bores.
For detailed measurements of the platforms and the attachment
points look at the drawings on the following pages (Figure 4.37 and
Figure 4.38) and also in the vehicle drawings on the Unimog Re-
source CD.
Holes for
implement
fastening
Holes for
implement
fastening
plate 3“ x 3“,
thickness ¼“
screw 7/8“
length 4“
Figure 4.48: Implement fastening with ring eyes
Dimensions without brackets are in [mm].
Dimensions in brackets are in [in].
The holes in the platform bottom can be sealed for transporting bulk
materials.
Note: To mount the 7/8 in eye nut the serial 17 mm – holes in
Figure 4.46: Positions of the fastening holes in platform P40 the platform have to be enlarged to 1 in!
Note: The existing tie-down eyes must not be the sole anchor
points for fastening heavy implements, but shall be used for
additional fastening.
Tie-down eye
Figure 4.52: Front end mounting with chains or belts Rear mounting
The rear of the implement has to be fastened using option code D50
brackets or alternatively using the holes in the chassis frame and
KENFORGING, Ohio
suitable eye bolts, chains and turnbuckles to avoid lift-off and slip-
Eye Nut Style B C1030
Stock No. EN-9-HD ping of the implement.
ENK
screw 7/8“
length 4“
Figure 4.53: Tie-down eye (option 1) Figure 4.55: Rear end mounting
ENKLER min. ¾“
ENKLER
plate
swivel plates
p Alternative solutions
ENKLER Alternatively, the implement may be bolted directly to the floor of the
ENKLER body. If you prefer this kind of mounting, please contact the Unimog
KENFORGING, Ohio
Eye Nut Style B C1030
Implement Manager for approval (submit an engineering drawing).
Stock No. EN-9-HD
eye nut 7/8“
grade 8 without D50
with D50
The diagram can be used to remind designers, and makes it easy for visual checking by anyone.
The following rule applies: The height of the center of gravity for a (heavy) body must be kept as low as possible.
Caution: Risk of damage to the platform subframe. The tip- Note: The power hydraulic components protrude approxi-
ping shell must not lay on the ball yoke (see mately 2.48 in / 63 mm above the upper edge of the plat-
Figure 4.59)! form subframe.
Two different ball half shells and locating bolts are available. Identi-
cal ball half shells must be mounted diagonally to avoid body or im-
plement damage (see Figure 4.66). Mounting the ball half shell in
diagonal manner will keep the operator from inserting the pins in the
wrong locations.
The height of the implement / body frame above the platform sub- Position of the contact points
frame longitudinal members must be designed in such a manner that of the polyamide plates
four plastic plates can be fitted at the implement / body frame. There
should be a distance of 0.06 in / 1.5 mm between the plastic plates
and the subframe (see Figure 4.67). In case of heavy bodies / im-
plements or dynamic loads (e.g. driving over uneven surfaces) the
body can be supported above the plastic plates directly against the
platform subframe longitudinal members. This method will prevent
overloading the platform subframe tubular cross members or ball
points which must only be vertically loaded with maximum 5,070 lbs
/ 2,300 kg. Use polyamide plates (nylon fiber) for best results.
Low platform subframe and short wheelbase Low platform subframe and long wheelbase
High platform subframe and short wheelbase High platform subframe and long wheelbase
Figure 4.73: Position of the magnet and the tilt control sensor
Further drawings with the position of the magnet and the tilt control
sensor are shown on the following two pages.
0.48 in / 12,2 mm
0.87 in / 22 mm
1.28 in / 32.4 mm
Figure 4.74: Position of the magnet for the tilt control sensor on the short wheelbase
Figure 4.75: Position of the magnet for the tilt control sensor on the long wheelbase
ABSETSKIPPER
Mounting
frame Mounting
frame
Vehicle Vehicle
frame frame
Figure 4.86: Sketches with dimensions of the subframe-frame-combination for the following section modulus diagrams
Figure 4.87: Section modulus of the frame-subframe-combination for a mounting frame with C-profiles (U.S. units)
Figure 4.88: Section modulus of the frame-subframe-combination for a mounting frame with C-profiles (metric units)
Figure 4.89: Section modulus of the frame-subframe-combination for a mounting frame with rectangular tubes (U.S. units)
Figure 4.90: Section modulus of the frame-subframe-combination for a mounting frame with rectangular tubes (metric units)
Figure 4.91: Overview of fastening plates for directly mounting (this figure shows a U500 with long wheelbase)
Figure 4.92: Tightening torques for mounting bodies/implements without outriggers directly to the chassis frame
1 x bolt M14x1.5x120,
grade 10.9
MB-No. N 910105014022
2 x A 405 520 10 33
2 x A 387 619 00 97
1 x nut M14x1.5
MB-No. N 913023014003
Nut Diameter 9/16” UNF Nut M14x1.5 4 Nut Diameter 9/16” UNF Nut M14x1.5 8
t=8mm
t=8mm
t=10mm
ENKLER
The mounting frame must be designed in such a way, that it reaches Note: Limited accessibility to holes on fastening plate D70:
under the cab to avoid abrupt changes of frame stiffness between
Access to the holes of the fastening plate (code D70)
the mounting frame and the chassis frame. It should run out at an
mounted on the left hand side longitudinal support of the
angle of 20 degrees to the longitudinal member (see Figure 4.77,
chassis frame is limited by installation of the mounting frame.
page 119).
Therefore it is allowed to use only two holes (see Figure
Note: Disassembly of the complete power hydraulic system for 4.100) of the D70 plate. All three holes of the fastening plate
implement mounting on the mounting parts is neces- (D70) mounted on the right hand side are accessible for in-
sary. stallation.
When the power hydraulics have been removed, the electrical con-
nector must be protected against moisture and dirt. The electrical
interface is electronically monitored for malfunctions. The hydraulic
control panel must be parameterized to prevent error messages in
the electronics system of the Unimog (see the relevant service in-
formation).
Warning: All permanently mounted, heavy implements (e.g.
cranes, aerial devices, backhoes, etc.) must be at-
tached with a sub frame on the Unimog frame. The
mounting frames must of sufficient size and be
properly mounted to the chassis frame (see also
pages 119 - 120).
Figure 4.100: Limited accessibility to holes on plate D70
A405 550 01 39
Figure 4.102: Overview of the different mounting points and fastening plates
Figure 4.104: Heavy implement mounting support, code D62 (Part-No.: A405 552 04 18)
Figure 4.105: Proposal for fastening of a mounting frame by use of heavy mounting brackets (code D62)
If, for example, the P27 tipping platform for a wheelbase of 3900 mm
is to be fitted to the implement subframe, the relevant ball points
should be ordered as original replacement parts. The ball point has
the part number MB 405 991 01 20.
Figure 4.121: Mounting frame with cross member and vertical frame
member (top view)
Figure 4.122: Wing plow-support mounted via code D62 and D70 on
the chassis frame (side view)
Figure 4.119: Cross member (top view)
Figure 4.120: Mounting frame with cross member and vertical frame Figure 4.123: Wing plow-support mounted via code D62 and D70 on
member (side view) the chassis frame (side view)
Figure 4.127: Top view of a Unimog with platform and mounted wing
plow-support
Figure 4.130: Front mounted crane Dimensioning of mounting frames for cranes
It is recommended the following materials or materials with a higher
yield stress be used for manufacturing the mounting frames
Tensile strength Yield stress
Material
106 Pa [N/mm2] 106 Pa [N/mm2]
E 460 TM > 560 > 560 460 460
E 500 TM > 610 > 610 500 500
Table 4.15: Material data
Equivalent materials:
SAE: 480 XLK or ASTM: A607 Grade 65
Important Note: The implement manufacturer is responsible for crane subframe dimen-
sions. The suggestions above are for information only.
Note: Subframe dimensioning according to section 4.14.4, page 119. The subframes must be mounted via heavy implement mounting
brackets (code D62, see section 4.14.6, page 137.
Note:
Bolts and nuts used to attach the
rear axle to the chassis frame
brackets may only be used once
and have to be replaced before
reassembly.
Torque to:
• 520 Nm or
• 383 lb·ft
Part Numbers:
Nuts:
N 913 023 020 001
Nut, Hex.,
FLGD M20 x 1,5 -10 i.a.w
MBN 10112 – M20 x 1,5 - 10
Bolt:
N 000 000 000 620
Bolt Hex., FLGD
M20 x 1,5 x 300 – 10.9 i.a.w.
DBL 9440
Figure 4.144: Implement mounting support manufactured by SCHMIDT® (for an order address of SCHMIDT® - parts see page 83)
Figure 4.147: Implement mounting support, code D60 (Part-No: A427 551 03 21)
There are various possibilities to drive implements fitted to Transmission ratios lower than one (i < 1) cause higher PTO – speed
Unimog´s. than engine speed (step up).
See Section 3.2 Technical Data for implement drives, page 54, for
details. 5.2 General notes on mechanical implement drives
The following power take-offs are available:
The following applies to all mechanical implement drives:
• Auxiliary power take-off (Code N05)
In comparison with other power transfer systems, a mechanical power
• Power take-off shaft drive (Code N08) transfer is the most efficient system!
• High speed power take off (Code N16)
• High speed power take-off (Code N19) Important Notes:
The following chapter contains important and detailed information • Either option code N16 or N19 can be installed, not
about the different power take-offs (PTO’s) of the Unimog. A tech- both.
nical overview of the PTO’s is shown in Table 5.1, page 165.
• N16 and N19 PTO’s must only be used while stationary
or while driving without shifting gear, as the drag torque
5.1 Notes on the transmission ratio of the attachment connected to the auxiliary power
take-off prevents synchronization of the manual trans-
mission. Therefore shifting must not take place be-
General definition of the transmission ratio “ i ”:
cause the synchronizer rings will get damaged.
i=
(Transmission ) Input Speed i=
nengine • The current Unimog code list on the Unimog Resource
(Transmission ) Output Speed n power take−off CD provides information regarding the availability or
possible combinations of the optional equipment.
• Please contact the Unimog implement manager listed
Note: Definition of input and output is according to the direc- at the beginning of this guideline in the event of uncer-
tion of power flow! tainty regarding the suitability of an auxiliary power
The speed of the PTO – drive in relation to the power take-off / take-off for the planned use.
auxiliary power take-off speed is derived from the engine speed as
follows:
nengine
n power take −off =
i
5.8 Engine dependent power take-off (code N05) Important Notes: Freightliner Unimog Division approved
the N05 auxiliary power take-off only for
The power hydraulic system (Code H63 and H64), available ex fac- the drive of the power hydraulic system,
tory, is driven via a drive shaft by the N05 auxiliary power take-off. as available from the factory. Written
permission should be obtained from
In applications where neither H63 nor H64 are installed, the N05
Freightliner Unimog Division for all
auxiliary power take-off can be used to drive hydraulic pumps, water
other applications.
pumps etc. It is however necessary to install a vibration absorber
(damper) in the driveline (see Section 5.8.2 Vibration absorber, page
169).
Drawing of the N05 flange
The use of N05 for mechanical applications (e.g. drive of a rear PTO
- shaft for implement drives etc.) is not permitted!
N 05 - flange
5.8.1 Technical data for N05 auxiliary power take-off
The N05 auxiliary power take-off is driven via spur gears off the en-
gine camshaft. At the rear end of the engine there is a PTO flange
that is driven via a dog clutch. The PTO can only be engaged when
the engine is at standstill and the ignition is switched on.
Auxiliary power take-off (Code N05)
Gear ratio i = 0.933
Speed at rated engine speed (2,200 rpm) 2,356 rpm
Direction of rotation (viewed in direction of travel) Counter clockwise
Max. delivered torque (continuous) 442 lb⋅ft / 600 Nm
Max. torque delivered (intermittent) 531 lb⋅ft / 720 Nm
Max. continuous power output 185 hp / 138 kW
Max .moment of inertia w. rigid PTO drive 0.01 kgm2
Max. moment of inertia w. elastic PTO dr. 0.02 kgm2 Dimensions without brackets are in [mm].
Note: Engine dependent PTO, actuated via dog clutch
Dimensions in brackets are in [in].
Table 5.4: Technical data of N05 auxiliary PTO
Figure 5.2: Drawing of the N05 flange
Figure 5.3: PTO N05 with vibration absorber and hydraulic pump
Note for installation of the vibration absorber:
Refer to Figure 5.6 drawing of absorber.
The left side represented on the cut in the drawing must be bolted
with the device-sided consumer (e.g. hydraulic pump). The right side
(soft side) must be bolted with the prop shaft to the auxiliary power
take-off N05.
Observe installation directives
Figure 5.4: Installation of a vibration absorber on N05 Warning: Risk of damage to the vibration absorber!
Maximum thread engagement 0.59 in / 15 mm.
Figure 5.6: Drawing of the vibration absorber (part-no. A906 250 00 01)
5.9.1 General
The engine power take-off drive shaft is installed in front of the en- • The drive shaft joint angle must not exceed 15° (short periods
gine. It is actuated electrically and can be engaged under load of time up to max. 30°) in continuous operation.
when the vehicle is stationary or moving. It is driven by the front
end of the engine crankshaft via a torsion-vibration-damper and a • The drive shafts are to be arranged so that irregular running is
drive shaft through a gearbox to the PTO output shaft. An inde- impossible in all operating positions.
pendent oil supply and a hydraulic multi-disc clutch with slip brakes • The sliding parts of the drive shafts must be selected such that
(for slip compensation) are also part of the PTO drive code N08. easy movement is possible at maximum torque transfer. In
An oil/water heat exchanger cools the PTO gearbox. case of high torques, telescopic type ball bearing traveler pro-
For safety reasons, the power take-off shaft can only be engaged files are preferable.
when the engine is running. • Protection devices must be provided by the implement manu-
The safety and monitoring instruments include a digital rev facturer for all accessible rotating parts.
counter in the display (true PTO shaft speed) as well as elec- • The direction of rotation of all rotating parts of the PTO-drive
tronically monitored safety precautions (starter interlock, must be marked clearly (risk of accident!).
torque limit).
• For operation of a power take-off shaft, it must be ensured that
The one-step power take-off transmission was designed for a PTO the rotating shaft is sufficiently protected.
shaft speed of 1,000 rpm. A PTO shaft speed of 540 rpm can be
realized by setting the engine speed via hand throttle to approx. • Wear tightly fitting clothing when working near rotating drive
1,155 rpm. At a PTO shaft speed of 540 rpm there are at least shafts and other rotating components.
67 hp / 50 kW available at the power take-off shaft. • During stationary operation the vehicle must be secured
against rolling away (parking brake, wheel chocks)
Safety instructions for power take-off shaft operation: • Only connect and disconnect implements when the engine is
at standstill and the power take-off shaft is disengaged.
• The rated load must not be exceeded, taking the type of
operation (shock coefficients, duration of use, ambient con- • The engine must be switched off prior to performing any ser-
ditions etc.) into consideration. vice on implements which are driven by power take-off shafts,
and no work must be carried out until the implement has come
• The implement manufacturer is responsible for carrying out to a standstill.
practical tests with the implement to verify the operation of
the drive. • Only connect and disconnect the drive shaft to the PTO drive
using the appropriate coupling and never by joining / pulling
the drive shaft splines apart.
Note:
Dimensions marked with a * vary by
tires and/or vehicle (axle) loads.
Note:
Vehicle equipped with tires 315/80R22.5
Figure 5.9: Position of the PTO shaft in relation to the front mounting plate
∆h = (e FA − e RA ) *
b
l
Formula 5.3: Calculation of the suspension part
5.9.6 Calculation of the PTO shaft height above ground Example: U500 short, wheelbase 131.89 in, fully loaded
(FAW:15,100 lbs, RAW: 17,900 lbs), tires: 395/85R20
Dimension “h” (height of the power take-off shaft above the road sur- a = 8.66 in rstat = 21.34 in
face) can be approximately calculated by use of Formula 5.1. The b = 37.83 in eFA = 13.69 in
height depends on tire size and suspension spring compression l = 131.89 in eRA = 15.24 in
(axle loads, vehicle weight). A tolerance of +/- 3% of “h” must be al-
∆h = (e FA − e RA ) * = (13.69in − 15.24in ) *
b 37.83in
lowed for. = −0.44in
l 131.89in
h = rstat + e FA + a + ∆h + ∆tire *
h = rstat + e FA + a + ∆h = 21.34in + 13.69in + 8.66in + (−0.44in) = 43.25in
Formula 5.1: Calculation of the PTO shaft height
N 16 - flange
N 19 - flange
1300
1250 F1-41
F1-61
1200 F1-81
Engine speed [rpm]
1150
1100
1050
1000
950
0 5 10 15 20 25 30
Flow [gallons/minute]
Figure 5.18: PARKER® hydraulic pumps
The joint angles at both ends of the drive shaft must be equal.
The forks of the connecting shaft must be in the same plane.
A combined drive shaft assembly with Z deflection in one and
W deflection in the other plane should be avoided. This would
be the case if input and output shaft were not on one plane.
6 Hydraulic system
Dual circuit system (Code H06, H08)
Flow rates at rated Circuit 1 6.34 gal/min / 24 l/min
6.1 Overview of codes and hydraulic circuits on the engine speed
Unimog 2,200 rpm: Circuit 2 12.68 gal/min / 48 l/min
Up to four hydraulic circuits are available for the Unimog Pressure 2,900 psi / 200 bar
U500NA: Application Implement actuation, constant flow
Maximum 8 sockets, sep. return line,
6.1.1 Hydraulic drives Front connectors
pressure line (front)
Basic hydraulics Pressure line, separate return line
Middle connectors
(circuit 2)
Oil tank volume 11.89 gal / 45 l Maximum 4 sockets, sep. return line,
Rear connectors
Oil SAE 10 W pressure line (rear)
Valves 2 to 4
Oil issue quantity 2.64 gal / 10 l
Power hydraulic system (closed or open circuit)
Single circuit system (Code H02) Oil tank volume 13.21 gal / 50 l
Flow rate at rated Oil SAE 10 W
engine speed 12.68 gal/min / 48 l/min Oil issue quantity 2.64 gal / 5 l
2,200 rpm
Pressure 2,900 psi / 200 bar Max. flow rate circuit 3 at
rated engine speed 33.02 gal/min / 125 l/min
Application Implement actuation 1,800-1,900 rpm:
Front connectors Maximum 8 sockets, sep. return line Working pressure circuit 3 4,351 psi / 300 bar
Rear connectors Maximum 4 sockets, sep. return line Max. flow rate circuit 4 at
rated engine speed 23.78 gal/min / 90 l/min
Valves 2 to 4
1,800-1,900 rpm:
Working pressure circuit 4 4,061 psi / 280 bar
Pressure & return line in front
Connectors
and/or middle
Table 6.1: Technical data of available hydraulic circuits
H12 2 valve hydraulic system For use with implements with max. 2 actuating movements
H13 3 valve hydraulic system For use with implements with max. 3 actuating movements
H14 4 valve hydraulic system For use with implements with max. 4 actuating movements
H43 Tipping cylinder for platform Multistage tipping cylinder situated in the center under the platform
H58 Pressure line rear for dual circuit hydraulic system Connection for circuit 2 rear, return via H59
H59 Separate rear return line Return for H 58 or single circuit hydraulic system
H61 Hydraulic snow plow release Weight transfer to the vehicle via hydraulic pressure
H63 Power hydraulics, closed circuit (circuit 3) Integrated in platform subframe, couplers above the battery box
H64 Power hydraulics, open circuit (circuit 4) Integrated in platform subframe, couplers above the battery box
Additional pressure line for dual circuit hydraulic sys- For operation of a built-in continuous consumer, couplers above the
H68
tem, middle, inc. separate return line gas tank
H71 Hydraulic connection, front, 2 lines on valve 1 2 flush-face couplers
H78 Pressure line front for dual circuit hydraulic system Connection for circuit 2 front, return via H79
H79 Separate front return line Return for H 78 or single circuit hydraulic system
3 Hydraulic tank (basic hydraulics) and hydrostatic fan drive 4 Hydraulic cylinder, tipper body P3 Hydraulic pump hydrostatic fan drive
1 Oil filter 5 Hydraulic oil cooler Z1 Cell 1 in circuit I, connector 1 and 2
1a Valve block SR Return line Z2 Cell 2 in circuit I, connector 3 and 4
2 Snow-plow load release valve P1 Hydraulic pump circuit I Z3 Cell 3 in circuit I, connector 5 and 6
2a Shut-off valve for tipper cylinder P2 Hydraulic pump circuit II Z4 Cell 4 in circuit I, connector 7 and 8
Figure 6.3: Basic hydraulics circuit I and II – 4 cells
8 7 6 5
4 3 2 1
Figure 6.5: Front hydraulic connections (drive direction: right)
Figure 6.4: Front hydraulic connections (drive direction: left)
Note: Only one cell / valve can be used at the same time
1 3 2 4
C i rcu i t I + II w i t h co mb i n a t i o n s
2 5 ,0 0
circuit I
circuit II
circuit I + circuit II
2 0 ,0 0
Volume flow [gal/min]
1 5 ,0 0
1 0 ,0 0
5 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e sp e e d [rp m]
Figure 6.12: Flow rates of hydraulic circuits I + II with combinations in [gal/min]
C i rcu i t I + II w i t h co m b i n a t i o n s
1 0 0 ,0 0
c irc uit I
9 0 ,0 0 c irc uit II
c irc uit I + c irc uit II
8 0 ,0 0
7 0 ,0 0
Volume flow [l/min]
6 0 ,0 0
5 0 ,0 0
4 0 ,0 0
3 0 ,0 0
2 0 ,0 0
1 0 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e sp e e d [rp m]
Figure 6.13: Flow rates of hydraulic circuits I + II with combinations in [l/min]
Figure 6.18: Hose laying of the H94 lines above the battery box Circuit VI
• Maximum and temporary oil flow 90l/min (23.77
Figure 6.18 shows the laying of the hoses and lines of the front gal) at 280 bar (4060 psi)
power hydraulic connections (code H94). These three lines are
connected at the side of the subframe longitudinal member
above the battery box with the serial connections of the power
hydraulic circuit 4. When code H94 is specified, the space un- 6.3.5 Volume flows of the Unimog power hydraulic sys-
der the cab above the longitudinal frame member is used and tems
cannot used for other applications (see also 4.14.7, page 156).
The figures on the following pages show the flow rates of
available Unimog power hydraulic circuits.
C irc u it III + IV
3 5 ,0 0
2 5 ,0 0
Volume flow [gal/min]
2 0 ,0 0
1 5 ,0 0
1 0 ,0 0
5 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e sp e e d [rp m ]
Figure 6.19: Flow rates of hydraulic circuits III + IV without combinations in [gal/min]
C irc u it III + IV
1 4 0 ,0 0
1 0 0 ,0 0
Volume flow [l/min]
8 0 ,0 0
6 0 ,0 0
4 0 ,0 0
2 0 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e s p e e d [r p m ]
Figure 6.20: Flow rates of hydraulic circuits III + IV without combinations in [l/min]
Port A Connector
G 3/8” HS10-2-IGF06
G 1/2" HS10-2-IGF08
NTPF 1/2-14 HS10-2-INF08
Table 6.12: Parts list for high working pressure power hydraulic
system
7 Electrical system
Trailer socket rear 7-pin
Implement socket at battery box 16-pin
7.1 General notes on the electrical system Permanent power socket with speed signal in cab 3-pin
Implement socket front (optional, Code E45) 7-pin
The U500NA has a 12 V vehicle circuit voltage and a serial bat- Table 7.2: Electrical interfaces
tery-isolating switch.
Important Note: The vehicle has also 24 V in some loca- Option
Descriptions:
tions in the electrical system. codes:
E44 12 V jump start terminals
Preparation for CB / mobile telephone (12 V), incl.
E53
antenna
7.1.1 Technical data of the electrical system E54 Preparation for two-way radio (12 V), incl. antenna
Alternator 14 V, 145 A E55 Antenna and two loudspeakers
Alternator with increased power (option Table 7.3: Optional electrical equipment
14 V, 270 A
code M37)
Starter 12 V, 3 kW
Batteries 3x12 V, 96 Ah 7.1.2 Lighting
Lights 12 V Following the mounting of implements/bodies on the Unimog the
Electronics (except FR1 and MR2) 24 V adjustment of the headlights should be checked.
Table 7.1: Technical data of the electrical system In case of attaching an implement/body, the implement/body
manufacturer is responsible for compliance with regulations to
Note: lighting of a vehicle.
1
ECU for chassis (12V)
2
ECU for engine (12V)
7.2 Electric cables • Do not change standard connections, e.g. ground con-
nections.
Conductor cross sections
• When changing the length of cables or on installing fur-
When determining cable cross-sections, the loss of voltage in ther cables, waterproofed connectors must be used.
the conductors must be considered. If the voltage drop is too
great, it may lead to the conductors becoming heated and, under • If the installation position of electric or electronic compo-
certain circumstances, to a cable fire. Conductor cross-sections nents is changed, the length of the electric cable must be
of less than 18AWG / 1 mm2 are to be avoided due to the low adapted. Routing may compensate for slight excess in
stability of the conductor. The positive and negative cables must the cable length. Excess length must not be routed in
have the same cross-section. Technical literature provides in- rings or loops.
formation regarding the cross-sections of electric conductors that When routing cables from one side of the frame to the other, use
are to be used or which are suitable. No more than 5 A should existing holes. An additional hole may only be drilled if there is
be carried per mm² cable cross-section. no other possibility for passing the cable through the frame. Re-
The necessary cross-section must be calculated by the im- ferring to section 10.6 Mounting of implements on page 266. The
plement manufacturer and must be tested under concrete, hole must be provided with edge protection (grommet), so that
practical conditions. the cables are protected against damage.
The power outlet in the cab is fused with fuse number F2/14.
This fuse is located in the fuse box behind the right passenger
7.4.3 Implement socket on the battery box Note: EPS is an abbreviation for electro-pneumatic gear
shifting.
This implement socket is intended as electrical interface for im-
plements and bodies. It is located at the right hand side of the
battery box (at the left hand side of the vehicle). It is a 16-pin Current up to 40 A can be tapped from the implement socket.
socket with the following pin assignment: For this purpose the pins 1, 2 and 3 (+12 V) must be con-
Pin nected. The same applies to ground connection pins 4, 5 and
Function: Description: 6.
number:
1 Terminal 30 +12 V; steady plus; fused (15A)
2 Terminal 30 +12 V; steady plus; fused (15A)
3 Terminal 30 +12 V; steady plus; fused (15A)
4 Terminal 31 Ground
5 Terminal 31 Ground
6 Terminal 31 Ground
7 Terminal 15 Ignition
8 Terminal 58 Parking light / side marking lamps
9 Terminal W Alternator speed signal
10 WB Warning beacon closed opened
11 BUL Back up light
12 C3 Road speed signal Figure 7.5: Implement socket
13 C4 Distance signal
Not con-
14 -
nected
15 UI* Universal input to EPS control unit
16 UI ground EPS - Ground for universal signal
Table 7.6: Pin assignment of implement socket 16-pin
Two different types of suitable plugs are available for the con- Part numbers for plug with screw connectors:
nection of implements/bodies to this implement socket.
Description AMP Part-No.: MB Part-No.:
Housing, Plug:
51.42.42.16.07 A 043 545 15 28
The plug is available with crimp connectors and also with HB-K.16.STS-GR.1.21
screwed connectors. In both cases the necessary plug (size 6) Cartridge, screw:
66.12.16.40 ---
can be ordered at AMP or at any authorized Freightliner Unimog HX.16.Sti.S
dealer. Terminal, screw
--- ---
for pins 1 thru 6
AMP order address: Terminal, screw
--- ---
AMP Regional Center for pins 7 thru 16
Harrisburg, PA, USA Table 7.8: Part numbers for plug with screw connectors
Phone: +1.717.564.0100
Fax: +1.717.986.7575
Pin assignment:
Cable
Pin-no.: Lamp and Signal Circuit
Color1
1 white Ground return to towing vehicle (31)
Clearance, side marker and identifica-
2 black
tion lamps (58LI)
3 yellow Left turn signal and hazard lamps (L)
4 red Stop lamps a antilock device (54)
5 green Right turn signal and hazard lamps (R)
6 brown Tail and license plate lamps (58RE) Dimensions in [mm]
Continuous ABS power / auxiliary
7 blue Figure 7.9: Pin and color assignment
(AUX + 54G) 12V, 20A (steady plus)
Table 7.9: Pin assignment of the rear trailer socket
7.5 Engine remote control Note: Since connecting pin 15 and pin 16 stops the engine, the
implement socket should always be kept clean and the
An engine remote control system is available for the Unimog. lid should be closed when ever no connector is attached.
Such remote controls systems can be primarily used in conjunc-
tion with N16 / N19 auxiliary PTO applications like cranes, back-
hoes, aerial devices, emergency stop switches on implements • Engine speed remote control:
etc.
o Operation code W04
Remote controls use the implement socket (at the battery box).
o Carried out via UI (pins 15 and 16)
Prerequisite is the activation of operation codes “W” (see section
7.6, page 227). o Change in resistance between UI and signal ground
Before enabling the engine remote control system, the engine
variable speed governor must be activated using the manual
• Other functions (refer also to W-codes):
throttle control switch at the gearshift console (take place auto-
matically when an auxiliary power take-off is switched on). o Warning buzzer W06
Important Note for following descriptions: o Limitation of max. engine speed W09 thru W20
Necessary resistor power 1 Watt. All Pin numbers refer o Transmission lock W30
to the implement socket at the battery box.
o Useful as a safety feature to prevent driving off
when support legs are extended (e.g. cranes)
7.5.1 Remote control functions o Speed limit W35
• Engine Start/Stop: o Useful as a safety feature with waste disposal
trucks
o Operation code W01, W02 or W05 (refer to page 229)
must be activated
o Carried out via UI (pins 15 and 16) A cable runs to the cab from pin 14 of the socket. Other func-
tions can be directly wired or programmed at the request of the
o Engine stop via connection between pin 15 and pin 16
implement manufacturer. Contact the Unimog Implement Man-
(signal ground)
ger listed at the beginning of this guideline.
o Engine start with 470 Ohms resistor (1 W) between pins 15
and 16
4000
3000
resistor
On large front mounted implements, e.g. large snow plows with Pin: Description:
wind deflectors, the auxiliary driving lamp (code L47) may get 1 12 V ground (terminal 31), right
covered by the implement in transport position. The implement 2 Side marker lights (terminal 58), right
manufacturer must draw attention to this in the operators 3 Low beam light (terminal 56), right
instruction manual. 4 High beam (terminal 56), right
5 Turn signal light, right
6 Not connected
Code L49: Preparation for Roof-mounted headlights may be or- 7 12 V ground (terminal 31), right
dered ex factory. The auxiliary driving lights (code L47) may not 8 Side marker lights (terminal 58), left
be ordered together with code L49. 9 Low beam light (terminal 56), left
Code L49 includes the main headlamp switch and an electrical 10 High beam (terminal 56), left
interface, which is located in the switch box in the area behind 11 Turn signal light, left
the power outlet (behind driver seat) in the cab. 12 Not connected
Table 7.11: Pin assignment of code L49 connector
To connect your roof-mounted headlamp support you will need:
• 1x Housing, socket; part-no.: A 013 545 62 26 (12-
pin housing)
• 10x Terminal, clamp for 14AWG / 1.5 mm2 cable cross-
section; part-no.: A013 545 78 26
8V
T time
t=1/f
0
7.9 Road speed signal and travel dependent signal
distance travelled
1.0 m s (m)
The road speed signal and travel dependent signal comply with
ISO 16844-2.
The road speed signal (C3) can be taken from the power supply Figure 7.19: Travel distance signal C4
socket in the cab (behind the driver’s seat) and also from the
implement socket at the battery box.
The travel distance signal (C4) can only be taken from the im-
plement socket at the battery box.
8 Pneumatic Consumers
8.2 Technical data of the compressed air system
8.1 General notes to pneumatic consumers Operating pressure 117.5 psi / 8.1 bar
Delivery at rated engine 79.25 gal / min / 300 l / min
The Unimog is serially equipped with a air brake system. When speed at 117.5 psi / 8.1 bar
attaching pneumatic consumers on the Unimog the following Tire inflating valve at test con-
Compressed air connection
items must be considered: nection of reservoir
Reservoir, brake system 2 x 7.53 gal / 2 x 28.5 l
• Only small air extraction values are permitted, for exam-
Table 8.1: Technical data of the compressed air system
ple implement actuations
• Pneumatic consumers with high air consumption must
not be attached to the Unimog air system
• Continuous consumers with constant air flow must not be
attached to the Unimog air system
The implement/body can be equipped with an additional air tank.
In this case the time limit for filling the air tanks to reach the nec-
essary brake pressure must be considered (FMVSS 121 /
CMVSS 121).
Applications, which require a high airflow, must be equipped with
an external mechanically, hydraulically or electrically driven air
compressor. For additional or larger air compressors engine
mounting is not possible.
To protect the air brake system, the air may only be tapped be-
hind an pressure protection valve. Figure 8.1: Location of the compressed air system
The air extraction interfaces are different for vehicles with CTIS
(central tire inflating system, code A30) and vehicles without
CTIS. Pneumatic consumers may only be connected to the fol-
lowing described interfaces.
Connected to secondary
supply reservoir
Connected to secon-
dary supply reservoir
CTIS
interface
Connected to secondary
supply reservoir
Interface for
additional
pneumatic
consumers
Figure 8.6: Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS
Connected to secon-
dary supply reservoir
CTIS
Interface
Figure 8.7: Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS
Meritor Wabco
0 1 1 1 A005 429 55 44
Part-No.: 934 899 0207
There are two ways to facilitate cable passage into the cab:
• Cable passage through the rear wall of the cab
• Cable passage through the front wall of the cab
In the rear wall and also in the front wall of the cab are holes
for cable passages into the cab. The cable passages are
closed with seal caps (part-no. A405 583 00 83, see Figure
9.6). The seal caps can be cut in for cable passages into the
cab.
9.3.1 Cable passage through the rear wall of the cab
The cable passage in the rear wall of the cab is provided in the
area behind the driver seat near the power outlet (see Figure Dimensions without brackets are in [mm].
9.4). Since the Unimog cab can be tilted, plug-connections Dimensions in brackets are in [in].
must be provided for the cables so the lines are not damaged Figure 9.4: Cable passage through the rear wall of the cab
when the cab is tilted.
9.3.2 Cable passage through the front wall of the cab
A similar cable passage in the front wall of the cab is located in
the area of the right (passenger) footwell (see Figure 9.6). This
is intended for front implement cables or cables which are
passed over the pivot point and therefore need not be taken
apart when the cab is being tilted (in particular with perma-
nently mounted implements / bodies).
For the exact position of the front cable passage, see vehicle
drawings on the Unimog Resource CD.
Figure 9.5: Cable passage through the front wall of the cab
Figure 9.16: Use of seal cap (part no. A409 583 00 83)
laminated
tube
By mounting of these front supports the following measure- The following sleeve should be used for fastening the roof-
ments for fastening of roof-mounted devices will be achieved: mounted devices on the stands:
Figure 9.25: Sleeve for beacon light stand (Part-No.: A405 821 0028)
Figure 9.27:Routing of the cable behind the chimney of the air intake
4 fastening points
on the gearshift
console for light-
weight control
panels
3 additional fas-
tening points for
heavy control
panels
Control unit
Floor panel
Floor panel
control unit
mounting frame control unit
mounting frame
Figure 9.34: position of the frame for center mounting (use Figure 9.36: position of the frame for left mounting
with VarioPilot)
Figure 9.35: 3D view of the frame for center mounting (use with Figure 9.37: 3D view of the frame for left mounting
VarioPilot) RK 999 000 P 207 RK 999 000 P 245
In case of frame extensions the quality and dimensions of the The chassis frame of the Unimog must always be equipped
extension material must be equivalent to the standard chassis with a rear cross member, even in non-trailer use. Otherwise
frame. The chassis frame material is E460 TM or E500 TM on the frame will be damaged.
the Unimog U500 NA.
A 47.24 in / 1,200 mm long piece of factory frame material is
10.5 Wheel chocks
also available as a spare part (part-no.: A405 311 08 01) and
can be ordered at authorized Freightliner Unimog Dealers.
The wheel chocks must be mounted without play in suitable
brackets. They must be easily accessible, secured against
loss and removable without risk of injury.
Bolts and nuts that are mounted on the Unimog and the Uni-
mog frame may only be replaced by bolts with the same di-
ameter, the same grade and the same thread pitch.
Observe prescribed tightening torque.
Following items should be considered by using bolt connec-
tions:
• Use fit bolts, headless bolts or flange head bolts (grade
8 and if available SAE fine thread) and flange nuts or
flange lock nuts for bolt connections on the Unimog Figure 10.6: Use of clamping sleeves
(see Figure 10.8).
• Use existing drillings and drill new holes only if it is es-
sential.
• Adapt the number of bolts to the load, if necessary re-
move paint down to the primer to minimize setting
symptoms.
• Use sufficiently strong washers for clamping sleeves
and anti-fatigue sleeves.
Examples for bolted connections:
In case of transferring lateral forces with positive locking bolted
connections a clamping sleeve should be used (see Figure
10.6). For minimizing the loss of preload force caused by sub-
sidence sufficiently long bolts or anti-fatigue sleeves should be
used (see Figure 10.7).
Figure 10.12: Frame extension with Figure 10.13: Reinforcement plates on inside/outside of the
reinforcement plates frame
11 Appendix
To convert
Name To Multiply by
from
11.1 Conversion Table Pressure lbf/in2 Pa 6894.757
2
Pressure lbf/ft Pa 47.88026
B = A*C
Pressure bar Pa 100,000
Pressure lbf/in2 bar 0.0689475
2
Pressure Pa lbf/in 1.4504E-04
A B C Pressure Pa lbf/ft2 0.0208854
Name To convert Pressure Pa bar 1E-05
To Multiply by
from Pressure bar lbf/in2 14.50377
Acceleration ft/sec2 m/s2 0.3047987 Temperature Temp.[°C] = (Temp.[°F]-32)*5/9
Acceleration m/s2 ft/sec2 3.2808539 Temperature Temp. [°F] = Temp. [°C] * 9/5 + 32
Area ft2 m2 0.09290304 Torque ft*lbf Nm 1.35582
Area in2 m2 0.00064516 Torque in*lbf Nm 0.1129848
Area m2 ft2 10.76391 Torque Nm ft*lbf 0.737561
Area m2 in2 1550.1473 Torque Nm in*lbf 8.8507481
Force lbf N 4.4482225 Velocity ft/s m/s 0.3048
Force N lbf 0.2248089 Velocity miles/hour m/s 0.44704
Length ft m 0.3048 Velocity km/hour m/s 0.2778
Length in m 0.0254 Velocity miles/hour km/hour 1.609344
Length mile m 1,609.344 Velocity m/s ft/s 3.28084
Length in mm 25.4 Velocity m/s miles/hour 2.2369363
Length m ft 3.2808399 Velocity m/s km/hour 3.6
Length m in 39.370079 Velocity km/hour miles/hour 0.6213712
Length m mile 6.2137E-04 Volume ft3 m3 0.02831685
Length mm in 0.03936996 Volume in 3
m3 1.638706E-05
Mass lb kg 0.4535929 Volume Liters m 3
0.001
Mass kg lb 2.20462 Volume U.S. gallons m3 0.003785412
Moment of inertia ft*lb*s2 kg*m2 1.3557 Volume U.S. gallons Liters 3.785412
Moment of inertia in*lb*s2 kg*m2 0.1130 Volume m 3
ft 3
35.314725
Moment of inertia kg*m2 ft*lb*s2 0.7376 Volume m3 in3 61,023.759
Moment of inertia kg*m2 in*lb*s2 8.4956 Volume m3 Liters 1,000
Power hp W 745.71 Volume m3 U.S. gallons 264.17287
Power W hp 1.341E-03 Volume Liters U.S. gallons 0.264172
Table 11.1: Conversion Table
Figure 4.2: Minimum rear axle loads ...................................................62 Figure 4.24: Integrated implement support ......................................... 86
Figure 4.3: Weight distribution (example) ............................................63 Figure 4.25: Integrated implement support with cross member (MB
part-no. A405 520 00 48) ............................................................. 87
Figure 4.4: Sketch of the upper edge frame level over the wheel center
......................................................................................................63 Figure 4.26: Permitted implement weights .......................................... 88
Figure 4.5: Suspension graph with measurements in metric units ......64 Figure 4.27: Sketch to front end dimensions....................................... 88
Figure 4.6: Suspension graph with measurements in U.S. units .........65 Figure 4.28: Fastening of wheels and wheel hub chassis supports .... 90
Figure 4.7: Unimog frame with the zero point of the coordinate system Figure 4.29: Standard fastening of wheels on the Unimog ................. 90
......................................................................................................66 Figure 4.30: Fastening of the MULAG wheel hub chassis support ..... 90
Figure 4.8: Detail drawing of zero point ...............................................66 Figure 4.31: Drawing of the wheel hub chassis support...................... 91
Figure 4.9: Sketch for center of gravity and axle load calculations......68 Figure 4.32: Ball half shell assembly................................................... 92
Figure 4.10: Determining the height of the center of gravity................69 Figure 4.33: Securing platform against tipping.................................... 92
Figure 4.11: Tilting test ........................................................................71 Figure 4.34: Overview of the platform and subframe mounting parts
Figure 4.12: Minimum bending radius .................................................75 at the U500 with a short wheelbase ............................................. 93
Figure 4.13: Incorrect pipes .................................................................75 Figure 4.35: Overview of the platform and subframe mounting parts
at the U500 with a long wheelbase .............................................. 94
Figure 4.14: Front mounted counterweights ........................................76
Figure 4.36: Overview of available platforms ...................................... 95
Figure 4.54: Tie-down eye (option 2) ................................................ 102 Figure 4.78: Front end of a mounting frame higher than 6.3 in..........119
Figure 4.55: Rear end mounting........................................................ 102 Figure 4.79: Possible profiles for mounting frames............................120
Figure 4.56: Rear end mounting with additional plate ....................... 103 Figure 4.80: Possible transition from closed to open profiles ............120
Figure 4.57: Center mounting of heavy implements.......................... 103 Figure 4.81: Possible transition from closed to open profiles ............120
Figure 4.58: Correct and incorrect gritter design............................... 104 Figure 4.82: Suggestion for design of cross members ......................121
Figure 4.59: Mounting diagram on the platform subframe ................ 105 Figure 4.83: Suggestion for design of cross members ......................121
Figure 4.60: Overview of the available platform sub frames ............. 106 Figure 4.84: Suggestion for a custom-manufactured low mounting
frame ..........................................................................................122
Figure 4.61: Platform sub frames for short wheelbases.................... 107
Figure 4.85: Suggestion for a custom-manufactured high mounting
Figure 4.62: Platform sub frames for long wheelbases ..................... 108 frame ..........................................................................................123
Figure 4.63: Ball half shell, Part-No.: A405 610 00 35 ...................... 109