Professional Documents
Culture Documents
Unimog - Tech All - Models
Unimog - Tech All - Models
Unimog - Tech All - Models
- General Information -
U20, U300-500, U3000-5000
2008 Edition Part A
Daimler AG
Mercedes-Benz Special Trucks
D-76742 Wörth
Printed in Germany
All technical data, illustrations, dimensional data and other information correspond to the status at the date of publication stated below.
Update notes
3 Damage prevention
3.1 Vehicle modifications/chassis modifications .................................................................................................................................. (Z page 42)
3.4.2 Euro battery terminal – Current tap 40 A ........................................................................................................................................ (Z page 49)
3.5 Power supply for auxiliary consumers ............................................................................................................................................. (Z page 53)
3.6 Illumination equipment.................................................................................................................................................................... (Z page 54)
3.7 Control units ................................................................................................................................................................................... (Z page 66)
3.14.5 Underride guards and side protective devices................................................................................................................................. (Z page 94)
3.19.1 Installation and assembly................................................................................................................................................................ (Z page 104)
3.24 AdBlue tank, metering unit and supply unit ..................................................................................................................................... (Z page 114)
3.28.2 Compressed-air brake system......................................................................................................................................................... (Z page 124)
3.28.3 Hydraulic hoses............................................................................................................................................................................... (Z page 128)
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008
Part A: General Information
Contents
Contents
1 Introduction.......................................................................................................................................................................................................... 9
1.1 The aim of these directives .............................................................................................................................................................................. 10
1.2 Conventions..................................................................................................................................................................................................... 12
1.3 Vehicle safety .................................................................................................................................................................................................. 13
1.4 Operational safety............................................................................................................................................................................................ 15
1.5 Accident prevention ......................................................................................................................................................................................... 16
2 General ................................................................................................................................................................................................................ 18
2.1 Technical advice and contact persons ............................................................................................................................................................. 18
2.2 Issuing of letters of confirmation and certificates of endorsement .................................................................................................................. 19
2.2.1 Letter of confirmation/certificate of endorsement .......................................................................................................................................... 19
2.2.2 Required documents ........................................................................................................................................................................................ 22
2.2.3 Procedure ........................................................................................................................................................................................................ 23
2.2.4 Legal claim....................................................................................................................................................................................................... 24
2.3 Product liability ................................................................................................................................................................................................ 25
2.3.1 Product liability in other countries ................................................................................................................................................................... 27
2.3.2 Guarantee of traceability.................................................................................................................................................................................. 27
2.4 Legal references .............................................................................................................................................................................................. 28
2.4.1 Road traffic legislation (Germany) .................................................................................................................................................................... 28
2.4.2 Design and attachment of the license plate according to Art. 60 StVZO (German licensing regulations) ......................................................... 28
2.5 CE mark ........................................................................................................................................................................................................... 30
2.6 Warranty claims ............................................................................................................................................................................................... 31
2.7 Registration ..................................................................................................................................................................................................... 32
2.7.1 Registration in Germany................................................................................................................................................................................... 32
2.7.2 Acceptance/approval in the EU ....................................................................................................................................................................... 33
2.8 Bodybuilder Information Portal......................................................................................................................................................................... 34
2.8.1 Your company profile (Bodybuilder Profile) and the Qualified Partner List (QPL).............................................................................................. 34
2.8.2 MB-AS (Mercedes-Benz Bodybuilder System) .................................................................................................................................................. 34
2.8.3 Workshop Information System (WIS)................................................................................................................................................................ 36
2.9 Mercedes star and badge................................................................................................................................................................................. 37
2.10 Reprocessing of components — recycling......................................................................................................................................................... 39
Status: 31.10.2008 Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-5000
Part A: General Information
Contents
3 Damage prevention............................................................................................................................................................................................ 42
3.1 Vehicle modifications/chassis modifications................................................................................................................................................... 42
3.2 Dimensions, weights and overall vehicle height ............................................................................................................................................... 44
3.3 Vehicle overhang ............................................................................................................................................................................................. 45
3.3.1 Front vehicle overhang..................................................................................................................................................................................... 45
3.3.2 Rear vehicle overhang...................................................................................................................................................................................... 46
3.4 Electrical system.............................................................................................................................................................................................. 47
3.4.1 Batteries .......................................................................................................................................................................................................... 48
3.4.2 Euro battery terminal – Current tap 40 A ......................................................................................................................................................... 49
3.4.3 Electrical wiring................................................................................................................................................................................................ 51
3.4.3.1 Wiring cross-sections....................................................................................................................................................................................... 51
3.4.3.2 Lengthening electrical cables........................................................................................................................................................................... 51
3.5 Power supply for auxiliary consumers .............................................................................................................................................................. 53
3.6 Illumination equipment .................................................................................................................................................................................... 54
3.6.1 Turn signals, taillamps and brake lamps........................................................................................................................................................... 54
3.6.2 Backup lamps .................................................................................................................................................................................................. 55
3.6.3 Rear fog lamp................................................................................................................................................................................................... 56
3.6.4 Licence plate lamp and licence plate installation height .................................................................................................................................. 56
3.6.5 Reflectors (rear) ............................................................................................................................................................................................... 57
3.6.6 Side reflectors.................................................................................................................................................................................................. 57
3.6.7 Side marker lamps ........................................................................................................................................................................................... 58
3.6.8 Position lamps ................................................................................................................................................................................................. 59
3.6.9 End-outline marker lamps ................................................................................................................................................................................ 60
3.6.10 Distinctive markings ........................................................................................................................................................................................ 61
3.6.11 Headlamp adjustment...................................................................................................................................................................................... 65
3.7 Control units .................................................................................................................................................................................................... 66
3.8 Mobile communications systems ..................................................................................................................................................................... 67
3.9 Electromagnetic compatibility (EMC) ............................................................................................................................................................... 69
3.10 Welded connections......................................................................................................................................................................................... 71
3.11 Bolted connections .......................................................................................................................................................................................... 73
3.12 Frame .............................................................................................................................................................................................................. 78
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008
Part A: General Information
Contents
Status: 31.10.2008 Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-5000
Part A: General Information
Contents
4 Calculation........................................................................................................................................................................................................142
4.1 Trailer coupling .............................................................................................................................................................................................. 142
4.2 Connecting element....................................................................................................................................................................................... 144
4.3 Axle load calculation ...................................................................................................................................................................................... 145
4.4 Centre of gravity ............................................................................................................................................................................................ 146
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008
Part A: General Information
Contents
Status: 31.10.2008 Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-5000
Part A: General Information
1 Introduction
1 Introduction
Daimler AG, as the manufacturer of Mercedes-Benz vehicles, publishes these Body and Implement Mounting Directives to provide body manufacturers
with important technical information about the vehicle. This information must be observed by the body manufacturer when mounting implements and
bodies on Mercedes-Benz vehicles.
Due to the large number of body manufacturers and body types, Daimler AG cannot take into account all the possible modifications to the vehicle, e.g.
performance, stability, load distribution, centre of gravity and handling characteristics, that may result from the design of implements or bodies. For
this reason, Daimler AG can accept no liability for accidents or injuries sustained as a result of such modifications to your vehicles if such modifications
have a negative impact on the entire vehicle. Accordingly, Daimler AG will only assume liability as manufacturer within the scope of the design and
production work which it has performed itself. As manufacturer of the entire vehicle, the body manufacturer will undertake to ensure that the
attachments or bodies that it produces are not defective in themselves, nor are they capable of causing defects to or hazards on the entire vehicle.
If this obligation is violated in any way, the body manufacturer will assume full product liability. Daimler AG uses the Body and Implement Mounting
Directives to instruct body manufacturers with regards to important aspects to be observed when mounting implements, attachments and bodies.
These Body and Implement Mounting Directives are primarily intended for the professional manufacturers of implements or bodies for our vehicles.
As a result, these Body and Implement Mounting Directives assume that the body manufacturer has suitable background knowledge. If you intend to
mount implements or bodies on or carry out modifications to our vehicles, please be aware that certain types of work (e.g. welding work on load-
bearing components) may only be carried out by qualified personnel. This will avoid the risk of injury and will attain the degree of quality required for
the implements and bodies.
The instructions given must be observed exactly to maintain the operating and road traffic safety of the chassis and to maintain warranty rights.
Illustrations and schematic drawings are examples only and serve to explain the texts and tables. References to regulations, standards, directives etc.
are given in keywords and serve for information only.
Further information can be obtained from the TE/OVG-B Team.
Daimler AG
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008 9
Part A: General Information
1 Introduction
1.1 The aim of these directives
The development and review of implements or bodies for the UNIMOG does not, in principle, entitle to claims for costs or damages against Daimler AG.
The cooperation of Daimler AG in solving technical problems is of an advisory nature only. In the case of equipment operated in the Federal Republic of
Germany, this applies also in respect of compliance with the provisions of road traffic legislation and accident prevention in the context of the German
Technical Equipment Law.
Daimler AG makes particular reference is made to the responsibility of the implement manufacturer for his scope of delivery and to the rules of safety
to be complied with in respect of the vehicle/implement interface.
The following applies to the entire Body and Implement Mounting Directives and all drawings, sketches and technical data contained therein:
Confidential! All rights reserved. Disclosure or reproduction only with the written approval of Daimler AG
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Part A: General Information
1 Introduction
1.1 The aim of these directives
Implement manufacturers and companies who mount implements or bodies on UNIMOG vehicles should have available the following documents:
• The current UNIMOG price list containing descriptions and prices of the UNIMOG models and all optional equipment available
• The applicable Technical Manual containing all technical data and important additional information
• The applicable UNIMOG Body and Implement Mounting Directives containing information about mounting implements and bodies and the
Daimler AG requirements for implement/body mounting
• The applicable “Chassis drawing” CAD data
General technical data regarding the vehicle is not contained in these Body and Implement Mounting Directives; please refer to the currently valid
version of the publication entitled “UNIMOG Technical Manual”, which can be obtained from Product Division Special-Purpose Vehicles/UNIMOG,
Sales/Marketing Department (TE/OMM), fax +49(0)7271/71-8363. The Technical Manual can be used to preselect a suitable vehicle model. If
required, detailed technical data and drawings may be ordered by e-mail or fax from Product Division Special-Purpose Vehicles/UNIMOG, Bodies and
Implement Carriers Engineering Department (TE/OVG-B), stating the name of the company and the body/implement to be mounted; see Part A,
section 2.1 “Technical advice and contact persons” (Z page 18).
Further information and technical data can be obtained at the Bodybuilder Information Portal (Z page 27).
Make absolutely sure that you observe the threshold values listed in section 4 “Risk of the trailer breaking away from the tractor vehicle!” (Z page
142) as all planning of implements and bodies must be based on these values.
Part 2, with the sections 1 “Planning of implements and bodies”, 2 “Technical threshold values for planning”, 3 “Mounting of implements and bodies”,
4 “Drive of implements and bodies” and 5 “Modifications to the basic vehicle”, provides the essential technical content of these directives.
Before starting to install implements and bodies on the vehicle, please read the relevant sections of the vehicle Instruction Manual and the operating
and assembly instructions from the manufacturers of the accessories and special equipment.
You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
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Part A: General Information
1 Introduction
1.2 Conventions
1.2 Conventions
The following symbols are used in these directives:
Warning
A warning draws your attention to possible risks of accident and injury to yourself and others.
Environmental note
Z section/page This symbol indicates the section or page on which you will find further information on a topic and is linked in PDF format.
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Part A: General Information
1 Introduction
1.3 Vehicle safety
The use of parts, assemblies or conversion parts and accessories which have not been approved may jeopardise the safety of the vehicle.
Before starting to install implements or bodies on the vehicle or on major assemblies, please read the relevant sections of the vehicle Instruction
Manual and the operating and assembly instructions from the manufacturers of the accessories and special equipment.
You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
Official acceptance by public testing bodies or official approval does not rule out safety hazards.
Daimler AG can give no guarantee with regard to reliability, safety and suitability in the following cases:
• If genuine parts or approved conversion parts or accessories have been exchanged for other parts or other changes have been made to the vehicle.
• If bodies are not manufactured or mounted according to the valid Mercedes-Benz Body and Implement Mounting Directives or if, in case of
deviations, the approval of Daimler AG is not sought.
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Part A: General Information
1 Introduction
1.3 Vehicle safety
Make absolutely sure that you comply with national registration regulations as the mounting of implements or bodies on the vehicle may change the
vehicle type approved and may invalidate the general operating permit.
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Part A: General Information
1 Introduction
1.4 Operational safety
Risk of accident
Before starting to install implements or bodies on the vehicle or on major assemblies, please read the relevant sections of the vehicle Instruction
Manual and the operating and assembly instructions from the manufacturers of the accessories or special equipment.
You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
Work incorrectly carried out on electronic components and their software could prevent this equipment from working correctly. Since the electronic
systems are networked, this might also affect systems that have not been modified.
Malfunctions in the electronic systems could seriously jeopardise the operating safety of the vehicle.
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Part A: General Information
1 Introduction
1.5 Accident prevention
The body and the attached or mounted implements must comply with the applicable laws and ordinances as well as work safety or accident prevention
regulations, safety rules and bulletins of public insurance institutions.
All technical means shall be used to avoid operating conditions that may be unsafe or liable to cause an accident.
In Germany, information is provided to commercial carriers by the “Vehicles” Working Group of the “Traffic” Technical Committee at the following
address:
All national laws, directives and registration requirements must be complied with!
The body and equipment manufacturer is responsible for compliance with these laws and regulations. This also applies to interfaces
between the vehicle and the implement and to safety when mounting or removing interchangeable implements.
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Part A: General Information
1 Introduction
1.5 Accident prevention
• Drive shafts must also be equipped with protection against accidental contact; shearing and crushing points must be avoided.
• Connectable systems must be protected against improper use and unintentional actuation.
• Fans for oil radiators, etc. must be enclosed in such a way that access to the rotating fan is impossible.
• All kinds of sharp corners and edges must be avoided.
• The implement or body manufacturer must ensure that servicing and maintenance operations can be carried out safely.
Risk of accident
All accident prevention regulations listed in the Instruction Manual must be adhered to.
The driving speed must be appropriate to the prevailing road, road traffic and terrain conditions, whereby the influence of the attached
implement/body on braking, cornering, driving on a slippery road surface or unpaved ground, on side slopes, on inclines or on declines, etc. must be
taken into consideration by driving in a foresighted manner.
The body manufacturer must ensure that the vehicle owner/customer is trained and familiarised with the theory and practice of operating the
implement and/or the vehicle/implement combination.
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008 17
Part A: General Information
2 General
2.1 Technical advice and contact persons
2 General
2.1 Technical advice and contact persons
The members of the UNIMOG Equipment Team (TE/OVG-B) can issue letters of confirmation and certificates of endorsement for the Mercedes-Benz
UNIMOG & ECONIC model series. They are also responsible for providing technical advice regarding implements, bodies and chassis conversions, and
are available to answer all technical and design-related questions.
They can be contacted on:
Name E-mail Telephone Area of responsibility
Contact person: Rainer Thomas rainer.thomas@daimler.com +49 (0) 72 71/71 - 76 14 Team leader, standards & procedures for all model series
Volker Jungmann volker.jungmann@daimler.com +49 (0) 72 71/71 - 76 23 U20, U300, U400, U500 (UGN)
Andreas Merkel andreas.ma.merkel@daimler.com +49 (0) 72 71/71 - 76 13 Mowers and fire service (all model series), hydraulic
system
Christian Kirmeier christian.kirmeier@daimler.com +49 (0) 72 71/71 – 79 01 Railroaders, chassis conversions, Econic
Andreas Rödler andreas.roedler@daimler.com +49 (0) 72 71/71 – 75 97 U3000, U4000, U5000 (UHN)
Fabian Wey fabian.wey@daimler.com +49 (0) 72 71/71 – 80 68 Bodies mod. des. 437.465, bodies Zetros civilian
Please forward any queries, suggestions or criticism you may have about these Body and Implement Mounting Directives to the TE/OVG-B team at the
relevant e-mail address.
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Part A: General Information
2 General
2.2 Issuing of letters of confirmation and certificates of endorsement
For extensive chassis conversions which are not adequately covered in these body/equipment mounting directives (part A and part B) such as:
• Conversion of a 4x4 to a 6x4 or 6x6 chassis
• Installation of a different engine
• Installation/retrofit of a hydrostatic drive (except retrofit of series production solution on U300/U400/U500)
• Conversion to a hybrid vehicle
• Change in vehicle concept to suit completely different applications (e.g. traction head, etc.)
the following applies:
6. Company performing conversion takes on full responsibility for product and warranty:
− The company performing the conversion becomes the vehicle manufacturer
− Mercedes star and Mercedes-Benz emblem must be removed
− Chassis number must be visibly stamped over with XXXX and new chassis number must be applied below
7. Certificate of non-objection for conversion after check by Daimler AG:
− All required documents must be submitted by the conversion company
− The documents will be checked by Daimler AG
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008 19
Part A: General Information
2 General
2.2 Issuing of letters of confirmation and certificates of endorsement
Implement and body manufacturers can apply to Daimler AG (TE/OVG-B Equipment Team) for the issue of a letter of confirmation or certificate of
endorsement. Daimler AG issues letters of confirmation/certificates of endorsement voluntarily. The certificates are issued by TE/OVG-B after
inspection, if the implement/body satisfies the requirements of Daimler AG.
Letter of confirmation
All implement manufacturers may apply for a letter of confirmation. The application for a letter of confirmation must be accompanied by the following
documents: Z see Part A, section 2.2.2 “Required documents”, page 22.
In all cases, Daimler AG, TE/OVG-B, will carry out a practical inspection of the mounted implement/body prior to issuing a letter of confirmation.
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Part A: General Information
2 General
2.2 Issuing of letters of confirmation and certificates of endorsement
All national laws, directives and registration requirements must be complied with.
Please send the full documents to the TE/OVG-B Equipment Team, address see Part A, section 2.1 “Technical advice and contact persons”
(Z page 18).
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Part A: General Information
2 General
2.2 Issuing of letters of confirmation and certificates of endorsement
The following data must be included and should be available to the relevant contact person in the format specified:
PDF format:
• Supplier/manufacturer with full postal address and name of contact person responsible (including telephone no., fax no. and e-mail address)
• Description of implement/body
• Equipment identification (equipment designation, model/group, serial number)
• Technical data
• Scope of delivery (basic equipment, special equipment)
• Equipment functions with description of the controls
• Fields of application
• Necessary modifications to the vehicle etc.
• Operating instructions
• Power demand from the vehicle (kW, bar, Nm, l/min)
• Certification and special confirmation (“e” mark, CE mark, field of vision test, DIN/EN standards etc.)
• All deviations from the Mercedes-Benz Body and Implement Mounting Directives
• How the body is attached to the chassis
• The vehicle's conditions of use, e.g.
− on poor roads
− in very dusty conditions
− at high altitude
− at extremely high or low ambient temperatures
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Part A: General Information
2 General
2.2 Issuing of letters of confirmation and certificates of endorsement
Excel format:
• Complete data on dimensions, weights and centre of gravity (weight certificates, axle load calculations)
Dwg/dxf format:
• Technical construction drawings, preferably in the form of CAD data
Jpg format:
• Pictures (of similar or already existing bodies)
Submitting the required documentation in full will make queries on our part unnecessary and will speed up the approval procedure.
For filing purposes, all documents submitted must bear (e.g. in the footer line) the name of the body manufacturer, the body, body type, modification
status and, if appropriate the relevant UNIMOG model.
If complex calculations and/or vehicle tests are necessary for the inspection, all costs arising must be borne by the vehicle implement/body
manufacturer or his client. The extent of testing required is defined by the relevant department of Mercedes-Benz UNIMOG/ECONIC Development, see
Part A, section 2.1 “Technical advice and contact persons” (Z page 18).
2.2.3 Procedure
When the required documents (see Part A, section 2.2.2 “Required documents” (Z page 22)) have been submitted by the body/implement
manufacturer, they will be examined by the relevant contact person in the Equipment Team, see Part A, section 2.1 “Technical advice and contact
persons” (Z page 18).
If the results of the inspection and testing are positive, a letter of confirmation/certificate of endorsement will be issued for the body or implement.
A letter of confirmation can only be granted after practical approval testing of the vehicle with the body/implement has been carried out by the
Equipment Team (TE/OVG-B).
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Part A: General Information
2 General
2.2 Issuing of letters of confirmation and certificates of endorsement
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Part A: General Information
2 General
2.3 Product liability
With regard to product liability, Daimler AG would draw your attention to the following points:
• Every manufacturer shall be liable for the product that he has manufactured.
• Daimler AG will only assume liability as manufacturer of Mercedes-Benz vehicles within the scope of the design and production work which it has
performed itself. Daimler AG shall not therefore accept any liability for damage resulting from defects in retrofitted products produced by third-party
manufacturers.
In the case of implements or bodies which are reviewed by Daimler AG, the body manufacturer shall bear responsibility for:
• design, mounting, structural stability and function of the implement or body.
• the operating and road safety of the implement or body.
• the operating and road safety of parts and conversions which are not covered in the documents submitted.
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Part A: General Information
2 General
2.3 Product liability
In the case of implements or bodies not reviewed by Daimler AG, the body manufacturer shall bear sole responsibility for:
• the operating safety and road safety of the vehicle/implement combination as a whole and the influences of components or modifications on the
chassis.
• testing and maintaining the operating and handling safety of the vehicle after the body/equipment is mounted (the body and/or equipment must
not have a negative effect on the driving, braking or steering characteristics of the vehicle).
• consequential damage resulting from the mounting of the implement or body.
• consequential damage resulting from the retrofitting of electrical or electronic systems.
• consequential damage resulting from influences on the existing electronic systems in the vehicle.
• the operational reliability and freedom of movement of all moving parts of the chassis after the body/implement is mounted (e.g. axles, springs,
propeller shafts, steering, engine control, transmission linkage, brake components etc.) even in the case of diagonal torsion between the chassis
and the implements/bodies.
Work on or modifications to the chassis or body must be entered in the Maintenance Booklet in the section “Body manufacturer's confirmation”.
The body manufacturer must indemnify Daimler AG against all liability for damage occurring due to:
• non-compliance with the Body and Implement Mounting Directives.
• use of the vehicle or the vehicle/implement combination not in compliance with the regulations, particularly with regard to the application of
implements.
• deficient design, manufacture or installation.
• failure to observe the appropriate basic principles in any other regard.
• inadequate operating instructions of the attachments/body.
• lack of knowledge and training of the vehicle owner/customer/driver.
Only basic notes regarding product liability can be provided within the framework of these Body and Implement Mounting Directives.
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Part A: General Information
2 General
2.3 Product liability
Example file:
Body Model Serial Delivery date Vehicle Model Vehicle identification Customer
number number
Embankment mower, BM450 789 05.05.2008 UNIMOG U20 405050 1V 456789 Müller,
platform body Hauptstrasse 10,
Cologne
Front mulcher, on FM2100 1234 06.07.2008 UNIMOG U20 405050 1V 123456 Schmidt,
front mounting plate Kaiserstrasse 20,
D11 Munich
Table 2.1
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008 27
Part A: General Information
2 General
2.4 Legal references
2.4.2 Design and attachment of the license plate according to Art. 60 StVZO (German licensing regulations)
Extract from the construction and use regulations
The licence plate is to be securely affixed to the front and rear of the vehicle. On vehicles permitted to carry light bars according to Art. 49a Sec. 9, the
rear license plate — or, if necessary, an additional license plate — may be affixed to the light bar. On all vehicles the bottom edge of the front license
plate may be no less than 200 mm above the road, and that of the rear licence plate no less than 300 mm above the road.
Licence plates at the front and rear of the vehicle must be legible at an angle of 30° either side of the longitudinal axis of the vehicle and at a
reasonable distance.
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Part A: General Information
2 General
2.4 Legal references
Mercedes-Benz Body and Implement Mounting Directives for UNIMOG U20, U300-500, U3000-U5000 Status: 31.10.2008 29
Part A: General Information
2 General
2.5 CE mark
2.5 CE mark
Machinery Directive 98/37/EC succeeds the multiply amended 89/392/EEC
including 93/68/EEC.
The new edition with the number 2006/42/EC will come into force on
29th December 2009.
Only certain versions of the UNIMOG (e.g. tipper, power take-off) fall under the EC
Machinery Directive.
Please note that with effect from 1st January 1995 (among others), all body and
implement mountings which, in accordance with the EU Machinery Directive (see
above), are considered complete machines, must comply with this directive, must
have a certificate of conformity and must be marked with a CE mark.
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Part A: General Information
2 General
2.6 Warranty claims
Operating and driving safety must not be affected by the implement or body. In the case of cabs, free movement for tilting must be guaranteed. In the
case of implements and bodies, asymmetrical load on the chassis must be avoided wherever possible.
If asymmetrical load is unavoidable (e.g. in the case of a side-mounted loading crane, generator, mower, etc.), the approval of Department TE/OVG-B is
necessary if the difference in wheel loads exceeds 10 % of the relevant axle loads (for further information on "axle loads and gross vehicle weights" see
Part A, section 4 “Risk of the trailer breaking away from the tractor vehicle!” (Z page 142) and Part B, section 2 “Technical threshold values for
planning”.
Driving trials may be required.
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Part A: General Information
2 General
2.7 Registration
2.7 Registration
2.7.1 Registration in Germany
All UNIMOG model series are delivered from the factory with a registration certificate. The vehicle type is registered according to the platform length,
wheelbase, equipment and/or tyres:
• Tractor (code no. 870000)
• Truck - open-top box (code no. 100200)
• Truck - tipper, open-top box (code no. 000200)
• X53 – agric./forestry tractor unit/agricultural tractor (code no. 891000)
• X54 – agric./forestry tractor unit/implement carrier (code no. 892000)
In most countries permanently mounted implements must be approved by an officially accredited specialist and recorded in the vehicle registration
papers. In Germany the “Instructions for Mounted Implements” apply for interchangeable, temporarily mounted implements. It is normally not
necessary to enter detachable implements in the vehicle registration papers.
In some countries a UNIMOG equipped with permanently mounted implements (e.g. crane) may – subject to assessment by an officially accredited
specialist – also be classified and approved as a self-propelled working machine. Please note that normally neither the transport of goods nor the use of
trailers is permitted with self-propelled working machines.
An exception is the transport of equipment which is necessary for the use of the working machine (e.g. excavator accessories).
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2.7 Registration
Following national type approval in the relevant country, the vehicles may be sold and registered in accordance with the local registration formalities.
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2 General
2.8 Bodybuilder Information Portal
2.8.1 Your company profile (Bodybuilder Profile) and the Qualified Partner List (QPL)
Gain access to the full range of information in the Portal. All you have to do is identify yourself as a body manufacturer on your first visit to the Portal.
To do this, simply enter the name of your company, your contact details, your user profile and the contact persons at your company in the on-screen
fields.
Further advantages and attractive sales opportunities are available to you if you become a Qualified Partner of Mercedes-Benz. To do this, enter the
self-information process for QPL. You can initiate this process at a later date, completely independent of the registration process. On the basis of your
information your company will be evaluated by a team of experts at Daimler AG according to standard criteria related to quality, marketing and service.
You can update your details at any time in the “My Portal” menu.
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2.8 Bodybuilder Information Portal
• You will find a comprehensive range of information extending from “Current Topics”, to “MBAS-Web (Technology)”, “Partnership”, “Tools” and
“Search”.
• Select the “MBAS-Web (Technology)” heading to access Body Mounting Directives, drawings and other technical information. Mercedes-Benz
recommends that body manufacturers register to gain full access to all the technical data and drawings.
• Select the “Body Mounting Directives” tab.
To gain access to the correct Body Mounting Directive, begin by selecting the required commercial vehicle category from the menu on the left. Then
select the language required and the respective model series and click on ‘Continue’ in order to begin the download.
• Select the “Catalogues” tab.
You will find all technical information available for Mercedes-Benz commercial vehicles via the catalogues on this page and the associated sub-pages.
Information categories:
• Scale dimensional CAD chassis drawings in DXF format
• Simplified outline drawings with reduced lines and the most important vehicle dimensions in DXF or PDF format
• Technical data sheets (description of technical data and standard equipment)
• Optional equipment with code designations and brief descriptions
• Implement manufacturer information describing changes to Mercedes-Benz UNIMOG and ECONIC vehicles that are relevant to body manufacturers
• UNIMOG Technical Manual with detailed technical data (engine output diagrams, tractive power graphs, weights etc.)
• Body Mounting Directives for UNIMOG & ECONIC (accessible even without registration)
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2.8 Bodybuilder Information Portal
Information about WIS can be obtained from any Mercedes-Benz Service Centre or from:
Telephone: +49 (0) 7 11 / 17 – 8 31 70
Fax: +49 (0) 7 11 / 17 – 4 00 82
Postal address: Daimler AG
HPC R800
Department GSP/TIM
D-70546 Stuttgart
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2.9 Mercedes star and badge
The Mercedes star and Mercedes-Benz badge may not be affixed to bodies/implements.
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2.9 Mercedes star and badge
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2.10 Reprocessing of components — recycling
Environmental note
When planning bodies and implements, the following principles for environmentally compatible design and material selection shall be taken into
account, in particular with regard to EU Directive 2000/53/EC.
Materials with risk potential, such as halogen additives, heavy metals, asbestos, CFCs, CHCs etc., are to be avoided.
• It is preferable to use materials which permit recycling and closed material cycles.
• Materials and production processes that generate only low quantities of waste during production must be selected in such a way that this waste can
be easily recycled.
• Plastics are to be used only where they provide advantages in terms of cost, function or weight.
• In the case of plastics, and composite materials in particular, only compatible substances within one material family are to be used.
• For components which are relevant to recycling, the number of different types of plastics used must be kept to a minimum.
• It must be assessed whether a component can be made from recycled material or with recycled elements.
• It must be ensured that components can be dismantled easily for recycling, e.g. by snap connections, predetermined breaking points, easy
accessibility, or by using standard tools.
• It must be ensured that service products can be removed simply and in an environmentally responsible manner by means of drain plugs, etc.
• Wherever possible, components should not be painted or coated; coloured plastic parts are to be used instead.
• Components in areas at risk from accidents must be designed in such a way that they are damage-tolerant, repairable and easy to replace.
• All plastics are to be marked in accordance with VDA code of practice 260, e.g. “PP – GF30R”.
• EU Directive 2000/53/EC must always be complied with.
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2.11 Quality system
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2.11 Quality system
Daimler AG advises body manufacturers to set up a quality management system with the following minimum requirements:
• To devise, set up and monitor a quality assurance system within the company concerned
• To set out responsibilities in an organisational chart
• To appoint a manager responsible for quality
• To ensure that the instructions for processes, work and inspections are up-to-date and available in all departments and at all workplaces
• To ensure that the employees concerned are adequately qualified
• To document and archive the necessary quality assurance measures on the product
• To make available suitable test equipment (e.g. torque wrenches) and to maintain a continuous test equipment review
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3.1 Vehicle modifications/chassis modifications
3 Damage prevention
In all operations with the vehicle or the vehicle/implement combination, the accident prevention directives, especially the directives and
recommendations listed in the operating instructions of the vehicle and the body/implement etc. must be complied with.
Risk of accident
Do not carry out any modifications to major assemblies (steering, brake system etc.)!
Any modifications to the steering and the brake system may result in these systems malfunctioning and ultimately failing. The driver could lose control
of the vehicle and cause an accident.
Alterations to the basic vehicle are permitted only within the framework of the procedures described in these Body and Implement Mounting
Directives.
Standard production vehicles comply ex factory with EU Directives and national regulations (vehicles produced for countries outside of Europe may be
exceptions). The vehicles must still comply with EC Directives or national regulations after modifications have been carried out.
The body manufacturer must inform the officially recognised approval authority or inspector of any modifications to the chassis when the vehicle is
inspected. If necessary, present a certificate of endorsement from Daimler AG (e.g. drawing with approval note) or the applicable Body Mounting
Directive.
Modifications may have to be made to the chassis when installing a body. Even minor modifications (e.g. to the exhaust system or brake system) can
cause the General Operating Permit (GOP) to be rendered void. Following all work on the brake system, i.e. even if merely disassembling parts, a
complete check (operation, effectiveness and visibility) of the entire brake system must be performed. Should modification of the original arrangement
of the brake system in the chassis be unavoidable, lines and fittings of the same quality and dimensions must be used.
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3.1 Vehicle modifications/chassis modifications
In cases where Daimler AG performs inspections on a modified vehicle, the body manufacturer is not entitled to expect that all chassis modifications
performed externally (after the vehicle has left the production plant) will be identified and pinpointed by employees of Daimler AG due to the complex
nature of the chassis.
No modifications may be made to the chassis (MB scope of delivery) without the approval of Daimler AG. In the case of the following modifications, the
TE/OVG-B Equipment Team of Daimler AG must be consulted in advance:
• Shortening or lengthening of the chassis overhang • Modifications that impair the safety of the cab (e.g. drilling in the
• Drilling and welding on the chassis frame or on the axles A-pillar or B-pillar)
• Modifications to the frame • Modifications to the hydraulic system
• Modifications to the brake and steering systems • Modifications to the lighting system
(e.g. changing the length of the brake lines) • Modifications to the soundproofing
• Modifications to the intake and exhaust systems • Modifications to the engine
• Modifications to wheels, tyres, springs • Modifications to the electrical system, e.g. including the relocation
(e.g. locking the suspension) of electrical control units
Mercedes-Benz expressly points out that only the items on the list that are explicitly confirmed by Daimler AG can be considered to be approved and
safe.
A vehicle inspection by employees of Daimler AG does not form a basis for assuming that any items not contained on this list have been approved.
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3.2 Dimensions, weights and overall vehicle height
Risk of accident
The vehicle tyre load capacity may not be exceeded by overloading the vehicle beyond its specified gross vehicle weight. The tyres could overheat and
suffer damage. This could cause you to lose control of the vehicle and cause an accident with possible injury to yourself and others.
Information on the permissible axle loads can be found on the vehicle model plate.
All legal provisions governing the permissible vehicle height must be taken into account when planning bodies. In the Federal Republic of Germany the
permissible vehicle height is limited to max. 4 m. In other countries (and if the vehicle is operated on international services), comply with all the
relevant national regulations. Observe the Instruction Manual.
Dimensions and weight details can be found in the drawings and technical data. The vehicle kerb weights depend on the equipment fitted. Weight
tolerances of +5 % in manufacture must be taken into consideration (permissible in the Federal Republic of Germany according to DIN 70020).
The permissible axle loads and the maximum permissible gross vehicle weight specified in the technical data may not be exceeded. The technical data
can be found in the vehicle documents, on the vehicle model plate or in the code definitions (codes for weights start with X) in the order data.
Information on weight changes is available from the TE/OVG-B Equipment Team see Part A, section 2.1 “Technical advice and contact persons”
(Z page 18).
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3.3 Vehicle overhang
Risk of accident
The body must be designed in such a way that a placing of excessive load weight at the rear is prevented. The following points must be complied with
otherwise the steering and braking forces necessary for safe driving cannot be transmitted.
• When setting the overhang length, the permissible axle loads and the respective minimum front axle load must always be taken into consideration.
• The minimum front axle load and the maximum rear axle load must always be complied with (Z see Part B for the respective vehicle model series,
chapter “Permissible load values” and chapter “Minimum axle loads”).
• The weight of any special equipment must also be taken into account for the calculations.
Country-specific laws, guidelines and vehicle registration rules must be observed, as must the specifications in the body/equipment mounting
directives with respect to front and rear frame/vehicle overhang, permissible axle loads and angles of approach/departure.
The angles of approach and departure must be suitable for the usage profile of the respective vehicle.
For further information, see the “Notes on mounting equipment”, chapter 2.4.1 (Z page 25).
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3.3 Vehicle overhang
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3.4 Electrical system
Risk of accident
Work carried out incorrectly on the electrical system may impair its function. This may lead to the failure of components or parts relevant to safety.
Any work carried out on the vehicle must comply with accident prevention regulations.
Comply with all national regulations and laws!
Risk of fire
The notes on operating and vehicle safety in Part A, section 1 “Introduction” (Z pages 13 to 15) must be complied with.
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3.4 Electrical system
3.4.1 Batteries
• Never place any metal objects or tools on the batteries
• Never start the engine unless the battery is firmly connected (battery terminals connected)
• Incorrect polarity of the supply voltage can cause irreparable damage to the control units
• Never disconnect or remove the battery terminals while the engine is running
• If the batteries are flat, the engine can be jump-started using jump leads connected to the battery of another vehicle running on the same voltage.
Observe the Instruction Manual!
• Jump-starting with a quick charger (overvoltage) is not permitted
• Only tow-start the vehicle with the batteries connected
• Quick-charge the batteries only after disconnecting them from the vehicle's electrical system. Both the positive and negative terminals must be
disconnected. Observe the Instruction Manual
• For information about the installation of additional electrical consumers, see Z Part B, section “Current draw of auxiliary consumers”
• Cables routed in the vicinity of exhaust systems must be protected against the high temperatures prevailing there
• Cables must not be routed near the exhaust manifold or turbocharger
• Install the cables in such a way that there are no chafe or shear points (consider chassis torsion and relative movement between chassis and
implement or body parts), particularly at crossing points and sharp edges and use cable channels or conduits if necessary
• Department TE/OVG-B must be consulted if a battery isolating switch is to be retrofitted
• Never fasten electrical cables to brake lines
• Do not carry out tests at connector terminals using unsuitable tools (test probes, wire ends, etc.). This may lead to contact damage and subsequent
problems. Use suitable test leads
The further information on welding work in Part A, section 3.10 “Welded connections” (Z page 71) and section 3.12.3 “Welding work on the vehicle
frame” (Z page 81) must be complied with.
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3.4 Electrical system
Converting a battery terminal without additional stud to a battery terminal with additional stud
• Check whether the cable length is sufficient, never cut off battery cable
• Remove the existing pressed-on battery terminal
• Install new Euro battery terminal on battery cable with a professional clamp/solder connection
The following battery terminals with additional stud can be procured either via the Global Logistics Center or via the replacement parts system:
• Cross-section 50 mm2 for positive terminal A 002 546 35 44
• Cross-section 50 mm2 for negative terminal A 002 546 38 44
• Cross-section 70 mm2 for positive terminal A 002 546 36 44
• Cross-section 70 mm2 for negative terminal A 002 546 39 44
The use of battery terminals from other accessories suppliers is only permissible after inspection by the TE/OVG-B Equipment Team, see chapter 2.1
“Technical advice and contact persons” (Z page 16).
The square fuse can also be connected via an additional copper lug, see Figure 3.3.
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3.4 Electrical system
Figure 3.2: Connection lines for negative terminal Figure 3.3: Connection of square fuse to positive terminal
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3.4 Electrical system
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3.4 Electrical system
Observe the work instructions for repairing and lengthening wiring harnesses. These are available through the Mercedes-Benz Bodybuilder System
(MB-AS).
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3.5 Power supply for auxiliary consumers
Risk of accident
Work incorrectly carried out on electronic components and their software could prevent this equipment from working correctly. Since the electronic
systems are networked, this might also affect systems that have not been modified.
Malfunctions in the electronic systems could seriously jeopardise the operating safety of the vehicle.
If additional electrically powered assemblies are installed, uprated batteries or alternators may be necessary (code M37). It is possible for the
implement or body manufacturer to retrofit higher-capacity batteries.
If, despite these measures, the on-board electrical system is still insufficient, a power supply that is independent of the vehicle must be installed.
The following points must be observed when electrical consumers are retrofitted by body/equipment manufacturers:
• No additional consumers may be connected to assigned fuses.
• No additional lines may be connected to existing lines (e.g. with cut-and-clamp connections).
• Consumers must be adequately fused with additional fuses.
• Power may only be supplied to 12V devices via a voltage converter because all vehicles are equipped with 24V systems.
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3.6 Illumination equipment
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3.6 Illumination equipment
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3.6 Illumination equipment
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3.6 Illumination equipment
Visibility: Side reflectors must be yellow in colour; however, the rearmost side reflector may be red if it is integrated with the taillamp, the
rear end-outline marker lamp, the rear fog lamp, the brake lamp or the rearmost red side marker lamp or if it shares an illuminated
surface with one of these.
Horizontal angle: 45° to the front and rear
Vertical angle: 10° above and below the horizontal plane. The vertical angle below the horizontal plane may be reduced to 5° if the
installation height of the reflector is less than 750 mm.
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Colour: Yellow; However, the rearmost side marker lamp may be red if it is integrated/combined with the taillamp, rear end-outline marker
lamp, rear fog lamp or brake lamp or if it is integrated with the rear reflector or shares an illuminated surface with it.
Visibility: Horizontal angle: 45° to the front and rear. This value may however be reduced to 30° on vehicles where the installation of side marker
lamps is merely permissible. If the vehicle is equipped with side marker lamps which are intended to compensate for reduced
geometric visibility of the front and rear turn signals and/or position lamps, then the angles to the front and rear must be 45° and the
angle to the vehicle centre must be 30°.
Vertical angle: 10° above and below the horizontal plane. The vertical angle below the horizontal plane may be reduced to 5° if the
installation height of the side marker lamp is less than 750 mm.
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3.6 Illumination equipment
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3.6 Illumination equipment
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3.6 Illumination equipment
Example
approx. 3530 mm
250 – 1500 mm
Figure 3.4: Full contour marking Figure 3.5: Partial contour marking
1
1
60% is possible for justified exceptions
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3.6 Illumination equipment
Requirements: For a partial contour marking, each upper corner must be identified by two lines which form an angle of 90° and whereby each line is
at least 250 mm long.
Each section must be at least long enough that at least one approval mark (of ECE-R 104 ⇒ Component approval for retro-reflective
materials) is visible.
The width of the markings should be at least 50 mm and at most 60 mm.
Distinctive markings are considered to be continuous if the distances between adjacent sections are as small as possible and not
greater than 50% of the shortest length of such a section.
Marking plates in accordance with ECE-R 70 (uniform provisions for the approval of rear marking plates for heavy and long vehicles)
are acceptable as part of the contour marking.
Attachment: Vehicles with a permissible gross vehicle weight greater than 7.5 t and a vehicle width > 2100 mm (except vehicles with chassis with
cab, incomplete vehicles and semitrailer tractors) must be fitted with a full contour marking at the rear of the vehicle.
For the vehicles specified above that are greater than 6000 mm in length, partial contour marking is compulsory at the side of the
vehicle. If it is not possible to apply a partial contour marking due to the shape of the body, design or operating conditions of the
vehicle, a line marking may be applied.
The application of distinctive markings is permissible on all vehicles not covered by the above-specified regulations.
The distance between the distinctive marking applied at the rear of the vehicle and each compulsory brake lamp should be greater
than 200 mm. The locations on the vehicle where distinctive markings are applied must be large enough that markings with a width
of at least 60 mm can be applied.
Compulsory markings may be replaced with markings of the next higher category. Accordingly, a partial contour or full contour marking may be
applied in place of a compulsory line marking and a full contour marking may be applied in place of a compulsory partial contour marking.
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3.6 Illumination equipment
Distinctive markings should be applied so that they are positioned as close as possible to horizontal and vertical in a location which is compatible with
the shape, the body, the design and the operating conditions of the vehicle. In addition, the markings should be applied so that they are as parallel as
possible to the longitudinal/lateral centre plane of the vehicle in a location which is compatible with the shape, the body, the design and the operating
conditions of the vehicle.
Horizontal position: The distinctive marking must be applied as close as possible to the outside edge of the vehicle. The overall length of the
horizontal distinctive markings applied to the vehicle must be at least 80% of the overall length of the vehicle; this does not take overlapping of
individual sections of horizontal marking into account. If the shape of the body does not allow compliance with the value of 80%, the overall length of
the marking may be reduced to 60%.
In longitudinal direction: The distinctive marking must be applied as close as possible to each end of the vehicle (up to 600 mm from each end of the
vehicle). The overall length of the distinctive markings applied horizontally to the vehicle must be at least 80% of the length of the body, not taking
individual sections of horizontal marking into account. If the shape of the body does not allow compliance with the value of 80%, the overall length of
the marking may be reduced to 60%.
Vertical position: The lower section/sections of line markings and contour markings must be applied as low as possible within the following range.
Minimum value: Not less than 250 mm above the ground; Maximum value: Not more than 1500 mm above the ground.
However, markings may be applied at a height of 2100 mm if technical conditions do not allow for compliance with the maximum value of 1500 mm, do
not allow the above-specified regulations to be fulfilled or do not allow the line marking/lower sections of the contour marking to be positioned
horizontally.
Upper sections of contour markings must be applied as high as possible but may be up to 400 mm from the upper edge of the vehicle.
Colour of retro-reflective markings on vehicle side: White or yellow
Colour of retro-reflective markings on vehicle rear end: Red or yellow (depending on applicable national regulations)
Visibility: The distinctive marking is considered visible if at least 80% of the illuminated surface of the marking is visible to an observer who is
positioned at any point between the planes of observation defined in Directive ECE-R48-03.
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3.6 Illumination equipment
See the operator's manual for further information on adjusting the headlamps.
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3.7 Control units
The following relays with freewheeling diodes are available from the Global Logistics Center:
• A 004 545 35 05 Micro relay (24 V, 5/10 A)
• A 003 545 57 05 Mini relay (24 V, 20/20 A)
• A 004 545 33 05 Mini relay (24 V, 10/20 A)
The following relays with freewheeling diode are not available from the Global Logistics Center but they may be available from various replacement part
logistics centres or in store in workshops:
• A 003 545 98 05 Mini relay (24 V, 10/20 A) (Bosch 0 332 209 205)
• A 000 545 58 05 Mini relay (24 V, 10/20 A) (Bosch 0 332 202 134)
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3.8 Mobile communications systems
Equipment
• The device must bear the CE mark and must satisfy the tests according to Directives 2004/104/EC to 2005/83/EC.
• The device must be permanently installed.
• Operation of portable or mobile equipment inside the cab is only permitted if this equipment is connected to a permanently installed external aerial.
• The transmitter must be installed separately from all other vehicle electronics.
• Protect the device from moisture.
• Observe the permissible operating temperature, and protect against strong vibration.
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3.8 Mobile communications systems
The notes on operating and vehicle safety in Part A, section 1 “Introduction” (Z pages 13 to 15) must be complied with.
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3.9 Electromagnetic compatibility (EMC)
Information on certified EMC testing agencies in Germany is contained in the bulletin “Recognition and Accreditation of Technical Services and Test
Laboratories” (VO no. 39, published on 15th March 2004), available from Verkehrsblatt-Verlag at the address below:
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3.9 Electromagnetic compatibility (EMC)
For questions regarding EMC or EMC tests you may contact EMCtech GmbH:
Daimler AG recommends testing according to 2004/104/EC, which is compulsory for new vehicle models as of 1st July 2006 and for all vehicles from
1st January 2009.
The notes on operating and vehicle safety in Part A, section 1 “Introduction” (Z pages 11 to 13) must be complied with!
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3.10 Welded connections
Welding work on the chassis/body may only be carried out by trained personnel.
The following safety measures must be observed to prevent damage to components caused by overvoltage during welding work:
• Disconnect the positive and negative terminals from the battery and cover them.
• Connect the welding-unit earth terminal directly to the part to be welded.
• Do not touch electronic component housings (e.g. control units) and electrical lines with the welding electrode or the earth contact clamp of the
welding unit.
• Before carrying out welding work, springs must be covered to protect them against welding spatter. Do not touch springs with welding electrodes or
welding tongs.
• Avoid welding work on inaccessible cavities in the cab.
• Cover the fuel tank, natural gas and fuel system (lines, etc.) before carrying out welding work.
• Plug welding is only permissible in the vertical webs of the longitudinal frame member.
• Always disconnect the plug from the engine control unit before commencing welding work.
• Welds must be ground down and reinforced with angular profiles to prevent notching from welding penetration.
• Avoid welds in bends.
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3.10 Welded connections
Further information can be found in part A, section 3.11 “Bolted connections” (Z page 73).
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3.11 Bolted connections
Risk of accident
Do not modify any bolted connections that are relevant to safety, e.g. that are required for wheel alignment, steering or braking functions.
When unfastening bolted connections make sure that, when work is complete, the connection again corresponds with the original condition.
Welding work on the chassis/body may only be carried out by trained personnel.
The body and the attached or mounted implements must comply with the applicable laws and ordinances as well as work safety or accident prevention
regulations, safety rules and bulletins of public insurance institutions.
If it is necessary to replace standard bolts with longer bolts, use only bolts
• of the same diameter
• of the same strength grade
• of the same type
• with the same thread pitch
Additional tensioned parts must be of equal or greater strength than the preceding tensioned assembly.
The use of Mercedes-Benz tightening torques assumes coefficients of friction for the bolts in the tolerance range of [= 0.08...0.14]. Mercedes-Benz
recommends the use of Mercedes-Benz standard parts.
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3.11 Bolted connections
Settling Creep
The surfaces of the parts in contact (e.g. nuts, washers) are coated with The pressure per unit area of the bolt and nut on the contact
corrosion protection and settle under the pressure of the clamping surfaces exceeds the specific pressure strength of the material of
force. This means that the more the connecting points that are bolted the clamped parts.
together, the greater the length change due to settling.
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Figure 3.6
Properties
Flange head bolts and nuts that comply with Mercedes-Benz standards (MBN) 10105 and 13023 reduce the danger of loss of pre-load by setting on the
bearing surface. The pressure intensity that is created during the process of tightening is low in contrast to other types of screw heads, because it is
spread over the increased bearing surface.
Advantages of flange head bolts and nuts to MBN 10105 and 13023
• Reduced risk of creep due to an enlarged contact area and thus a lower pressure per unit area than other types of bolt heads.
• Reduced settling effect due to a lower number of parts to be connected compared with bolted connections with washers.
• The concave contact disc increases the elasticity of the connection so that any settling or creep behaviour that still occurs can be compensated,
largely preventing any decrease in the clamping force.
• The elasticity of the bolted connection can be increased further by selecting a high clamping length ratio l/d
(l = shank length, d = shank diameter).
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3.11 Bolted connections
The use of flange head bolts and nuts guarantees a secure and maintenance-free bolted connection.
(For attached components, the maintenance guidelines of the component manufacturer should be followed!)
Conformity of lengths/reach in blind holes must be ensured.
As the nuts conforming with MBN 13023 feature clamp locking, they must not be used more than once.
When flange head bolts and nuts are used, the tightening torques in the following tables must be complied with.
Extract from MBN 10130 Part 3 Class II Extract from MBN 10130 Part 3 Class III
Torque variation in tightening process: ±3 % to ±8 % Torque variation in tightening process: ±8 % to ±20 %
Bolt driver with shutoff clutch; torque wrench: -5 % Impulse wrench; “good” impact wrench: -20 %
Thread Tightening torque Preload force Thread Tightening torque [Nm] Preload force
[Nm] FVmin [kN] FVmin [kN]
M8 x 1.25 29.5 ± 2.3 16.3 M8 x 1.25 26 ± 5 12.9
M10 x 1.5 58 ± 4.5 25.9 M10 x 1.5 51 ± 10 20.5
M12 x 1.5 106 ± 8 39.7 M12 x 1.5 92 ± 18 31.0
M14 x 1.5 172 ± 13 56.0 M14 x 1.5 150 ± 30 43.9
M16 x 1.5 260 ± 20 74.4 M16 x 1.5 225 ± 45 57.9
M18 x 1.5 380 ± 30 96.9 M18 x 1.5 330 ± 60 75.8
M20 x 1.5 520 ± 40 120 M20 x 1.5 460 ± 60 95.6
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3.11 Bolted connections
Environmental note
As of 1st July 2007 the surface protection (9440.40) must not contain chromium 6.
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3.12 Frame
3.12 Frame
Risk of injury
Do not modify any bolted connections that are relevant to safety, e.g. that are required for wheel alignment, steering or braking functions.
When unfastening bolted connections make sure that, when work is complete, the connection again corresponds with the original condition.
Welding work on the chassis/body may only be carried out by trained personnel.
The body and the attached or mounted implements must comply with the applicable laws and ordinances as well as work safety or accident prevention
regulations, safety rules and bulletins of public insurance institutions.
The UNIMOG chassis is designed in such a way that implements and bodies can usually be mounted to the existing implement mounting points without
a modification to the chassis.
If modifications are necessary, you must first inform the TE/OVG-B Equipment Team and/or apply for approval. No modifications may be made to the
chassis (MB scope of delivery) without the approval of Daimler AG.
Standard production vehicles comply ex factory with EU Directives and national regulations (vehicles produced for countries outside of Europe may be
exceptions). The vehicles must still comply with EC Directives and all pertinent national regulations after modifications have been carried out.
Vehicle or chassis conversions can only be carried out by the body manufacturers.
Examples of vehicle conversions:
• Wheelbase extension
• Frame modification
• Relocation of vehicle components, e.g. battery box, air reservoirs, exhaust system
• Modifications to systems, e.g. conversion of the hydraulic system
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In the case of the following modifications, the TE/OVG-B Equipment Team must be consulted in advance:
• Shortening or lengthening of the chassis overhang • Modifications that impair the safety of the cab
• Drilling and welding on the chassis frame or on the axles (e.g. drilling in the A-pillar or B-pillar)
• Modifications to the frame • Modifications to the hydraulic system
• Modifications to the brake and steering systems • Modifications to the lighting system
(e.g. changing the length of the brake lines) • Modifications to the soundproofing
• Modifications to the intake and exhaust systems • Modifications to the engine
• Modifications to the wheels, tyres, springs • Modifications to the electrical system, e.g. including the relocation of
(e.g. locking the suspension) electrical control units
Further information on bolted and welded connections can be found in Part A, section 3.7 “Welded connections” ( Z page 54) and
section 3.8 “Bolted connections” (Z page 56), and in the Mercedes-Benz Workshop Information System (Z page 28).
Frame profiles 1200 mm long can be obtained from your local Mercedes-Benz sales and service outlet for use in frame modifications.
Further information is available from the Equipment Team, see Part A, section 2.1 “Technical advice and contact persons” (Z page 16).
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3.12 Frame
Bore holes may be drilled in the chassis frame web for special cases.
Distance “a”:
at least 25 % of the frame height “H”
Side hole spacing:
at least 50 mm
Maximum hole diameter “d”:
15 mm
Deburr and ream all holes after drilling.
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Other precautions:
• Disconnect the battery and short the terminals
• Establish an earth connection between the negative terminal and the vehicle frame (the frame is unearthed!)
• Cover springs and remove if necessary
• Cover or remove plastic lines and electrical cables
• To protect the electronics, always disconnect the plugs of the engine control unit. The plugs are located on the left-hand side of the engine. Because
of the complexity of the plugs, this should be done with special care.
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3.12 Frame
Welding must not be performed on the upper and lower flanges of the chassis frame (except for wheelbase and frame extensions).
The earth terminal of the arc welder must be connected directly to the part of the vehicle to be welded.
• Only use dry electrodes with basic-coated jacket, electrode diameter 3.25, 4.00 or 5.00 mm.
• DIN 1913 E5154 B10, ISO 2560 E51.5 B12026
• Weld only with electrodes connected to the positive pole of a direct current source. Always weld from bottom to top.
• Inert gas welding is to be preferred over manual arc welding, welding wire SG 3 DIN 8559.
• The yield point and tensile strength of the welding material must be at least equal to that of the material to be welded.
• Welds must be ground down and reinforced with angular profiles to prevent notching from welding penetration. Avoid welds in bending radii
(radius ≤ 15 mm). There should be at least 15 mm between the weld and the outer edges.
After welding:
• Clean the weld thoroughly
• Remove all swarf
• Protect against corrosion
• Check the joint at regular intervals
Further information on welded connections can be found in Part A, section 3.7 “Welded connections” (Z page 54), and in the Mercedes-Benz
Workshop Information System (Z page 28).
3.12.4 Reinforcements
• If the frame is modified, internal or external reinforcing brackets must be installed.
• The reinforcing brackets should be bolted or riveted on and be flush with the end faces of the upper and lower flanges. As far as possible, use the
existing holes in the chassis longitudinal members.
• A sufficient gap must be left between the upper and lower reinforcing brackets on the frame web.
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Changes in the values for the chassis weight, axle loads, brake force distribution and turning circle must be taken into account.
The GOP (General Operating Permit) is invalidated if the wheelbase is modified.
Mercedes-Benz, UNIMOG Division, cannot vouch for the handling, braking and steering characteristics of vehicles on which the wheelbase has been
modified.
Further information can be found in Part A, section 3.8 “Bolted connections” (Z page 56) and section 3.9.2 “Drilling work on the vehicle frame”
(Z page 63).
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3.13 Frame modification
Risk of accident
Never carry out any modifications to the steering, brake system etc. Any modifications to the steering and the brake system may result in these
systems malfunctioning and ultimately failing. The driver could lose control of the vehicle and cause an accident.
The company carrying out the chassis conversion is responsible for ensuring that
• the Body and Implement Mounting Directives are present and complied with.
• in the case of changes in the brake system, a brake calculation and brake test according to 71/320/EEC (including response characteristics) are
performed.
• in the case of modifications to the overall vehicle geometry, a steering force measurement according to 70/311/EEC is performed.
• an additional label is affixed in the vicinity of the model plate clearly identifying the conversion work and the converting company.
• the conversion/retrofit is designed/carried out in such a way as to withstand the forces occurring in the vehicle throughout the vehicle's service life.
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• a torsion test (diagonal torsion) is conducted and, in the case of wheelbase extensions, the clearance of the propeller shaft at full rebound travel is
checked.
• the conversion/retrofit is documented and referenced to the chassis number.
• life cycle support is guaranteed for at least 10 years.
• a warranty system exists for the converted/retrofitted equipment.
• an instruction manual and, if necessary, maintenance and repair instructions are produced.
• the vehicle is licensed by means of individual official approval because the Daimler GOP (K832) is generally no longer applicable.
• the vehicle manufacturer is informed immediately on being made aware of any damage to the conversion/retrofit that influences the safety of the
vehicle or adversely affects other vehicle components.
• the legal requirements are complied with, e.g. as regards licensing provisions, road traffic regulations, health and safety at work, occupational
medicine, accident prevention regulations, equipment and product safety laws etc., and that the conversion conforms with the state of the art in
general.
• the design of the conversion/retrofit is of the correct strength and construction.
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3.13 Frame modification
The longitudinal members may be cut as shown (Figure 3.10). Drilled holes must not
be cut. In order to reinforce the welded joint and to relieve load from the seam, a
reinforcement (see Figure 3.14) must be welded in. Weld on the upper and lower
flange reinforcement profiles according to DIN 18 800 Part 1, and weld on the flange
plate ends (for procurement sources for profiles Z see section Fehler!
Verweisquelle konnte nicht gefunden werden. “Fehler! Verweisquelle konnte
nicht gefunden werden.”, page Fehler! Textmarke nicht definiert.).
Figure 3.10: Cutting line for version a
b) Without reinforcement plates
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The seam form and dimensions are contained in DIN 8551 Part 1.
In the case of root seams, it must be ensured that even root penetration is achieved. The root seam must be of high quality and must not show any
fusion defects. The seam must then be ground as required. Depending on the desired form of the seam, filling layers must be applied.
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4 1
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3.13 Frame modification
Outside of frame
Inside of frame
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3.14 Mounting of implements and auxiliary components
Risk of accident
The use of parts, assemblies or conversion parts and accessories which have not been approved may jeopardise the safety of the vehicle.
Before starting to install implements or bodies on the basic vehicle or on major assemblies, please read the relevant sections of the vehicle Instruction
Manual and the operating and assembly instructions from the manufacturers of the accessories and special equipment.
You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
Official acceptance by public testing bodies or official approval does not rule out safety hazards.
All national laws, directives and registration requirements must be complied with.
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3.14 Mounting of implements and auxiliary components
Figure 3.15: Bolt arrangement with clamping sleeve for form-locking Figure 3.16: Bolt arrangement with expansion Figure 3.17: Bolt arrangement
lateral force transfer sleeve to reduce any loss of tension due to
settling effects
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3.14 Mounting of implements and auxiliary components
Mounting:
• Without play in a suitable bracket so that they cannot rattle
• Secured with 2 locks to prevent loss
• Easily accessible
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3.14 Mounting of implements and auxiliary components
In the case of conversions, the details for individual approval must be clarified with the local authorities.
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Side underride guard are usually not required for the U20 because this vehicle has a wheelbase of 2700 mm.
The U20 is fitted with one side underride guard between the left front wheel and the AdBlue reservoir.
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3.15 Corrosion prevention measures
Planning measures
Anti-corrosion protection measures should be included in the planning stages by selecting suitable materials and designing components accordingly.
A conductive connection occurs if two different metals are brought into contact with each other through an electrolyte (e.g. air humidity). This causes
electrochemical corrosion and the less base of the two metals is damaged. The further apart the two metals are in the electrochemical potential
series, the more intense electrochemical corrosion becomes.
For this reason, electrochemical corrosion must be prevented by insulation or by treating the components accordingly, or it can be minimised by
selecting suitable materials.
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3.15 Corrosion prevention measures
Coating measures
The vehicle can be protected by applying protective coatings (e.g. galvanisation, painting or zinc coating applied by flame).
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3.16 Painting work
Environmental note
Paints and lacquers are harmful to health and to the environment if they are not handled correctly.
Dispose of paints and lacquers in an environmentally responsible manner.
Paint compatibility should be checked when repainting. In order to avoid colour variations on painted bodies, Mercedes-Benz recommends that paints
be used only if they have been tested and approved for the vehicle model in question. Information on the primers used at the factory and on Mercedes-
Benz colour numbers can be obtained from the relevant department, Z see Part A, section 2.1 “Technical advice and contact persons”, page 18.
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3.16 Painting work
Further information on painting can be found in the Mercedes-Benz Workshop Information System (WIS).
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3.17 Engine
3.17 Engine
A warning buzzer is installed in the cab within the hearing range of the driver.
The buzzer serves as an acoustic warning when e.g.
• the maximum permissible engine speed is exceeded
• the maximum permissible oil temperature is exceeded
• the maximum permissible coolant temperature is exceeded
• the coolant level is too low
• the oil level or oil pressure in the engine is too low
When the warning buzzer sounds, the operating safety of the vehicle is in danger. Switch off the engine immediately (taking into account the traffic
situation) and ascertain the cause.
If implements or bodies are operated from outside the cab (e.g. loading crane,, winch), an additional visual warning system must be installed in the
vicinity of the controls.
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3.18 Implement drive
Caution:
The permissible drive loads must never be exceeded, taking the type of operation (variable loads, load factors, duration of usage, usage profile, etc.)
into consideration. It is the responsibility of the implement manufacturer to carry out the necessary implement operation tests! All consumers
(mechanical, hydraulic, pneumatic, electric) must be made compatible with one another. Outputs, maximum draw, direction of rotation, speeds etc.
must be taken into account (for further information on “implements and auxiliary components” see Part A, section 3.11 “Mounting of implements and
auxiliary components” ( page 74) and “Current draw of auxiliary consumers” (see Part B, section 4 “Drive of implements and bodies”). Make sure that
the drive system does not overheat. In the case of continuous consumers, the implement manufacturer must ensure that the maximum permissible
temperature (engine oil, transmission fluid, coolant) is not exceeded under the expected conditions of vehicle use. In the case of hydraulically driven
continuous consumers, the implement manufacturer must ensure, with the use of matched hydraulic components, that the maximum permissible
operating temperature is not exceeded under the expected conditions of use.
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3.19 Propeller shafts for implements
Risk of accident
Guards for rotating parts, especially in the area of the propeller shaft connection on the vehicle, must be provided by the implement manufacturer.
Propeller shafts located in work areas or other areas frequented by people must be enclosed or covered.
Accident prevention regulations must be observed.
Delivery condition
Propeller shafts are delivered assembled and ready for installation. They have been balanced, outfitted in accordance with the technical documentation,
and painted. Maintenance-free drive shafts are lubricated for life and do not require subsequent lubrication.
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3.19 Propeller shafts for implements
Figure 3.18: Propeller shafts Figure 3.19: Propeller shaft length adjuster
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3.19 Propeller shafts for implements
3.19.1.1 Layout
The following points regarding layout must be observed and complied with to minimise vibrations and noise:
The critical rpms must be calculated. These are dependent on the rotational speed, length and tube dimensions. The maximum permissible operating
rpm must be at least 20 % below the critical rotational speed. If this is cannot be achieved, even when the maximum possible tube diameter is used, the
length of the propeller shaft must be reduced or an intermediate bearing fitted.
The correct design of the propeller shaft train prevents noise and the development of vibrations. Use original Mercedes-Benz parts where possible.
Caution:
In order to compensate for rpm variations, the inner joint forks must be offset.
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Single-plane layout
Figure 3.20: “Z” propeller shaft layout Figure 3.21: “W” propeller shaft layout
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The combinations of vertical and horizontal angles can produce an infinite number of possible layouts. The advice of the propeller shaft manufacturer
should be sought when determining the offset angle.
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3.19 Propeller shafts for implements
When a propeller shaft or a shaft drive line is being installed, the joints must be assembled so that the markings on the parts are in alignment.
Depending on type, one of the two markings is located underneath the rubber boot.
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3.19.2 Bearings
The drive shaft (transmission) and output shaft bearings (axle) are subjected to radial and axial loads by static and dynamic forces and moments. The
bearings must be appropriately dimensioned.
3.19.3 Imbalance
Propeller shafts are balanced in two planes to balance grade G16 (DIN ISO 1940). The residual imbalance depends on the mass of the propeller shaft
and the rotational speed. The balancing speed depends on the size of the shaft and is based on the statistical speed distribution of the shaft according
to the class of vehicle.
After any repairs to the propeller shaft it must be rebalanced in accordance with the relevant specifications.
3.19.4 Maintenance
In the case of propeller shafts that are not maintenance-free, care must be taken to ensure that the lubrication points are easily accessible and that
they are lubricated with grease approved in accordance with the Specifications for Service Products. Maintenance-free drive shafts are lubricated for
life and do not require subsequent lubrication. Service and maintenance work must be carried out in accordance with the manufacturer's instructions
taking operating conditions into account. Possible defects or damage may only be repaired at an authorised workshop using genuine spare parts.
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3.20 Anti-roll bars
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3.21 Tyres
3.21 Tyres
The implement and body manufacturer must ensure that:
• approved wheels and tyres with sufficient load capacity are used
• the permissible axle loads are observed
• the tyre pressures specified in the Operating Instructions are maintained
• there is sufficient clearance, even at maximum torsion, maximum axle loads and the maximum steering angle, between the tyres and chassis
components (mudguards, wheel arches, etc.), and all pertinent regulations are complied with
• there is sufficient clearance when tyre chains are used, even in the event of torsion, if such a usage profile is necessary
You can obtain tender drawings and technical data from the (MB-AS) Mercedes-Benz Bodybuilder System (Z page 27).
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3.22 Cooling
3.22 Cooling
The cooling system (coolant radiator, charge-air cooler, fan, mechanical fan drive, radiator grille, air ducts, coolant circuit, etc.) must not be modified.
Sufficient cooling air flow must be guaranteed.
• Keep the radiator inlet free from obstructions
• Do not obstruct the air outlet behind the radiator
• Do not affix warning signs, badges or other trim parts in the area in front of the radiator
• If possible, design implements in such a way that the radiator is not exposed to dirt or dust
Provide additional cooling facilities for major components if the usage profile suggests that there may be temperature problems.
Do not install an additional radiator in front of the standard coolant radiator or intercooler. Only use auxiliary cooling units that are equipped with fans,
e.g. electrically-driven.
Disc brakes:
Disc brake cooling must not be impaired by additional wheel covers or brake disc covers, etc.
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3.23 Engine air intake
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3.24 AdBlue tank, metering unit and supply unit
Tank
min. 200 l
0
2
Valid for Shurflo pump
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3.24 AdBlue tank, metering unit and supply unit
Case 1 is a new addition to the specification and has been valid since 23.06.2008.
Other configurations are possible in individual cases but these must be discussed separately with the equipment team, see chapter 2.1 “Technical
advice and contact persons” (Z page 16), and their suitability must be proven through an appropriate testing program.
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3.25 Soundproofing
3.25 Soundproofing
If modifications are carried out on any parts whose operation produces noise, e.g.
• engine
• exhaust system
• air intake system
• tyres
• encapsulation etc.
then a re-inspection (noise measurement) must be carried out by the Technical Inspection Association in the case of vehicles registered in Germany. An
entry must then be made in the vehicle registration papers.
In the case of vehicles which are certified in EU countries in accordance with EU approval, the vehicle manufacturer's EU certificate must also be
changed in the event of a modification to the soundproofing. Modifications to EU certificates may only be made by the applicant, i.e. the vehicle
manufacturer. Certification modifications involve a great deal of effort on the part of the vehicle manufacturer. The costs of such modifications are
borne by the body/implement manufacturer.
To prevent modifications from changing the vehicle's sound levels, it must be ensured that interior sound levels are reduced when planning implements
and bodies.
• All components of the original soundproofing system are certified vehicle components and part of the general operating permit and must therefore
not be removed, relocated, bypassed or modified in any way.
• The level of interior noise must not be adversely affected.
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3.25 Soundproofing
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3.26 Exhaust system
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3 Damage prevention
3.26 Exhaust system
If these distances cannot be maintained, replace plastic lines with tombac lines in accordance with DIN 1755, material CuZn20F33, of the same
internal diameter.
• Additional shielding may be necessary near operating equipment, assemblies and implements and fittings.
• If parts of the exhaust system have been modified, the supply of replacement parts must be guaranteed by the implement manufacturer.
Corresponding notes must be included in the implement operating instructions.
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3 Damage prevention
3.27 Springs
3.27 Springs
• Only use springs which have been tested and approved for the vehicle model in question. Spring reinforcements and shock absorber modifications
are not permitted.
• Do not damage the surface or the corrosion protection of the springs when carrying out installation work.
• Before carrying out welding work, cover springs to protect them against welding spatter. Do not touch springs with welding electrodes or welding
tongs.
• Do not perform any welding work on springs.
• Springs must not be shortened. Shorter or longer springs or spring pads may not be installed.
The spring/shock absorber combination must not be modified without the written authorisation of Daimler AG. A practical inspection and road test is
generally necessary before approval is granted.
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3 Damage prevention
3.28 Brake system
Risk of accident
Work carried out incorrectly on the brake system may impair its function. This may lead to the failure of components or parts relevant to safety. This
could cause you to lose control of the vehicle and cause an accident with possible injury to yourself and others.
The automatic load-dependent brake pressure control (ALB) is fitted as standard equipment to all UNIMOG vehicles. Modifications to the position of
the ALB valve, the ALB lever (kinematic) and the mounting point of the linkage at the rear axle are not permitted.
Changes to brake lines, e.g. longer lines, may affect the time response of the brake and must be checked in accordance with EC Directives.
UNIMOG vehicles are equipped with ABS (anti-lock brake system) as standard. No modifications whatsoever may be made to any part of the system.
All accident prevention regulations must be complied with when working on the vehicle.
Comply with all national regulations and laws.
After any modifications the brake system must be tested for proper operation and approved by a technical inspection authority otherwise the
operating permit will be invalidated.
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3.28 Brake system
Risk of accident
Work carried out in correctly on the brake hoses, cables and lines may impair their function. This may lead to the failure of components or parts
relevant to safety.
Compressed-air, fuel and hydraulic lines, plastic pipes and brake hoses must be covered or removed if necessary before carrying out any welding,
drilling and grinding work and before working with cutting discs.
After installing compressed-air, fuel and hydraulic lines, plastic pipes and brake hoses, the system must be tested for pressure loss and leaks.
Retrofitted lines (e.g. hydraulic lines from implements and bodies) must not be attached to the chassis lines (e.g. brake hoses, hydraulic lines etc.). The
relative movement which occurs between body and chassis in case of chassis torsion, and the subsequent stretching or compression of the lines, must
be taken into consideration when lines are routed. Mercedes-Benz recommends that, when routing lines, implement manufacturers make and fit
suitable brackets for the line or pipe routing on the chassis. The brackets must be attached using existing holes in the chassis. Never attach them to
existing, highly-stressed fasteners, such as longitudinal member frame connections, engine bearings, anti-roll bar mountings, spring mountings etc.
Lines must be protected from heat by means of insulation.
Lines must be routed so as to rule out any additional pressure losses.
Existing brackets on the chassis may be used, provided that the bracket can bear the additional load. Changes to the brake system (e.g. wheelbase or
frame extensions) may only be carried out using the pipe fittings and plastic lines which have been approved by us.
Plastic ties are required for mounting. The maximum distance between ties may be 500 mm. If plastic lines are not available, the installation of steel
pipes with identical dimensions, which have been electro-galvanised both inside and out, is permissible.
Comply with all national regulations and laws!
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3.28 Brake system
For plastic lines, the following minimum bending radii must be adhered to:
Only genuine lines or lines of equivalent quality (e.g. PA11-PHLY, material complying with DIN 74324) with a pressure strength of at least 18 bar may
be used.
If modifications to the brake or air supply lines have been made, a new acceptance test has to be carried out by an authorised technician because the
modifications may have adversely affected the response time of the brake system (according to EC Directive 71/320).
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3.28 Brake system
Mercedes-Benz recommends that you only use tested connecting parts and line connections which have been approved for the model of vehicle
concerned.
The approved system is VOSS 232.
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3.28 Brake system
The approved systems are based on nipple connector systems. These systems have been tested for the relevant operating conditions and offer the
necessary quality and service life.
Connectors that have not been approved are only accepted for use on separately protected auxiliary consumer circuits connected to connection 24 of
the 4-circuit protection valve.
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3.28 Brake system
Figure 3.24: Without line attached Figure 3.25: With line attached
Ordering information:
• Press-in gripper with clamping jaws 5994506500
• Tool insert 5994691149
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3.28 Brake system
Routing lines
Lines must be routed at a safe distance from heat sources, sharp-edged and moving parts.
Use plastic straps for fastening.
The use of plastic lines between the air compressor and compressed air drier is not permissible if the ambient temperature rises above 80 °C or in
hydraulic systems.
Material
Plastic lines: Use polyamide PA 11 PHLY or PA 12 PHLY complying with DIN 74324 and DBL 6270.12.
The routing of additional lines along the brake hoses is only permissible with the agreement of the relevant department, see chapter 2.1 “Technical
advice and contact persons” (Z page 16).
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3.28 Brake system
Mercedes-Benz recommends the use of hoses and hose assemblies manufactured by HANSA-FLEX.
In general, hydraulic hoses can be fixed in place both with clamps and with Panduit straps. Observe the following points:
• As of a certain length of approx. 0.8 m, pipes with threaded connections suitable for the respective pressure should be used instead of hoses
• The body manufacturer must select the brackets used for the pipes/hoses and document the routing. The body manufacturer is solely responsible
for this.
• Hoses must be equipped with chafe protection in cramped areas and at all attachment points
• Where applicable, the maintenance/replacement intervals for the hoses must be specified in the instruction manual/maintenance manual for the
body.
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3.29 Steerability
3.29 Steerability
Risk of accident
The following points must be complied with otherwise the steering and braking forces necessary for safe driving cannot be transmitted.
To ensure sufficient vehicle steerability, the minimum front axle load must be maintained under all load conditions. In case of deviations, the relevant
department must be consulted in advance, see Part A, section 2.1 “Technical advice and contact persons” (Z page 18).
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3.30 Clearance for assemblies and cab
Read and comply with the relevant sections of the Instructions Manual.
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3 Damage prevention
3.31 Secure mounting of the implement/ballast on the vehicle
Counterweights or ballast must be positioned in such a way that they cannot move or work loose.
The moving parts of the implement must be braced without play and locked mechanically wherever possible.
In the case of crane and excavator attachments, the boom must either be manually secured to prevent it from extending or slewing (e.g. using a tie
rod), or must be locked against unintentional movement from the transport position using an appropriate shutoff cock in the hydraulic system of the
crane or excavator.
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3 Damage prevention
3.32 Towing and tow-starting
Before towing or tow-starting, please make sure that you read the “Towing” section in the detailed Instruction Manual. You could otherwise fail to
recognise dangers and cause an accident, which could result in injury to yourself or others.
Failure to observe the instructions in the Instruction Manual can result in damage to the vehicle, e.g. in the drive train.
Only tow-start the vehicle with the battery connected.
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3.33 Fire hazard
Fire hazard
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3 Damage prevention
3.34 Special equipment
The use of parts, assemblies or conversion parts and accessories which have not been approved may jeopardise the safety of the vehicle.
Before starting to install implements or bodies on the basic vehicle or on major assemblies, please read the relevant sections of the vehicle Instruction
Manual and the operating and assembly instructions from the manufacturers of the accessories and special equipment.
You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
Mercedes-Benz recommends using equipment available as option codes (SA) to adapt the vehicle to the body optimally.
All equipment available as option codes is available from your Mercedes-Benz Service Centre or from body manufacturer advisors, see Part A, section
2.1 “Technical advice and contact persons” (Z page 18).
Optional equipment (e.g. hydraulic system, frame reinforcement, auxiliary transmission, etc.) or retrofitted equipment increases the unladen weight of
the vehicle.
When chassis are fitted with different tyres, the frame height can change considerably in both the laden and unladen state.
The actual vehicle weight and axle loads must be determined by weighing before mounting.
Not all optional equipment can be installed in any vehicle without problems. This applies in particular for retrofitted equipment because the installation
space may already be occupied by other components or the optional equipment may require other components.
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3.35 Maintenance and repairs
Always have maintenance work performed at a qualified specialist workshop possessing the required expertise and tools in order to perform the
necessary work.
Mercedes-Benz recommends a Mercedes-Benz Service Centre for this work.
It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.
Before performing any maintenance work, always read the technical documentation, such as the Instruction Manual and the workshop information.
Have maintenance work carried out at the proper time. If this is not done, malfunctions or failures may occur in systems that could be relevant to
safety. This could make you cause an accident, which could result in injury to yourself or others.
Maintenance and repair of the vehicle should not be made unnecessarily difficult by the body or the implement.
Maintenance points and major assemblies must be easily accessible.
In the case of bodies, the accessibility of the brake fluid reservoir in particular must be guaranteed.
• The Instruction Manual must be complied with and supplemented as necessary.
• The battery compartment must be sufficiently ventilated, with provision for air to enter and exit.
• Check the condition and capacity of batteries and service them in accordance with the manufacturer's specifications, see Part A, section 3.35.3
“Battery maintenance and storage” (Zpage 139).
• Fit maintenance flaps or removable panels where required.
If, in exceptional cases, these requirements cannot be met, the mounting of implements or special bodies or parts thereof must be of a quick-release
design.
Any additional expenses arising from the body in connection with warranty, maintenance or repair will not be borne by Daimler AG.
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3.35 Maintenance and repairs
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3.35 Maintenance and repairs
For vehicle deliveries in winter (gritted roads). To prevent surface damage, please clean the vehicle at the earliest opportunity.
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3.35 Maintenance and repairs
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3.35 Maintenance and repairs
If the battery voltage drops below 12.1 V, the battery is damaged and it will have to be replaced.
Leaving the vehicle parked up for long periods of time can lead to battery damage. This can be avoided by disconnecting the battery and storing it
appropriately.
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3.35 Maintenance and repairs
Further details are available from any Mercedes-Benz Service Centre or can be found in the Mercedes-Benz Workshop Information System.
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3.36 Storing and handling over the vehicle
Handing over
To prevent damage to the vehicle or to repair any existing damage, Mercedes-Benz recommends that the vehicle be subjected to a full function check
and a complete visual inspection before it is handed over.
When delivering chassis, the Mercedes-Benz requirements for the minimum axle loads must be observed, see Z Part B, section 2 “Technical
threshold values for planning”. Chassis which do not meet these requirements must not be delivered under their own poser.
Mercedes-Benz recommends that chassis without bodies be delivered by truck or train.
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4 Calculation
4.1 Trailer coupling
4 Calculation
4.1 Trailer coupling
Risk of accident
If trailer couplings are retrofitted, only use the makes and models and end cross members approved by Mercedes-Benz. The approval of a technical
inspectorate and an entry in the vehicle documents may be necessary.
To determine the size of the coupling, refer to the hole pattern in the end cross member.
The size of the trailer coupling is defined by the drawbar ratio, see section 4.2 “Connecting element” (Z page 144). The drawbar ratio is defined as the
theoretical comparative force for the force between tractor vehicle and implement/body. The data on drawbar load on the trailer coupling or in the
vehicle documents must be observed. In the Federal Republic of Germany, the jaw coupling must comply with DIN 74050 or EC Directive 94/20/EC.
When mounting, the following points must be observed:
• The distance from the centre of the trailer coupling pin to the end of the body may be a maximum of 420 mm. In exceptional cases the distance of
420 mm may be exceeded:
− Distance max. 650 mm for vehicles with tipper bodies or rear-mounted implements
− Distance max. 1350 mm if the clearance between the road surface and the bottom edge of the body is at least 1150 mm
• Trailer towing is only permissible if the trailer coupling is in its normal position and the clearance angles specified by the relevant road traffic
regulations are maintained:
− at least ±60° about the vertical axis
− at least ±20° about the transverse axis
− at least ±25° about the longitudinal axis
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4.1 Trailer coupling
• In exceptional cases, e.g. on tipper bodies, use a trailer coupling with joint in order to allow the coupling jaw to move vertically.
• Easy and safe operation of the coupling must not be impaired.
• The clearances around the coupling heads of the trailer brake system for trailer towing must not be obstructed.
Clearance dimensions
If one or more of the regulations concerning simple and safe operation cannot be complied with, a coupling with remote control must be used. The
remote control must fulfil the following requirements:
• Faultless operation.
• The control unit must be permanently secured to the vehicle and must not be removable.
• The mechanism must be easily accessible, simple, safe and impossible to mistake for another device.
• It must be possible to release the coupling reliably even with axial twist of at least +10°.
• When a trailer has been coupled up, it must be possible to see without hindrance, either directly or via a suitable display, whether the coupling pin is
engaged and secured.
The operating instructions must be supplied in the vehicle and they must refer to the special features and operation of the coupling.
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4.2 Connecting element
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4.3 Axle load calculation
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4 Calculation
4.4 Centre of gravity
Procedure:
• The vehicle must be parked horizontally on level ground for weighing.
• First weight the individual axle loads (front and rear axle loads) and then the gross vehicle weight.
• The measured values can be used to calculate the potion of the centre of gravity in the longitudinal direction.
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4.4 Centre of gravity
Gmi
GG Ghi z
Gvo
GVA GHA
Weights: Dimensions:
Gfr = Weight of front implement I1 = Distance from CoG of Gfr to front axle
Gce = Weight of centre implement I2 = Distance from CoG of Gce to front axle
Gre = Weight of rear implement I3 = Distance from CoG of Gre to front axle
Iv = Distance from overall CoG of unladen vehicle to front axle
I = Wheelbase
Gtot = Gross vehicle weight (unladen) Gtot = GFA (unladen) + GRA (unladen)
GFA = Front axle load GFA (unladen) = Front axle load of unladen vehicle (specified or weighed for the chassis concerned)
GRA = Rear axle load GRA (unladen) = Rear axle load of unladen vehicle (specified or weighed for the chassis concerned)
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4.4 Centre of gravity
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4.4 Centre of gravity
Daimler AG recommends the following procedure for determining the CoG height hs
• Check the tyre inflation pressure and correct if necessary.
• Determine the axle loads of the front axle GFA and rear axle GRA with the vehicle on a level surface.
• To eliminate the influences of spring compression during measurement, the vehicle springs must be locked, e.g. by removing the shock absorbers
and installing a suitable spacer.
• Lock the cab suspension.
• Top up all fluids (fuel tank, hydraulic tanks) to the maximum level or empty them completely (correct all fluid levels again after determining the
centre of gravity).
• Park the vehicle/implement combination in a horizontal and level position with one axle on the scales.
• Raise the other axle by at least 1/3 of the wheelbase.
• Weigh the axle load (QRA with the front axle raised, QFA with the rear axle raised). Then measure the exact height h‘ by which the vehicle was raised.
As an alternative to measuring the raised height, the angle α between the wheel hubs can be determined.
• With the measured values the height of the centre of gravity can be calculated according to equations VII to XI.
• Afterwards, continue to raise the axle (e.g. another 100 mm) and determine the CoG height again in order to confirm the result.
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4.4 Centre of gravity
α = arcsin( )
h' h'
where sin α = →
l l
⎛ l Q − GRA ⎞
hs = ⎜⎜ ⋅ RA ⋅ l ² − h'² ⎟⎟ + rstat Equation IX
⎝ h' Gtot ⎠
⎛ Q − GFA 1 ⎞
hs = ⎜ ´FA ⋅l ⋅ ⎟ + rstat Equation X
⎝ G tan α ⎠
h'
where sin α =
l
⎛ l Q − GFA ⎞
hs = ⎜⎜ ⋅ FA ⋅ l ² − h'² ⎟⎟ + rstat Equation XI
⎝ h' Gtot ⎠
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Example: Calculating the CoG position in the z-direction above the wheel centre on the U20
QFA = 4365 daN
Gtot = 8500 daN
GFA = 3900 daN
h‘ = 800 mm
rstat = 477 mm with tyres: 12.5 R 20 MPT
l = 2700 mm
Definition:
G = 1 daN = 10 N is the weight force corresponding to the mass m = 1 kg.
Practical determination of the height of the centre of gravity may only be carried out by experienced personnel using suitable lifting equipment.
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The position of the overall centre of gravity can then be calculated to a sufficient degree of accuracy:
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4.4 Centre of gravity
In order to simplify the calculation, we determine the CoG of the unladen vehicle, as described in section 4 “Calculation” (Z page 142) with the springs
compressed 3. We can thereby dispense with the subtraction of the spring deflection xspring in the above formula.
3
The vehicle is loaded to the permissible gross weight, the spring lock is installed and the vehicle unloaded again. This simulates the spring deflection of the fully
loaded state on an unladen vehicle.
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4.4 Centre of gravity
Risk of accident
With the tilt angle at the axle determined, the approximate CoG
height hs can be calculated from:
s
hs =
Pivot point 2 ⋅ tan α
The tilt angle at the frame/body is significantly greater than the angle α measured at the wheels/axles due to the one-sided compression of the
suspension.
A more accurate calculation of the static tilt angle can only be performed on a tilting lift platform.
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Example:
With tyres 335/80 R20 rstat = 482 mm
hs = ha + rstat
hs = 910 mm
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Equation XIV does not take account of either the static or the dynamic chassis and body tilt.
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4.4 Centre of gravity
s
μk = μk = minimum lateral friction coefficient for initiation of tilt
2⋅h
If the actual tyre/road friction coefficient μ is greater than μk, the vehicle will tend to tilt when near the critical limits. If μ is less than μk, the vehicle will
tend to slip when near the critical limits. The friction coefficient μ is dependent on tyres, road surface and speed, and can assume any value between
almost 0 and 1 under normal road conditions.
Example:
• Icy road μ ≈ 0.1
• New UNIMOG tyres on dry road μ ≈ 0.7
The following should always apply when planning a body: μk > 0.7
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The tilt speed when cornering can be calculated using the lateral friction coefficient k; tilting can only occur when
μ k
<μ
.
Practical determination of the tilt speed when cornering may only be carried out by an expert driver on an enclosed property.
We strongly advise that this test is only carried out if tilt protection devices are fitted to the vehicle!
4.4.8 Bodies with variable overall CoG position during implement operation
In the case of implements which move during operation and thereby cause the overall centre of gravity to change constantly, e.g. when pivoting a
hydraulic boom with mower head, the tests described in sections 4.4.8.1 “Static test” and 4.4.8.2 “Dynamic test” must also be carried out. A boom
mower is used as example to explain the test procedure. It can, however, be applied to all vehicle/implement combinations with comparable usage
profiles.
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Test conditions:
Set the boom mower to the maximum boom length, use the heaviest attachments and fully extend the sliding or telescopic sections. The implement
must be kept free floating above the ground.
If ballast is necessary (e.g. for front-mounted implements), the test must be conducted with the ballast weight. The smallest wheel load must be at least
10 % of the relevant axle load. The opposite wheel must stand firmly (> 400 kg) on the road so that one side of the vehicle cannot lift off the ground,
even on sloping roads (cf. Figure 4.5: Static test).
If the implement is transverse to the direction of travel, the sum of the wheel loads on the opposite side must not be less than ¼ of the relevant
gross vehicle weight.
These limit values must also be complied with if several implements are operated simultaneously. If combinations of implements are to be approved
(e.g. a verge mower in conjunction with a rear boom mower), the above wheel load limits must be met and compliance must be verified by weighing.
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4.4 Centre of gravity
Weight force
of boom
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4.4 Centre of gravity
Stability must also be tested by the sudden interception of the quickest possible lowering movement of the fully extended loaded boom:
• The wheel opposite the boom may lift no more that 20 mm off the ground.
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4.5 Clearance of implements/bodies with respect to the vehicle chassis
During the distortion test, care must be taken to ensure that the vehicle has a secure standing. Preferably, distortion or vehicle lifts should be used.
Alternatively, drive-on ramps may also be used. Where drive-on ramps are used, they have to be secured against slipping and tilting.
For safety reasons, achieving vehicle distortion with the aid of fork-lift trucks is not advisable.
On vehicle lifts, the tire contact patches should be wettened to help reduce (chassis) distortion, and the parking brake should be disengaged before
starting the distortion test. The vehicle must be secured with the aid of suitable means on the distortion/vehicle lift against any unintended rolling
(wheel chocks etc.).
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4.5 Clearance of implements/bodies with respect to the vehicle chassis
Figure 4.7: Distortion testing on vehicle lift, distortion of 500 mm introduced (front right and rear left)
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4.6 Field of vision
Blind spots caused by components (e.g. door posts, roof pillars, supporting structures and similar) are permitted only when the masking effects on the
semicircle of vision caused by them satisfy the following conditions:
• The masking effects must not exceed the values resulting from Figure 4.10 for the lower limit. The distance between the component obstructing
vision and the driver's eye is to be measured along the visual radius leading to the semicircle of vision, while the width is measured at the
intersection of the part with the visual radius.
• In the case of obstructing components more than 80 mm wide, there must be a minimum distance of 2.5 m – measured as a chord of the semicircle
of vision – between the centres of two masking effects.
• There may be no more than two masking effects inside the sector of vision defined in paragraph 3.
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4.6 Field of vision
• Wherever possible, no more than six masking effects should occur in the entire semicircle of vision.
• Masking effects arising from the values lying between the lower and upper boundary curve in Figure 4.9 are only permissible when they are caused
by structurally essential components which are unavoidable for reasons of strength. Such masking effects may only lie outside the sector of vision
and must be limited to one on each side.
The permissibility of the masking effect of individual vision-obstructing components can be determined as follows:
a
• A masking effect according to para. 4 no. 1 is only permissible when ≥ 22.4
b − 65
a
• A masking effect according to para. 4 no. 5 is only permissible when ≥ 10.6
b − 65
Where:
a = distance of the vision-obstructing component measured from the eye point in mm
b = width of the vision-obstructing component in mm
As a guideline a permissible masking effect of 600 mm (or 1200 mm) across the semicircle of vision has been defined for binocular vision (inter-
ocular distance 65 mm).
Overhanging vehicle parts or attachments mounted on the vehicle may only protrude into the field of vision from above as far as the point of origin.
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The implement/body manufacturer must verify and record compliance with these requirements. This can be done by the manufacturer
himself if appropriate facilities are available, otherwise by a technical inspectorate.
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4.6 Field of vision
3,0
Wid
Masking effect measured as chord of semicircle of vision
th o
f vis
[m]
ion-
2,5 obs
c ur i n
gp
art
from
[mm driv
] er ’ s
2,0 view
poin
t
1,5
Limit of permissible masking effect
outisde
sector of vision
1,0
inside
0,5
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4.6 Field of vision
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Daimler AG
Wörth Plant
Mercedes-Benz Special Trucks
D-76742 Wörth
Germany