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Unimog U500 Mounting Manuallines

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BODY & IMPLEMENT
MOUNTING GUIDELINES
N O R T H
A M E R I C A

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Summary of Contents for Unimog U500

  • Page 1 BODY & IMPLEMENT MOUNTING GUIDELINES N O R T H A M E R I C A...
  • Page 2 Table of Contents New standards and amendments issued by the National Highway Traffic This is the 2005 Body and Implement Mounting Guideline for the Unimog Safety Administration will appear in the Federal Registry from time to time. U500 North America.
  • Page 4 Body and Implement Mounting Guidelines U500 North America Table of Contents For your orientation: This is the fifth edition of the Unimog Body & Implement Mounting Guidelines and contains the following new subjects: • Chapter 6 Hydraulic system: o Front hydraulic connectors of power hydraulics, closed circuit (code H93) •...

  • Page 6: Table Of Contents

    Body and Implement Mounting Guidelines U500 North America Table of Contents Table of Contents Applications ..............29 Front mounted mowers..........29 General Information.............15 Rear mounted mowers ..........30 Introduction ..............15 Spreaders ..............31 Emission, Noise and Safety ...........17 Snow plows ..............32 Identification..............19...
  • Page 7 Secure mounting of implements / counterweights ..80 Vehicle drawings............59 4.11 Bodies with changing overall center of gravity....82 3.3.1 U500 NA, wheelbase: 131.89 in / 3,350 mm ....59 4.11.1 Static check ..............82 3.3.2 U500 NA, wheelbase: 153.54 in / 3,900 mm ....61 4.11.2...
  • Page 8 Body and Implement Mounting Guidelines U500 North America Table of Contents 4.15 Rear mounting of implements and bodies ....166 5.11.2 Angle of deflection/joint angle “β” of drive shafts ..190 Mechanical drive of implements.......168 5.11.3 Forces in the drive shaft system ........191 Notes on the transmission ratio ........168...
  • Page 9 W code descriptions ............235 10.2.1 Cross-section of the chassis frame......272 Preparation for the installation of roof-mounted ....10.2.2 Chassis frame of the U500, short wheelbase ....273 auxiliary headlights ............238 10.2.3 Chassis frame of the U500, long wheelbase ....274 7.10 Modification of the raised headlights code L47....239...
  • Page 10 Body and Implement Mounting Guidelines U500 North America Table of Contents 10.7 Drilling on the frame.............276 10.8 Bolted connections ............277 10.9 Welding on the frame...........278 10.9.1 General notes for welding on the frame.......278 10.9.2 Welding preparation.............279 10.9.3 Regulations for seam preparation........280 10.9.4...
  • Page 11 Body and Implement Mounting Guidelines U500 North America Table of Contents Page 14 of August 2005...

  • Page 12: General Information

    1.1 Introduction This Body and Implement Mounting Guideline covers the following vehicles Unimog U500 NA, wheelbase: 131.89 in / 3,350 mm Unimog U500 NA, wheelbase: 153.54 in / 3,900 mm Regulations such as those issued by the Federal Highway Ad-...
  • Page 13 Unimog. The development and review of implements or bodies parts and accessories, which have been explicitly approved by for the Unimog does not, in principle, entitle claims for costs or dam- Freightliner for use with your vehicle model. Such parts have been ages to be made against Freightliner LLC.

  • Page 14: Emission, Noise And Safety

    Braking Effect, if no alterations are made to the shift pattern dis- (FMVSS) and Canadian Motor Vehicle Safety Standards (CMVSS) for play(s). vehicles and how to apply to the sale of the Unimog U500 NA in the FMVSS 103 / CMVSS 103 U.S. and Canada.
  • Page 15 Body and Implement Mounting Guidelines U500 North America General Information FMVSS 113 / CMVSS 113 FMVSS 206 / CMVSS 206 This vehicle will conform to FMVSS / CMVSS No. 113, Hood Latch Sys- This vehicle will conform to FMVSS / CMVSS No. 206, Door...

  • Page 16: Identification

    E3 = 405.230 class 6 E4 = 405.230 class 7 1.3 Identification CS = Mercedes-Benz OM Engine The Unimog has the following identification characteristics for clear iden- Check digit tification: 4 = 2004,…, 9 = 2009 Model year •...

  • Page 17: Requirements For Implement Mounting And Operating

    The implement mounting instructions shall de- Warranty obligations are not assumed by Freightliner LLC if scribe the mounting of the implement on the Unimog. It should consider • Unimog-specific details explained by pictures or exploded drawings. The...

  • Page 18: Corrosion Protection Measures

    Body and Implement Mounting Guidelines U500 North America General Information • 1.8 Accident prevention The batteries must be checked for capacity and condition and must be serviced in accordance with the manufacturer's specifi- cations. The body and implement manufacturer is responsible for damage: •...

  • Page 19: Recycling - Re-Use Of Components

    Body and Implement Mounting Guidelines U500 North America General Information 1.9 Recycling – Re-use of components 1.10 Product liability The following principles for environmentally compatible design and se- The body manufacturer shall bear responsibility for: lection of materials shall be taken into consideration from the early stages of development of the implement or body onwards.

  • Page 20: Damage Prevention And Safety Regulations

    If the vehicle has to be delivered under its own power, the rear axle manufacture and fit brackets appropriate for the line or pipe rout- must be properly ballasted to the minimum rear axle load. U500 chassis ing on the chassis. The brackets must be attached to existing from the factory only achieve the minimum rear axle load with platforms holes in the chassis.

  • Page 21: Welding Operations

    Body and Implement Mounting Guidelines U500 North America General Information • Disconnect the positive and negative battery terminals and cover them (for protection). Plastic loops are required for mounting. The maximum distance between loops must not exceed 19.68 in / 500 mm. If no plastic lines are avail- •...

  • Page 22: Springs

    In order to avoid color variations on painted bodies, information regarding the primer coats and cover coats used in manufacturing may be requested by the Unimog Implement Manager listed at the beginning of this guideline. Figure 1.2: Plugs at the engine control unit Before painting, cover the following areas: •...

  • Page 23: Pushing And Towing

    Body and Implement Mounting Guidelines U500 North America General Information • For information about the installation of additional electrical components, see Section 7 Electrical system, page 221. Caution: Temperatures of 176°F / 80°C must not be ex- • ceeded for paint drying.

  • Page 24: Mobile Communication Systems

    1.11.11 Electromagnetic compatibility (EMC) The electric and electronic components of the UNIMOG are tested in the factory with regard to their electromagnetic compatibility in the vehicle. If additional implement or body components, which affect the electro-...
  • Page 25 Body and Implement Mounting Guidelines U500 North America General Information Page 28 of August 2005...

  • Page 26: Applications

    Body and Implement Mounting Guidelines U500 North America Applications 2 Applications 2.1 Front mounted mowers Overview of related sections: Front mounting plate Mounting: → Section 4.13, page 85 (code D12) → Section 5.9, page 176 Front PTO (code N08) Drive: →...

  • Page 27: Rear Mounted Mowers

    Body and Implement Mounting Guidelines U500 North America Applications 2.2 Rear mounted mowers Overview of related sections: → Section 4.14.2, page 96 On platform P27 / P40 or Mounting: On ballpoints P60 → Section 4.14.3, pg. 109 → Section 5.8, page 172...

  • Page 28: Spreaders

    Body and Implement Mounting Guidelines U500 North America Applications 2.3 Spreaders Overview of related sections: → Section 4.14.2, page 96 On platform P27 / P40 Mounting: → Section 4.14.3, page 109 On ballpoints P60 Directly on the chassis → Section 4.14.5, page 133 Hydraulic connector →...

  • Page 29: Snow Plows

    Body and Implement Mounting Guidelines U500 North America Applications 2.4 Snow plows Overview of related sections: Front mounting plate Mounting: → Section 4.13, page 85 (code D12) → Section 6.2, page 199 Basic hydraulic Drive: → Chapter 6, page 194 Snow plow load release Figure 2.6: Snow plow...

  • Page 30: Wing Plow

    Body and Implement Mounting Guidelines U500 North America Applications 2.5 Wing plow Overview of related sections: → Section 4.14.6.3, pg. 152 Proposal for a wing plow support Via sub frame directly on → Section 4.14.6, page 141 Mounting: the chassis (code D62) Front mounting plate →...

  • Page 31: Snow Cutters / Blowers

    Body and Implement Mounting Guidelines U500 North America Applications 2.6 Snow cutters / blowers Overview of related sections: Front mounting plate Mounting → Section 4.13, page 85 (code D12) → Section 5.9, page 176 Front PTO (code N08) Drive → Chapter 6, page 194...

  • Page 32: Suction Sweepers

    Body and Implement Mounting Guidelines U500 North America Applications 2.7 Suction sweepers Overview of related sections: Mounting: → Section 4.14.3, pg. 109 On ballpoints (code P60) → Section 6.3, page 211 Power hydraulic (code H63, closed circuit) Drive: Power hydraulic →...

  • Page 33: Front Mounted Sweepers

    Body and Implement Mounting Guidelines U500 North America Applications 2.8 Front mounted sweepers Overview of related sections: Front mounting plate Mounting: → Section 4.13, page 85 (code D12) → Section 5.9, page 176 Front PTO (code N08) Power hydraulic with →...

  • Page 34: Winches

    Body and Implement Mounting Guidelines U500 North America Applications 2.9 Winches Overview of related sections: Front mounting plate Mounting: → Section 4.13, page 85 (code D12) → Section 5.9, page 176 Front PTO (code N08) Drive: Basic hydraulic → Chapter 6, page 194 →...

  • Page 35: Aerial Devices (Man Lifts)

    Body and Implement Mounting Guidelines U500 North America Applications 2.10 Aerial devices (man lifts) Overview of related sections: Via sub frame directly on Mounting: → Section 4.14.6, page 141 the chassis (code D62) → Section 5.10, page 182 Gearbox- PTO (code N16)

  • Page 36: Cranes

    Body and Implement Mounting Guidelines U500 North America Applications 2.11 Cranes Overview of related sections: Via sub frame directly on → Section 4.14.6, page 141 the chassis (code D62) Mounting: Mounting of cranes on → Section 4.14.6.4, page 156 Unimog’s →...

  • Page 37: Drill Devices

    Body and Implement Mounting Guidelines U500 North America Applications 2.12 Drill devices Overview of related sections: Via sub frame directly on Mounting: → Section 4.14.6, page 141 the chassis (code D62) → Section 5.10, page 182 Gearbox- PTO (code N16)

  • Page 38: Front End Loaders

    Body and Implement Mounting Guidelines U500 North America Applications 2.13 Front end loaders Overview of related sections: → Section 4.13.3, pg. 89 Integrated implement support → Section 4.14.8.1, pg. 164 Code D60 (in combination with platform, code P60) or Mounting: →...

  • Page 39: Front Mounted Devices

    Body and Implement Mounting Guidelines U500 North America Applications 2.14 Front mounted devices Overview of related sections: → Section 4.13.2, pg. 85 Front mounting plate Mounting: (code D12) or Integrated implement support → Section 4.13.3, pg. 89 → Section 5.9, page 176...

  • Page 40: Sewer Cleaning Devices

    Body and Implement Mounting Guidelines U500 North America Applications 2.15 Sewer cleaning devices Overview of related sections: Front → Section 4.13, page 85 - front mounting plate D12 Center Mounting: → Section 4.14.2, page 96 - on platform P27 / P40 - on ballpoints P60 →...

  • Page 41: Water Tanks

    Body and Implement Mounting Guidelines U500 North America Applications 2.16 Water tanks Overview of related sections: → Section 4.14.2, page 96 On platform P27 / P40 Mounting: like Spreader mounting → Section 4.14.2.1, pg. 105 Drive: Not necessary Figure 2.18: Water tank...

  • Page 42: Front Mounted 3-Point Hitches

    Body and Implement Mounting Guidelines U500 North America Applications 2.17 Front mounted 3-point hitches Overview of related sections: → Section 4.13, page 85 Front mounting plate Mounting: (code D12) or Integrated implement support → Section 4.13.3, pg. 89 Drive: → Chapter 6, page 194...

  • Page 43: Rear Mounted 3-Point Hitches

    Body and Implement Mounting Guidelines U500 North America Applications 2.18 Rear mounted 3-point hitches Overview of related sections: < 1t: → Section 4.15, page 166 Implement mounting bracket rear (code D50) → Section 4.14.8.1, pg. 164 + undercarriage load → Section 4.14.8, pg. 160 bar under the rear axle 1t <...

  • Page 44: Fire Bodies

    Body and Implement Mounting Guidelines U500 North America Applications 2.19 Fire bodies Overview of related sections: → Section 4.14.3, page 109 On ballpoints P60 or Mounting: Directly on the chassis → Section 4.14.5, page 123 → Section 5.10, page 182 Gearbox- PTO code N19 or →...

  • Page 45: Refuse Collection Vehicles

    Body and Implement Mounting Guidelines U500 North America Applications 2.20 Refuse collection vehicles Overview of related sections: → Section 4.14.3, page 109 On ballpoints P60 or Mounting: Directly on the chassis → Section 4.14.5, page 123 → Section 5.8, page 172...

  • Page 46: Box Bodies

    Body and Implement Mounting Guidelines U500 North America Applications 2.21 Box bodies Overview of related sections: → Section 4.14.3, page 109 On ballpoints P60 or Mounting: Directly on the chassis → Section 4.14.5, page 123 → Section 5.8, page 172...

  • Page 47: Wood Chipper (Front Mounted)

    Body and Implement Mounting Guidelines U500 North America Applications 2.22 Wood chipper (front mounted) Overview of related sections: Front mounting plate Mounting: → Section 4.13, page 85 (code D12) → Section 5.9, page 176 Front PTO (code N08) Drive: → Chapter 6, page 194 Hydraulic Figure 2.24: Wood chipper...

  • Page 48: Concrete Mixers

    Body and Implement Mounting Guidelines U500 North America Applications 2.23 Concrete mixers Overview of related sections: → Section 4.14.3, page 109 On ballpoints P60 or Mounting: Directly on the chassis → Section 4.14.5, page 123 → Section 5.8, page 172...

  • Page 49: Diggers / Excavators

    Body and Implement Mounting Guidelines U500 North America Applications 2.24 Diggers / excavators Overview of related sections: Via sub frame directly on Mounting: → Section 4.14.6, page 141 the chassis (code D62) → Section 5.10, page 182 Gearbox- PTO (code N16)

  • Page 50: Skip Loader

    Body and Implement Mounting Guidelines U500 North America Applications 2.25 Skip loader Overview of related sections: → Section 4.14.3, page 109 On ballpoints P60 or Mounting: Directly on the chassis → Section 4.14.5, page 123 Hydraulic connector → Chapter 6, page 194...

  • Page 51: Rear Mounted Small Cranes

    Body and Implement Mounting Guidelines U500 North America Applications 2.26 Rear mounted small cranes Overview of related sections: < 3.5 mt: → Section 4.15, page 166 Implement mounting bracket rear (code D50) > 3,5 mt: Mounting: → Section 4.14.6, page 141...
  • Page 52 Body and Implement Mounting Guidelines U500 North America Applications August 2005 Page 55 of...

  • Page 53: Vehicle Information

    Body and Implement Mounting Guidelines U500 North America Vehicle Information 3 Vehicle Information Transmission Type BM: G 718.840 This body and implement guideline covers the following vehicles: All synchromesh MB 8-speed EPS-manual gearbox Unimog model / Wheelbase Output With integrated permanent front wheel drive (all wheel drive).
  • Page 54 Body and Implement Mounting Guidelines U500 North America Vehicle Information Electrical System Tires: Unimog Model: Unimog Model: Alternator 14 V, 145 A 445/70R24 XM47 405.210 405.230 Alternator with increased power (optional) 14 V, 270 A Angle of approach 29° 30°...

  • Page 55: Technical Data Of Implement Drives

    Body and Implement Mounting Guidelines U500 North America Vehicle Information 3.2.2 Hydraulic drives 3.2 Technical Data of implement drives Basic hydraulics Oil tank volume 11.89 gal / 45 l 3.2.1 Mechanical drives Oil issue quantity 2.64 gal / 10 l...

  • Page 56: Vehicle Drawings

    U500 NA, wheelbase: 131.89 in / 3,350 mm Note: Dimensions marked with a * vary by tires and/or vehicle (axle) loads. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 3.1: Side view of U500 NA, short wheelbase August 2005 Page 59 of...
  • Page 57 Vehicle Information Note: Dimensions marked with a * vary by tires and/or vehicle (axle) loads. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 3.2: Front view of U500 NA, short wheelbase Page 60 of August 2005...

  • Page 58: U500 Na, Wheelbase: 153.54 In / 3,900 Mm

    U500 NA, wheelbase: 153.54 in / 3,900 mm Note: Dimensions marked with a * vary by tires and/or vehicle (axle) loads. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 3.3: Side view of U500 NA, long wheelbase August 2005 Page 61 of...
  • Page 59 Vehicle Information Note: Dimensions marked with a * vary by tires and/or vehicle (axle) loads. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 3.4: Front view of U500 NA, long wheelbase Page 62 of August 2005...
  • Page 60 Body and Implement Mounting Guidelines U500 North America Vehicle Information August 2005 Page 63 of...

  • Page 61: Implement / Body Installation

    (left and right). Unimog Resource CD or may be requested from the Unimog Im- plement Manager listed at the beginning of this guideline. The inspection for free movement and sufficient clearance at the...

  • Page 62: Vehicle Modifications

    Modifications to soundproofing • Modifications to the engine The Unimog chassis is designed in such a way that all imple- ments and bodies can usually be mounted to the existing imple- • Modifications to the electrical system, including, for example ment mounting points without a modification to the chassis.

  • Page 63: Dimensions And Weight Specifications

    For detailed vehicle weights please use the Unimog weight calcula- tor. You can find this excel file on the available Unimog Resource CD or request it by the Unimog Implement Manager listed at the beginning of this guideline.

  • Page 64: Weight Distribution

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.5 Weight distribution 4.6 Suspension graph Unilateral (asymmetrical) weight distribution between wheel posi- tions must be avoided. To determine the distance between the upper edge frame level The difference in wheel loads may be a maximum of 10 % of the to the wheel center by different axle loads use the suspension existing axle load.
  • Page 65 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Part numbers of the springs: Front Axle Spring: A405 321 05 04 Rear Axle Spring: A405 324 03 04 Figure 4.5: Suspension graph with measurements in metric units...
  • Page 66 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Part numbers of the springs: Front Axle Spring: A405 321 05 04 Rear Axle Spring: A405 324 03 04 Figure 4.6: Suspension graph with measurements in imperial units...

  • Page 67: Coordinate Systems

    0.157 in / 4 mm above the lower edge of the longitudi- nal member See also detail drawing added in each vehicle drawing. Drawings of the U500 NA are available on the Unimog Resource CD or by the Un- Note: Dimensions are mostly CAD data and partially not imog Implement Manager listed at the beginning of this guideline.

  • Page 68: Center Of Gravity

    To calculate the c.o.g. use the calculation programs on the Unimog loads and gross vehicle weight in a (quasi) statically operation. Resource CD or the formulae on the following page.
  • Page 69 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Center of gravity distance from W to front axle Center of gravity distance from W to rear axle Center of gravity distance from W to rear axle Distance of the empty vehicle total weight c.o.g. to the front axle Distance of the empty vehicle total weight c.o.g.
  • Page 70 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Center of gravity coordinates in vertical – direction (center of gravity height) We recommended the following procedure to determinate the over- all height of the center of gravity: •...
  • Page 71 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Example: Calculation of the center of gravity height Code Tire stat 395/85 R20 XZL 21.34 in 542 mm 10,271 lbs 315/80 R22.5 XDN 19.88 in 505 mm 19,200 lbs 385/65 R22.5 XZY...
  • Page 72 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Calculation of the overall center of gravity simulated in the empty vehicle. Thereby the subtraction of the spring deflection travel x in the above mentioned equation is not appli- Spring To calculate the overall c.o.g., the positions of the center of gravity...

  • Page 73: Chassis Center Of Gravity

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.8.4 Permissible height of center of gravity Note: The actual tilting angle between the body and the The design of the implement or body must ensure that the overall...

  • Page 74: Anti-Roll Bars

    Freightliner Unimog Implement De- • approved wheels and tires with sufficient load-bearing capac- partment is necessary. In this case please contact the Unimog Im- ity are used plement Manager listed at the beginning of this guideline. The per- •...

  • Page 75: Cooling

    The cooling system (radiator, charge-air cooler, fan, hydrostatic or ble air intake restriction. If in doubt, contact the Unimog Im- electric driven fan, radiator grille, air ducts, coolant circuit, etc.) must plement Manager listed at the beginning of this guideline.

  • Page 76: Springs

    U500 manufactured by MULAG (937) 666-5006 Order Mog Implements ABS (anti-locking braking system) is fitted as standard on Unimog address: 171 Church Street, Suite 300 vehicles. No changes may be made to any part of the system.

  • Page 77: Secure Mounting Of Implements / Counterweights

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation We recommend the following: • Install maintenance flaps or removable rear walls • Observe the operating instructions, the driver’s manual and the maintenance manual Counterweight If, in exceptional cases, these requirements cannot be met, the im-...
  • Page 78 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Counterweight (max. 1.5 t) bolted front locking device Plate: 6x6in, thickness: Counterweight in the rear (150x150mm, thickness: 10mm) mounting brackets (Code D50), max. 1.5t (max. & min. axle loads must be considered).

  • Page 79: Bodies With Changing Overall Center Of Gravity

    The transport position of the implement / body must be specified unambiguously, e.g. Unimog with a snow cutter mounted to the front mounting plate and secured counterweight on the platform. Move- able implement parts must be secured so that they can’t move.

  • Page 80: Dynamic Check

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Example: Lateral boom mower, mounted on the ball points and fully extended to the right hand side as described previously. FAW: 12,200 lbs; RAW: 9,700 lbs; GVW: 21,900 lbs...

  • Page 81: Mounting Of Implements

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.12 Mounting of implements Center mounting Platform mounting see chapter 4.14.2 Ball points mounting see chapter 4.14.3 Direct mounted body see chapter 4.14.5 Mounting frame for implements with outriggers see chapter 4.14.6...

  • Page 82: Front Mounting Of Implements

    (code D50) to achieve the required rear axle load of at least 41% of the actual gross ve- hicle weight for the U500, see also Section 4.4, page 66. August 2005 Page 85 of...
  • Page 83 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions in [mm] and dimensions in brackets in [in] Figure 4.19: Front mounting plate (code D12, part-no. A 405 550 12 38) Page 86 of August 2005...
  • Page 84 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation For implement mounting to the front mounting plate, suitable Listing of the Schmidt mounting kit for implement mounting to the claws that are aligned with the pocket of the front mounting Unimog front mounting plate plate, should be used, see Figure 4.20.
  • Page 85 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation All dimensions are in [mm] ® Figure 4.21: Compatible claw for front mounting plate from SCHMIDT Page 88 of August 2005...

  • Page 86: Integrated Implement Support

    (optional mounting position of the front mounting plate) 4.13.3 Integrated implement support The Unimog front Standard to the Unimog is an integrated implement support in the mounting plate is fit- front part to which the front mounting plate is attached, for exam- ted to the lowest of ple.
  • Page 87 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions in [mm] and dimensions in brackets in [in] Figure 4.24: Integrated implement support Page 90 of August 2005...
  • Page 88 Table 4.9: Parts list for removing the front mounting plate For further information about removing the front mounting plate and retrofitting of the cross member please see the Unimog Service Bul- letin No. 31-2 or contact the Unimog Implement Manager listed at the beginning of this guideline.

  • Page 89: Permitted Implement Weights; Permitted Forces And ......... Torques On The Front Mounting Plate

    These dimensions are measured with the front mounting plate size 5 The maximum front implement weight on the Unimog U500NA is (code D12). Dimension ‘C’ depends on the tires fitted and on the ac- 4,409 lbs / 2,000 kg with a 39.37 in / 1 m distance from the cou-...

  • Page 90: Center Mounting Of Implements And Bodies

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14 Center mounting of implements and bodies The available vehicle wheelbases with platform and platform sub- frame and the different mounting parts are diagramed on the follow- General notes to center mounting ing two pages (Figure 4.34 and Figure 4.35).
  • Page 91 13.19 in / 335 mm around the center of the wheel. The part num- ber of the wheel nuts is A000 401 06 72. Disc wheels are fastened on all Unimog’s using thrust plate nuts only. The permissible thickness of wheel hub chassis supports fitted with the wheel hubs is shown in Figure 4.28 and Figure 4.29.
  • Page 92 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.31: Drawing of the wheel hub chassis support August 2005 Page 95 of...

  • Page 93: Bodies/Implements On The Platform

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.2 Bodies/implements on the platform Preparation of the vehicle for platform mounting of implements The body attachment on the platform must be designed by the For implements mounted to the floor of the body: body manufacturer in such a way that the dynamic stresses from •...
  • Page 94 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.34: Overview of the platform and subframe mounting parts at the U500 with a short wheelbase August 2005 Page 97 of...
  • Page 95 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.35: Overview of the platform and subframe mounting parts at the U500 with a long wheelbase Page 98 of August 2005...
  • Page 96 For detailed measurements of the platforms and the attachment points look at the drawings on the following pages (Figure 4.37 and Figure 4.38) and also in the vehicle drawings on the Unimog Re- source CD. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].
  • Page 97 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Holes for implement fastening Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.37: Platform P27 Page 100 of August 2005...
  • Page 98 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Holes for implement fastening Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.38: Platform P40 August 2005 Page 101 of...
  • Page 99 3,900 mm Table 4.12: Tipping cylinders for U500NA Note: If a Unimog with a long wheelbase shall be equipped with an implement mounting frame (e.g. for a crane) and a short platform (see Figure 4.36), the tipping cylinder for a short plat- form has to be used.
  • Page 100 Figure 4.44 or in the vehicle drawings on the Unimog Resource Figure 4.44: Positions of the tie down eyes on platform P40 The Unimog platforms have four holes (diameter 0.67 in / 17 mm) in the platform floor; see Figure 4.45 and Figure 4.46. These holes can be used for fastening heavy implements on the platform.
  • Page 101 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Holes for implement fastening Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].
  • Page 102 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.2.1 Spreaders on the platform Stipulated mounting method How to prevent the implement from sliding to the front General note: In case of a crash the spreader mounting...
  • Page 103 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation How to prevent lift-off and slipping of the implement (grit spreader) min. Ø ¾“ The front of the implement has to be fastened with approved and adequate straps or chains to avoid lift-off and slipping of the imple- ment.
  • Page 104 Alternatively, the implement may be bolted directly to the floor of the Figure 4.56: Rear end mounting with additional plate body. If you prefer this kind of mounting, please contact the Unimog Implement Manager for approval (submit an engineering drawing).
  • Page 105 Computer analysis of the height of the center of gravity on U500 gritter implements as well as experience from attempting to drive with loaded gritters have shown that the upper edge of the gritter must not be higher than the roof of the U500 cab under any circumstances (see the dia- gram below).

  • Page 106: Bodies/Implements On The Ball Points

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.3 Bodies/implements on the ball points Ballpoints and ball half shells (for positions and size see Figure 4.59, Figure 4.61 and Figure 4.62 or vehicle drawings on the Uni- mog Resource CD) are provided to mount the platform on the chassis.
  • Page 107 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.60: Overview of the available platform sub frames Page 110 of August 2005...
  • Page 108 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Platform sub frames dimensions Low platform subframe High platform subframe Part-No.: A405 610 04 03 Part-No.: A405 610 05 03 Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].
  • Page 109 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Low platform subframe High platform subframe Part-No.: A405 610 06 03 Part-No.: A405 610 07 03 Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].
  • Page 110 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.63: Ball half shell, Part-No.: A405 610 00 35 August 2005 Page 113 of...
  • Page 111 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.64: Ball half shell, Part-No.: A405 610 01 35 Page 114 of August 2005...
  • Page 112 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Two different ball half shells and locating bolts are available. Identi- cal ball half shells must be mounted diagonally to avoid body or im- plement damage (see Figure 4.66). Mounting the ball half shell in diagonal manner will keep the operator from inserting the pins in the wrong locations.
  • Page 113 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation The height of the implement / body frame above the platform sub- Position of the contact points frame longitudinal members must be designed in such a manner that of the polyamide plates four plastic plates can be fitted at the implement / body frame.
  • Page 114 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Reinforcement of the serial subframe code P60 for demount- able deposit skip on the ballpoints Figure 4.70: Implement / body fastening with additionally U-bolts Figure 4.69: Skip loader...
  • Page 115 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.71: Suggestion for reinforcing of the front fastening interface Page 118 of August 2005...
  • Page 116 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Low platform subframe and short wheelbase Low platform subframe and long wheelbase High platform subframe and short wheelbase High platform subframe and long wheelbase Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].
  • Page 117 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Bodies on ballpoints of subframe P60 for vehicles with tipping cylinder Vehicles with tilt able platforms and tipping cylinders (code H43) are equipped with a red tilt-warning lamp (code J48) in the instrument panel ex works.
  • Page 118 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.75: Position of the magnet for the tilt control sensor on the short wheelbase August 2005...
  • Page 119 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.76: Position of the magnet for the tilt control sensor on the long wheelbase Page 122 of...

  • Page 120: Dimensioning Of Implement Mounting Frames

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.4 Dimensioning of implement mounting frames • Mounting frames higher than 6.3 in / 160 mm: The implement / body manufacturer is responsible for the dimen- sions of the mounting frame. The longitudinal members of the...
  • Page 121 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.79: Possible profiles for mounting frames By use of closed or nested U - profiles, a smooth transition at the end of the closed profile will be necessary. Three different possibili- ties are shown in Figure 4.80 and Figure 4.81.
  • Page 122 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Suggestions for design of cross members: Cross members are to fit above the cross members of the chassis frame, additional cross members on the mounting frame may be necessary.
  • Page 123 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.84: Suggestion for a custom-manufactured low mounting frame Page 126 of August 2005...
  • Page 124 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.85: Suggestion for a custom-manufactured high mounting frame August 2005 Page 127 of...
  • Page 125 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Mounting frame with Mounting frame a rectangular tube with a C-profile Mounting Mounting frame frame Vehicle Vehicle frame frame Figure 4.86: Sketches with dimensions of the subframe-frame-combination for the following section modulus diagrams...
  • Page 126 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.87: Section modulus of the frame-subframe-combination for a mounting frame with C-profiles (U.S. units) August 2005 Page 129 of...
  • Page 127 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.88: Section modulus of the frame-subframe-combination for a mounting frame with C-profiles (metric units) Page 130 of August 2005...
  • Page 128 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.89: Section modulus of the frame-subframe-combination for a mounting frame with rectangular tubes (U.S. units) August 2005 Page 131 of...
  • Page 129 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.90: Section modulus of the frame-subframe-combination for a mounting frame with rectangular tubes (metric units) Page 132 of August 2005...

  • Page 130: Bodies/Implements Directly Mounted At The Chassis

    A405 611 01 11 (U500 short wheelbase), see pages 137 A405 611 03 11 (U500 long wheelbase), see page 138 Figure 4.91: Overview of fastening plates for directly mounting (this figure shows a U500 with long wheelbase) August 2005 Page 133 of...
  • Page 131 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.92: Tightening torques for mounting bodies/implements without outriggers directly to the chassis frame Page 134 of August 2005...
  • Page 132 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 1 x bolt M14x1.5x120, grade 10.9 MB-No. N 910105014022 20 x A 000 993 05 26 L= 1.35 in [34.2 mm] 2 x A 405 520 10 33 2 x A 387 619 00 97 1 x nut M14x1.5...
  • Page 133 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Implements like fire bodies, shelters, spreaders etc. can be • Suitable fastening material for attaching a mounting frame on mounted via a mounting frame directly on the chassis. Therefore...
  • Page 134 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation t=8mm Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.95: Fastening plate (only short wheelbase; Part-No.: A405 611 01 11) August 2005 Page 137 of...
  • Page 135 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation t=8mm Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.96: Fastening plate (only long wheelbase; Part-No.: A405 611 03 11) Page 138 of...
  • Page 136 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation t=10mm Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.97: Fastening plate (Part-No.: A405 611 00 11) August 2005 Page 139 of...
  • Page 137 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation For more details, see Figure 4.34 Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.98: Console (Part-No.: A405 520 10 33) Page 140 of...

  • Page 138: Bodies/Implements With Outriggers

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.6 Bodies/implements with outriggers All bodies and implements with outriggers or implements, which pass very high forces into the chassis, (e.g. cranes, aerial devices, drilling im- plements, etc.) require an implement-mounting sub frame. This sub frame must be fitted to the implement mounting points code D62 on the Un- imog frame (see the following figures and pages).
  • Page 139 The electrical interface is electronically monitored for malfunctions. The hydraulic control panel must be parameterized to prevent error messages in the electronics system of the Unimog (see the relevant service in- formation). Warning: All permanently mounted, heavy implements (e.g.
  • Page 140 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation A405 550 01 39 Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.101: Fastening plate code D70 (included in D62), Part-No.: A405 550 01 39 (left), A405 550 02 39 (right)
  • Page 141 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.6.2 Code D62: (Code D70 included) Proposal for an implement mounting support using D62: The heavy implement mounting supports (code D62, see Figure 4.104, page 147) fit to the serial hole pattern for implement brack- The implement mounting frame can be fastened using the heavy ets on the chassis frame.
  • Page 142 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation U500 NA; short wheelbase Mounting frame Fastening plate (Part-No. A405 611 00 11) Code D70 Code D62 Console U500 NA; long wheelbase Mounting frame Fastening plate (Part-No. A405 611 00 11)
  • Page 143 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.103: D60/D62 hole pattern in the vehicle frame Page 146 of August 2005...
  • Page 144 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.104: Heavy implement mounting support, code D62 (Part-No.: A405 552 04 18) August 2005 Page 147 of...
  • Page 145 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions with a * depends on the subframe height. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.105: Proposal for fastening of a mounting frame by use of heavy mounting brackets (code D62)
  • Page 146 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.106: Subframe tolerance when using code D62 August 2005 Page 149 of...
  • Page 147 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Platform mounting on custom subframes: If a platform is needed in combination with an implement subframe (e.g. crane) tubular cross members and ballpoints to mount the plat- form are required. Optional a loose platform (code P27) is available ex factory.
  • Page 148 The necessary ball points (part- no.: A405 991 01 20) can be ordered by any authorized Freightliner Unimog dealer. The ball points should be welded into a suitable tu- bular cross member (see Figure 4.109).
  • Page 149 Unilateral (asymmetrical) weight distribution between wheel posi- tions must be avoided (see Section 4.5, page 67). Figure 4.112: Example 1 for a wing plow on a Unimog The implement manufacturer is responsible for adequate de- signing; dimensioning and construction of a wing plow and a wing plow support on the Unimog! Figure 4.111: Suggestion for self-supporting frame with a wing plow-...
  • Page 150 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Detail sketches of wing plow-support suggestion: Figure 4.114: Mounting frame (side view) Figure 4.117: Vertical frame member (top view) Figure 4.115: Mounting frame (top view) Figure 4.118: Cross member (side view) Figure 4.116: Vertical frame member (side view)
  • Page 151 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.121: Mounting frame with cross member and vertical frame member (top view) Figure 4.122: Wing plow-support mounted via code D62 and D70 on the chassis frame (side view) Figure 4.119: Cross member (top view)
  • Page 152 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Figure 4.124: Side view of a Unimog with mounted wing plow-support Figure 4.126: Side view of a Unimog with platform and mounted wing plow-support Figure 4.125: Top view of a Unimog with mounted wing plow-support Figure 4.127: Top view of a Unimog with platform and mounted wing...
  • Page 153 The following key facts must be considered for mounting of cranes 4.14.6.4 Mounting of cranes on Unimog´s on Unimog´s: For the attachment of cranes on the Unimog it is necessary to install • GVW and maximum axle loads a sub frame above the Unimog chassis fame. Crane mounting, even •...
  • Page 154 SAE: 480 XLK or ASTM: A607 Grade 65 Possible outrigger principles The following outrigger principles are possible on the Unimog. The outriggers must always mount directly on the mounting frame or the crane. Outrigger fastening on the Unimog frame is not permitted.
  • Page 155 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Leveling jacks on the front mounting plate: Leveling jack on the front mounting plate Figure 4.133: Dual outriggers Figure 4.134: 4-point outriggers Figure 4.138: Leveling jack on the front mounting plate...
  • Page 156 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Suggestions for mounting frame dimensions The crane manufacturer is responsible for stability calculations. These are only suggestions. Assumptions for the calculations: • Crane mounted in center of the vehicle (crane pillar above vehicle longitudinal axis) •...

  • Page 157: Mounting Space Under The Cab

    Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.7 Mounting space under the cab 4.14.8 Implement mounting between the axles There is a square cross-sectional area with 2.17 in x 2.17 in (55 mm The implement mounting brackets (code D60 or D62) should be...
  • Page 158 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.141: Proposal for a implement mounting support on the rear stabilizer arm August 2005 Page 161 of...
  • Page 159 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.142: Counterpart of the implement mounting support on Figure 4.143: Proposal for fastening of an inter-axle implement...
  • Page 160 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Note: Bolts and nuts used to attach the rear axle to the chassis frame brackets may only be used once and have to be replaced before reassembly. Torque to: •...
  • Page 161 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation 4.14.8.1 Code D60: The implement mounting supports (code D60, see Figure 4.147, page 165) are available for the frame hole pattern shown in Figure 4.103, page 146. On vehicles with short wheelbase there are four D60 hole pattern and on the long wheelbase are six D60 hole pat- tern bored.
  • Page 162 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 4.147: Implement mounting support, code D60 (Part-No: A427 551 03 21) August 2005 Page 165 of...

  • Page 163: Rear Mounting Of Implements And Bodies

    Rear frame mounting supports (code D50) for implement mounting from the vehicle drawings on the Unimog Resource CD. are available for the Unimog. They are friction-locked installed with Implements or implement mounting frames can be quick-release fas- positive locking to the right and left in the longitudinal frame mem- ber.
  • Page 164 Body and Implement Mounting Guidelines U500 North America Implement / Body Installation August 2005 Page 167 of...

  • Page 165: Mechanical Drive Of Implements

    The following chapter contains important and detailed information Either option code N16 or N19 can be installed, not about the different power take-offs (PTO’s) of the Unimog. A tech- both. nical overview of the PTO’s is shown in Table 5.1, page 169.

  • Page 166: Overview Of Available Mechanical Pto's For Unimog

    Note: Shaft speed 500 - 1,000 rpm can be set using cruise control against unintentional actuation or improper use of all attach- Gearbox high speed power take-off (Code N16) ments connected to any of the PTO – facilities of the Unimog. Ratio i = 1...

  • Page 167: Overview And Positions Of Power Take-Offs

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.5 Overview and positions of power take-offs Figure 5.1: Overview of the available power take-offs Page 170 of 294 August 2005...

  • Page 168: Maximum Available Power Output Of The Pto's

    U500NA. The dimensions can be deter- control system. mined from the CAD chassis drawings on the Unimog Resource CD. In normal driving mode, only the idling speed and max. speed is controlled. With manual throttle setting applied and the auxiliary...

  • Page 169: Engine Dependent Power Take-Off (Code N05)

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements Important Notes: Freightliner Unimog Division approved 5.8 Engine dependent power take-off (code N05) the N05 auxiliary power take-off only for the drive of the power hydraulic system, The power hydraulic system (Code H63 and H64), available ex fac- as available from the factory.
  • Page 170 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements Figure 5.3: Drawing of the quick-interchangeable driveline (Part-no. A405 410 11 06) August 2005 Page 173 of...

  • Page 171: Vibration Absorber

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.8.2 Vibration absorber A vibration absorber (Part-No. A 906 250 00 01) has to be installed into the driveline if auxiliary power take-off N05 is used for applica- tions other than H63 or H64.
  • Page 172 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements Figure 5.7: Drawing of the vibration absorber (part-no. A906 250 00 01) August 2005 Page 175 of...

  • Page 173: Power Take-Off Shaft Drive (Code N08)

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.9 Power take-off shaft drive (code N08) 5.9.1 General notes The engine power take-off drive shaft is installed in front of the en- • The drive shaft joint angle must not exceed 15° (short periods gine.

  • Page 174: Usable Power Output Of The Power Take-Off Shaft

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements Power take-off shaft guards Example: Rotating shafts and other PTO – components, which could cause η accidents, must be equipped with protection devices. The guards − − ⋅...

  • Page 175: Technical Data Of Power Take-Off Shaft Drive N08

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.9.3 Technical data of power take-off shaft drive N08 5.9.4 Power take-off shaft profile (according to SAE J499a) Power take-off shaft (Code N08) Ratio i = 2.139 Speed at rated engine speed (2,200 rpm)

  • Page 176: Position Of Pto Shaft

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.9.5 Position of PTO shaft Note: Dimensions marked with a * vary by tires and/or vehicle (axle) loads. Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].

  • Page 177: Calculation Of The Pto Shaft Height Above Ground

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements ∆ − tire statFA statRA Formula 5.2: Calculation of the tire part ∆ − Formula 5.3: Calculation of the suspension part = Height of power take-off shaft above the road surface = Static tire radius;...
  • Page 178 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements Figure 5.12: Effect of suspension travel on dimension “h” August 2005 Page 181 of...

  • Page 179: Auxiliary Power Take-Off Drives (Code N16/N19)

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.10 Auxiliary power take-off drives (code N16/N19) 5.10.1 General notes on auxiliary PTO’s (code N16/N19) 5.10.2 Technical data on auxiliary PTO’s (code N16 / N19) Auxiliary power take-offs (N16 and N19) can only be engaged and High speed power take-off (Code N16) disengaged when the vehicle is stationary (electronic lock).
  • Page 180 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements Drawings of the N16 and N19 flanges N 16 - flange Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 5.13: Drawing of the N16 flange...
  • Page 181 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements N 19 - flange Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 5.14: Drawing of the N19 flange Page 184 of 294 August 2005...

  • Page 182: Hydraulic Pumps For N16 Auxiliary Power Take-Off

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.10.3 Hydraulic pumps for N16 auxiliary power take-off The implement / body manufacturer is responsible for select- ing and installing the components. The following hydraulic pumps can be driven via the N16 power take-off: •...
  • Page 183 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 1300 F1-41 1250 F1-61 1200 F1-81 1150 1100 1050 1000 Flow [gallons/minute] ® Figure 5.19: PARKER hydraulic pumps Page 186 of 294 August 2005...
  • Page 184 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements ® For further information to PARKER hydraulic pumps contact Pete Medins Sales Engineer Phone: +1-815-341-1509 Email: pmedins@parker.com ® or visit the PARKER website: www.parker.com Mass torque at N16 flange due to directly mounted hy-...

  • Page 185: Direct Flange Mounting On Auxiliary Pto N16

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.10.4 Direct flange mounting on auxiliary PTO N16 Direct flange mounting on the auxiliary power take-off N16 is possible. The maximum drive shaft angle must not exceed 6°.

  • Page 186: Drive Shafts For Implements

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.11 Drive shafts for implements Relevant vehicle safety components (e.g. brake, hydraulic and fuel lines) must be routed and protected in such a way that they cannot get damaged in the event of a drive shaft failure.

  • Page 187: Angle Of Deflection/Joint Angle "Β" Of Drive Shafts

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.11.2 Angle of deflection/joint angle “β” of drive shafts For continuous operation the angle of deflection β of the drive shafts must not exceed 15°. For short periods of time an angle β...

  • Page 188: Forces In The Drive Shaft System

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements β Three-dimensional deflection An infinite number of possible positions µ may be created by the combination of the β A three-dimensional vertical and horizontal angle of deflec- deflection is an in- β...

  • Page 189: Assembly Of The Drive Shaft

    Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements 5.11.4 Assembly of the drive shaft Optimization of synchronization • If the load is too high or too low All original (vehicle-side) drive shafts have been statically and •...
  • Page 190 Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements August 2005 Page 193 of...

  • Page 191: Hydraulic System

    6 Hydraulic system 6.1 Overview of codes and hydraulic circuits on the Unimog Dual circuit system (Code H06, H08) (continued) Up to four hydraulic circuits are available for the Unimog Application Implement actuation, constant flow U500NA: Maximum 8 sockets, sep. return Front connectors 6.1.1...

  • Page 192: Overview Of Available Hydraulic Equipment

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.1.2 Overview of available hydraulic equipment Code Designation Comment Simplest form of the UNIMOG hydraulic system, enables actuating Single circuit hydraulic system movements for an implement Enables the operation of two independent implements (actuating...
  • Page 193 Body and Implement Mounting Guidelines U500 North America Hydraulic system Code Designation Comment Power hydraulics, open circuit (circuit 4) Integrated in platform subframe, couplers above the battery box Additional pressure line for dual circuit hydraulic sys- For operation of a built-in continuous consumer, couplers above the tem, middle, inc.
  • Page 194 Body and Implement Mounting Guidelines U500 North America Hydraulic system Available hydraulic packages for the Unimog U500NA: H 02 Single pump hydraulic package Single circuit hydraulic system 2 valve hydraulic system Hydraulic connection, rear, 4 lines on valves 1 and 2...

  • Page 195: Hydraulic System

    Do not connect implements that are mounted at the front form subframe, has a cooling performance of approx. 15 kW and rear of the Unimog to the same valve cell (20 hp). If a higher cooling performance is required, the imple- ment must be equipped with an additional radiator.

  • Page 196: Basic Hydraulics

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.2 Basic hydraulics Sym- Symbol Sym- Symbol Circuit Cell Port Circuit Cell Port color color Coupler (female) ISO Coupler (female) ISO Yellow 16028 Size 12.5 (1/2”) 16028 Size 12.5 (1/2”)

  • Page 197: Information To The Basic Hydraulic System

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.2.1 Information to the basic hydraulic system 6.2.1.2 Hydraulic control unit Electrically controlled 4/3-way valves with neutral settings, two pressure settings and float setting are used for circuits 1 and 2.
  • Page 198 Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.2.1.4 Lowering function of circuit 1 Warning: Risk of injury and vehicle/implement damages! Hydraulic circuit 1, in conjunction with codes H02/H06/H08 has no braking or proportioning (code H08) function on the lowering function.
  • Page 199 Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.2.1.5 Basic hydraulic sketch Hydraulic tank (basic hydraulics) and hydrostatic fan drive Hydraulic cylinder, tipper body Hydraulic pump hydrostatic fan drive Oil filter Hydraulic oil cooler Cell 1 in circuit I, connector 1 and 2...
  • Page 200 6.2.1.6 Front basic hydraulic connections The following hydraulic connections of the basic hydraulic (cir- cuit 1 and 2) are on the front of the Unimog above the bumper (see Figure 6.4 and Figure 6.5). Figure 6.5: Front hydraulic connections (drive direction: right) Figure 6.4: Front hydraulic connections (drive direction: left)
  • Page 201 Body and Implement Mounting Guidelines U500 North America Hydraulic system Figure 6.6: Overview of hydraulic connections at the vehicle front Page 204 of 294 August 2005...
  • Page 202 The positions of these two center mounted connections can be seen in the following drawing or in the vehicle drawings on the Unimog Resource CD. Figure 6.8: H68 hydraulic connections Dimensions without brackets are in [mm].
  • Page 203 Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.2.1.8 Rear basic hydraulic connections There are 6 hydraulic connections available at the rear of the Unimog. Rear mounted implements can only be driven with circuit 1 and circuit 2. The following figures show the basic rear hydraulic connections at the left and right of the truck above the rear cross member of the chassis frame.

  • Page 204: Shut-Off Valve

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.2.2 Shut-off valve Figure 6.11: Shut-off valve The shut-off valve is located at the rear of the vehicle above the rear cross member on the left hand side of the vehicle in the direction of travel.
  • Page 205 Body and Implement Mounting Guidelines U500 North America Hydraulic system C i rcu i t I + II w i t h co mb i n a t i o n s 2 5 ,0 0 circuit I circuit II...
  • Page 206 Body and Implement Mounting Guidelines U500 North America Hydraulic system C i rcu i t I + II w i t h co m b i n a t i o n s 1 0 0 ,0 0 c irc uit I...

  • Page 207: Dealers For Hydraulic Couplings In The Usa

    Tema parts list for Unimog hydraulic connectors UNF – Inside thread ¾” – 16 IF7520PUUNF Suitable plugs for Unimog hydraulic circuit 1 (½”; ports 1 to 8) (Plug for separate return line) are listed in the following table: NPT – Inside thread ¾” – 14...

  • Page 208: Information To The Power Hydraulic Systems

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.3 Information to the power hydraulic systems 6.3.1 Power hydraulic flow rates A constant capacity is often necessary for the operation of a Symbol continuous consumer. This is why the Unimog has electrically...

  • Page 209: Drawings Of The Power Hydraulics

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.3.2 Drawings of the power hydraulics Hydraulic tank Pressure port circle III Hydraulic oil cooler circuit III Oil leakage pipe Oil filter for feeding pump Return line Valve Variable pump circuit III...
  • Page 210 Body and Implement Mounting Guidelines U500 North America Hydraulic system Hydraulic tank Pressure port circle IV Hydraulic oil cooler circuit IV Oil leakage pipe Oil filter circuit IV Return line Proportional valve Variable pump circuit IV Bypass Table 6.11: Power hydraulics circuit IV, code H64...

  • Page 211: Front Connectors Of The Power Hydraulic System

    There are 13 hydraulic connections available at the front of the integrated in the platform subframe. They are located on the Unimog. In addition to the basic hydraulic system (circuit 1 and left longitudinal subframe member above the battery box. The...

  • Page 212: Volume Flows Of The Power Hydraulic Systems

    Body and Implement Mounting Guidelines U500 North America Hydraulic system Important Note: The pressure-free leakage oil connec- tion of the power hydraulic system must not be used as a separate return line for implements connected to basic hydraulic system (circuit 1 and circuit 2).
  • Page 213 Body and Implement Mounting Guidelines U500 North America Hydraulic system C irc u it III + IV 3 5 ,0 0 c irc u it III c irc uit IV 3 0 ,0 0 2 5 ,0 0 2 0 ,0 0...
  • Page 214 Body and Implement Mounting Guidelines U500 North America Hydraulic system C irc u it III + IV 1 4 0 ,0 0 c irc u it III c irc u it IV 1 2 0 ,0 0 1 0 0 ,0 0...

  • Page 215: Parts List For Power Hydraulic System

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.3.6 Parts list for power hydraulic system Voswinkel HS 20 6.3.7 Dealer for power hydraulic couplings in the USA Hatec Hatec - Metric Hydraulic Components 10821 Train Ct. Houston, Texas 77041 Phone: 713.466.6678...

  • Page 216: Further Information On Unimog Hydraulic Systems

    Body and Implement Mounting Guidelines U500 North America Hydraulic system 6.4 Further information on Unimog hydraulic systems 6.4.1 Hydraulic output / standard values Corresponding formula in metric units: The installed output is generally calculated according to the fol- lowing formula: η...
  • Page 217 Body and Implement Mounting Guidelines U500 North America Hydraulic system Page 220 of 294 August 2005...

  • Page 218: Electrical System

    Body and Implement Mounting Guidelines U500 North America Electrical system 7 Electrical system Option Descriptions: codes: 12 V jump start terminals 7.1 General notes on the electrical system Preparation for CB / mobile telephone (12 V), incl. antenna The U500NA has a 12 V vehicle circuit voltage and a serial bat- Preparation for two-way radio (12 V), incl.
  • Page 219 Body and Implement Mounting Guidelines U500 North America Electrical system Since the Bulb Warning Indicator is not programmable the only Disconnect 1999A at cavity 15 and 1999B at cavity 12. The Bulb way to eliminate the indication is to disconnect the control mod- Warning System is now disconnected.

  • Page 220: Electric Cables

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.3 Electric cables • Do not change standard connections, e.g. ground con- Conductor cross sections nections. When determining cable cross-sections, the loss of voltage in • When changing the length of cables or installing further the conductors must be considered.

  • Page 221: Current Consumption - Auxiliary Consumers

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.4 Current consumption - auxiliary consumers The implement / body manufacturer may install additional electrical consumers ONLY if the following instructions are The following information may be used when installing electrical...
  • Page 222 Customer installed battery ground terminal point size. Connect to terminal 15 (ignition) at central connection location or 5. If higher loads are desired, please contact the Unimog switch. Should be fused! Implement Manager listed at the beginning of this guide- Relays line.

  • Page 223: Unimog Ground Points

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.5 Unimog ground points 7.6 Electrical interfaces Important Note: DO NOT ground the cab or chassis. The 7.6.1 Power outlet in the cab (E37) ground system is isolated as to prevent...

  • Page 224: Implement Socket At The Front Of The Vehicle

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.6.2 Implement socket at the front of the vehicle The vehicle can be ordered (code E45) with an optional imple- ment socket (EAS, 12 V, 7-pin) on the left hand side of the front bumper.

  • Page 225: Implement Socket On The Battery Box

    Body and Implement Mounting Guidelines U500 North America Electrical system Note: EPS is an abbreviation for electro-pneumatic gear 7.6.3 Implement socket on the battery box shifting. This implement socket is intended as electrical interface for im- plements and bodies. It is located at the right hand side of the battery box (at the left hand side of the vehicle).
  • Page 226 The plug is available with crimp connectors and also with Cartridge, screw: screwed connectors. In both cases the necessary plug (size 6) 66.12.16.40 HX.16.Sti.S can be ordered at AMP or at any authorized Freightliner Unimog Terminal, screw dealer. for pins 1 thru 6 AMP order address:...

  • Page 227: Rear Trailer Socket

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.6.4 Rear trailer socket The rear trailer socket and also the implement socket on the front bumper (code E45) comply with SAE J560. The rear trailer socket also can be used for the connection of imple- ments/bodies.

  • Page 228: Engine Remote Control

    Note: Since connecting pin 15 and pin 16 stops the engine, the implement socket should always be kept clean and the An engine remote control system is available for the Unimog. lid should be closed when ever no connector is attached.
  • Page 229 Body and Implement Mounting Guidelines U500 North America Electrical system Engine start Engine speed remote control Engine start is possible when the clutch pedal is depressed OR Operation codes W04 or W05 must be activated. With an open the transmission (EPS) is in neutral (idle).

  • Page 230: Examples For Designing An External Manual Control

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.7.2 Examples for designing an external manual control Figure 7.16: Suggestion for a variable engine speed limiting Figure 7.15: Suggestion for an engine speed remote control circuit circuit Note: Potentiometer R...
  • Page 231 Body and Implement Mounting Guidelines U500 North America Electrical system Circuit suggestion for a fixed speed of 1,200 rpm: Figure 7.17: Suggestion for an engine speed remote control unit 4000 Figure 7.19: Suggestion for an fixed engine speed of 1,200 rpm...

  • Page 232: Important Note For Engine Remote Controls

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.7.3 Important note for engine remote controls 7.8 W code descriptions All settings can be adjusted at authorized Freightliner Unimog dealers. Option codes W30 and W35 use the same electrical terminal (pin XT 1/18-10) at the transmission control unit (EPS).
  • Page 233 Body and Implement Mounting Guidelines U500 North America Electrical system Limitation of engine speed to 1,000 rpm when Variable engine speed limit via the implement transmission PTO (option code N16, N19) is ac- socket: tivated. Variable engine speed limit if a signal, which complies Engagement of transmission PTO will automatically with specifications (see 7.7 Engine remote control,...
  • Page 234 Body and Implement Mounting Guidelines U500 North America Electrical system Limitation of engine speed to 1,500 rpm when Limitation of engine speed to 2,000 rpm when transmission PTO (option code N16, N19) is acti- transmission PTO (option code N16, N19) is acti- vated.

  • Page 235: Preparation For The Installation Of Roof-Mounted

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.9 Preparation for the installation of roof-mounted auxiliary headlights Pin assignment: Pin: Description: On large front mounted implements, e.g. large snow plows with 12 V ground (terminal 31), right wind deflectors, the auxiliary driving lamp (code L47) may get Side marker lights (terminal 58), right covered by the implement in transport position.

  • Page 236: Modification Of The Raised Headlights Code L47

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.10 Modification of the raised headlights code L47 The speed signal (C3) is a pulse-gap modulated signal with a pulse of t = 2 ms * 8,000 per k (k = travel pulses per km), ampli- tude 8 V, I = 1 mA.

  • Page 237: Electromagnetic Compatibility

    Body and Implement Mounting Guidelines U500 North America Electrical system 7.12 Electromagnetic compatibility In the Unimog, the electric and electronic components have been checked in the factory with regard to their electromagnetic compatibility (EMC) in the vehicle. If additional implements or body components that affect the elec-...
  • Page 238 Body and Implement Mounting Guidelines U500 North America Electrical system August 2005 Page 241 of...

  • Page 239: Pneumatic Consumers

    79.25 gal / min / 300 l / min speed at 117.5 psi / 8.1 bar The Unimog is serially equipped with an air brake system. When Tire inflating valve at test con- attaching pneumatic consumers on the Unimog the following...

  • Page 240: Air Extraction

    Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers 8.3 Air extraction 8.3.2 Air extraction on vehicles with CTIS On vehicles with CTIS dried air can be extracted behind a pro- The locations on Figure 8.2 and Figure 8.3 called air extraction tection valve (part-no.: A005 429 55 44) at the ½...
  • Page 241 Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers Serial mounting parts on vehicles without CTIS: Connected to secondary supply reservoir Figure 8.4: Serial mounting parts on vehicles w/o CTIS Serial and additional mounting parts for pneumatic consumers on vehicles without CTIS:...
  • Page 242 Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers Serial mounting parts on vehicles with CTIS: Connected to secon- dary supply reservoir CTIS interface Figure 8.6: Serial mounting parts on vehicles with CTIS August 2005 Page 245 of...
  • Page 243 Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS: Connected to secon- dary supply reservoir CTIS Interface Interface for additional pneumatic consumers Figure 8.7: Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS...
  • Page 244 Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers Necessary parts for air extraction Quantity of parts on vehi- Quantity of parts on vehicles PARKER® Hannifin cles without CTIS with CTIS Part MB Part-No.: Part-No.: without with without with...
  • Page 245 Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers Page 248 of 294 August 2005...

  • Page 246: Cab

    Unexpected tipping The Unimog multi-layer cab is made with fiber composite. It is when the cab is not secured can cause injury. constructed around a steel pipe-supporting frame that is con- Keep other persons away from the unsecured nected to the chassis with vibration dampers.
  • Page 247 Body and Implement Mounting Guidelines U500 North America For bodies that project above the cab, free movement of the The free movement of the body must be guaranteed even in cab must be guaranteed. the event of maximum distortion of the chassis frame. Dis- tance “A”...

  • Page 248: Cable Passage Into The Cab

    Body and Implement Mounting Guidelines U500 North America 9.3 Cable passage into the cab There are two ways to facilitate cable passage into the cab: • Cable passage through the rear wall of the cab • Cable passage through the front wall of the cab In the rear wall and also in the front wall of the cab are holes for cable passages into the cab.

  • Page 249: Pass-Through Plug

    Body and Implement Mounting Guidelines U500 North America 9.3.3 Pass-through plug The rubber part shown in Figure 9.6 should be used to facili- tate cable passage into the cab. The cable passages at the front and rear wall of the cab are equipped with this pass- through plugs.
  • Page 250 Body and Implement Mounting Guidelines U500 North America Figure 9.8: Drawing of the pass-through plug August 2005 Page 253 of...
  • Page 251 Body and Implement Mounting Guidelines U500 North America Assembly instructions for cable passage Cut the plugs in accordance with the appropriate cable diame- ter. Option 1: Prepare the plug for the implement cable (i.e. before the plug / socket is fitted on the cable):...
  • Page 252 Body and Implement Mounting Guidelines U500 North America Option 2: Retrofitting of the pass-through plug If the pass-through plug needs to be attached to a cable at a later stage, e.g. if there is already a plug / socket on the cable, a cut can be made along the cable slits.
  • Page 253 Body and Implement Mounting Guidelines U500 North America Option 3: Use of the ex factory mounted pass-through Option 4: Use of a seal cap (part no.: A409 583 00 83): plug for several implements Alternatively, the seal cap (see Figure 9.16) with part no.

  • Page 254: Important Notes On Cable Passages Into The Cab

    Body and Implement Mounting Guidelines U500 North America 9.4 Mountings on the cab 9.3.4 Important notes on cable passages into the cab 9.4.1 Roof loads / roof bars Electrical connectors must be designed in such a way that Roof loads or the installation of roof bars are limited.
  • Page 255 Body and Implement Mounting Guidelines U500 North America The center of gravity of the roof-mounted device must be as close as possible at the laminated stands. A proposal for mounting of • Emergency lighting • Light bars • Light heads •...
  • Page 256 Body and Implement Mounting Guidelines U500 North America be ordered via the following part-no.: A381 811 04 96 at any authorized Unimog dealership. Figure 9.20: Dismounting of the interior light Figure 9.22: Mounting of the front support on the cab Dimensions without brackets are in [mm].
  • Page 257 Body and Implement Mounting Guidelines U500 North America By mounting of these front supports the following measure- The following sleeve should be used for fastening the roof- ments for fastening of roof-mounted devices will be achieved: mounted devices on the stands: Figure 9.25: Sleeve for beacon light stand (Part-No.: A405 821 0028)
  • Page 258 Body and Implement Mounting Guidelines U500 North America For electrical connection of roof-mounted devices the connec- tion of the beacon lights (12 V / 7.5 A) can be used. If greater electrical power is needed, the power outlet (12 V / 25 A) in the cab behind the driver seat combined with an external switch and a suitable fuse must be used.

  • Page 259: Aerial Mounting

    Body and Implement Mounting Guidelines U500 North America 9.5 Attaching of an implement control console in 9.4.2 Aerial mounting the cab A preliminary setup for CB / mobile telephone (code E53), two way radio (code E54) and radio aerial with speakers and con- Two different installation positions for the gearshift console are trol units are available as an option.
  • Page 260 Body and Implement Mounting Guidelines U500 North America Standard bolt holes are located under the floor mat for mount- Important Note: Pay attention to sufficient clearance be- ing implement control console supports. We recommend the tween the center console (switch panel) use of these for fitting of control consoles in the cab.
  • Page 261 Body and Implement Mounting Guidelines U500 North America These 3 holes are always acces- sible for mounting an implement control panel These 4 holes are only accessible on vehicles with VarioPilot (center mounted gearshift console) Figure 9.32: Accessibility of fastening points on the gearshift console...
  • Page 262 Body and Implement Mounting Guidelines U500 North America Control unit Floor panel Floor panel All thread insert M8 Usable thread length 16mm Figure 9.33: Position of the fastening points on the center console (All dimensions in millimeters!) August 2005 Page 265 of...
  • Page 263 Body and Implement Mounting Guidelines U500 North America Control unit Control unit mounting frame mounting frame Figure 9.36: Position of the frame for left mounting Figure 9.34: Position of the frame for center mounting (use with VarioPilot) Figure 9.37: 3D view of the frame for left mounting Figure 9.35: 3D view of the frame for center mounting (use with...
  • Page 264 Body and Implement Mounting Guidelines U500 North America Figure 9.38: 3D view of the frame for left mounting (All dimensions in millimeters!) August 2005 Page 267 of 294...
  • Page 265 Body and Implement Mounting Guidelines U500 North America Figure 9.39: 3D view of the frame for left mount (All dimensions in millimeters!) Page 268 of 294 August 2005...
  • Page 266 Body and Implement Mounting Guidelines U500 North America Figure 9.40: 3D view of the frame for left mount (All dimensions in millimeters!) August 2005 Page 269 of 294...
  • Page 267 Body and Implement Mounting Guidelines U500 North America Figure 9.41: 3D view of the frame for left mount (All dimensions in millimeters!) Page 270 of 294 August 2005...
  • Page 268 Body and Implement Mounting Guidelines U500 North America August 2005 Page 271 of 294...

  • Page 269: Chassis Frame Modifications

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10 Chassis frame modifications 10.2 Chassis frame dimensions 10.2.1 Cross-section of the chassis frame 10.1 Chassis frame data Maximum GVW: 33,000 lbs 15,000 kg Frame outline (inner dim.): 31.14 in 791 mm Frame width (outer dim.):...

  • Page 270: Chassis Frame Of The U500, Short Wheelbase

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10.2.2 Chassis frame of the U500, short wheelbase Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 10.2: Chassis frame of the U500, short wheelbase August 2005 Page 273 of 294...

  • Page 271: Chassis Frame Of The U500, Long Wheelbase

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10.2.3 Chassis frame of the U500, long wheelbase Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 10.3: Chassis frame of the U500, long wheelbase Page 274 of 294 August 2005...

  • Page 272: Chassis Frame Material

    In case of frame extensions the quality and dimensions of the extension material must be equivalent to the standard chassis The chassis frame of the Unimog must always be equipped frame. The chassis frame material is E460 TM or E500 TM on with a rear cross member, even in non-trailer use.

  • Page 273: Drilling On The Frame

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10.7 Drilling on the frame The chassis frame may be drilled in special cases. The spac- ing dimension “a” (see Figure 10.5) must not be less than 2.44 in / 62 mm. The drillings must be spaced at intervals of less than 1.97 in / 50 mm.

  • Page 274: Bolted Connections

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10.8 Bolted connections Bolts and nuts that are mounted on the Unimog and the Uni- mog frame may only be replaced by bolts with the same di- ameter, the same grade and the same thread pitch.

  • Page 275: Welding On The Frame

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10.9 Welding on the frame 10.9.1 General notes for welding on the frame Only trained personnel may carry out welding operations on the frame. Prior to welding, the frame must be in its normal position and free of pre-tension due to external forces.

  • Page 276: Welding Preparation

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications Further measures: 10.9.2 Welding preparation • It is recommended that a double-V seam (see Figure 10.11) Only use well-dried out electrodes with lime-based be used on the upper and lower flange of the frame. The use coating with an electrode diameter of 1/8 in or 5/32 in.

  • Page 277: Regulations For Seam Preparation

    Transmission mounting supports • Profile modifications and cross members Every Unimog frame must be fitted with an end cross member also in the case of frame extensions and without use of trailer hitch. Note: Axle loads and gross vehicle weight decreases in Figure 10.12: Welding procedure...

  • Page 278: Design Instructions For Extending The Frame

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications 10.10.1 Design instructions for extending the frame In principle, there are two possible methods of welding. Weld- The following shows examples of web plates and frame rein- ing can be carried out forcement plates.
  • Page 279 Body and Implement Mounting Guidelines U500 North America Chassis frame modifications Dimensions without brackets are in [mm]. Dimensions in brackets are in [in]. Figure 10.15: Reinforcement plates Page 282 of 294 August 2005...

  • Page 280: Shortening Of The Frame

    Body and Implement Mounting Guidelines U500 North America Chassis frame modifications Frame extension without reinforcement plates 10.11 Shortening of the frame In the case of direct welding, the cut must be diagonal. The cut On shortening the end of the frame, the end transverse member must correspond to Figure 10.16 whereby the cutting angle must...
  • Page 281 Body and Implement Mounting Guidelines U500 North America Chassis frame modifications Page 284 of 294 August 2005...

  • Page 282: Appendix

    Body and Implement Mounting Guidelines U500 North America Appendix 11 Appendix To convert Name Multiply by from Pressure lbf/in 6894.757 11.1 Conversion Table Pressure lbf/ft 47.88026 Pressure 100,000 Pressure lbf/in 0.0689475 Pressure lbf/in 1.4504E-04 Pressure lbf/ft 0.0208854 Name To convert...

  • Page 283: List Of Abbreviations

    Body and Implement Mounting Guidelines U500 North America Appendix 11.2 List of Abbreviations 11.3 Table of Figures Defined abbreviations often used in drawings in this guideline: Figure 1.1: Unimog U500 North America ..........15 Front edge Rear edge Figure 1.2: Plugs at the engine control unit......... 25 Lower edge Figure 2.1: Front mounted mower ............
  • Page 284 Figure 4.20: Schmidt claw size 5 ............87 Figure 2.29: Sketch of a rear mounted crane < 3.5 mt......54 Figure 4.21: Compatible claw for front mounting plate from Figure 3.1: Side view of U500 NA, short wheelbase ......59 ® SCHMIDT ..................88...
  • Page 285 Body and Implement Mounting Guidelines U500 North America Appendix Figure 4.36: Overview of available platforms........99 Figure 4.63: Ball half shell, Part-No.: A405 610 00 35 ...... 113 Figure 4.37: Platform P27..............100 Figure 4.64: Ball half shell, Part-No.: A405 610 01 35 ...... 114 Figure 4.38: Platform P40..............101...
  • Page 286 Figure 4.91: Overview of fastening plates for directly mounting (this figure shows a U500 with long wheelbase)........ 133 Figure 4.112: Example 1 for a wing plow on a Unimog .....152 Figure 4.92: Tightening torques for mounting bodies/implements Figure 4.113: Example 2 for a wing plow on a Unimog .....152 without outriggers directly to the chassis frame ......
  • Page 287 Figure 4.147: Implement mounting support, code D60 (Part-No: ....................155 A427 551 03 21)................. 165 Figure 4.126: Side view of a Unimog with platform and mounted wing Figure 4.148: Drawing of the rear mounting bracket (code D50) ..166 plow-support ................155 Figure 5.1: Overview of the available power take-offs ......
  • Page 288 Body and Implement Mounting Guidelines U500 North America Appendix Figure 5.21: Directly mounted flange drive on auxiliary PTO N16 ..188 Figure 6.19: Hose laying of the H94 lines above the battery box ..215 Figure 5.22: Sketch of the connecting flange ........188 Figure 6.20: Flow rates of hydraulic circuits III + IV in [gal/min]..216...
  • Page 289 Body and Implement Mounting Guidelines U500 North America Appendix Figure 8.1: Location of the compressed air system ......242 Figure 9.19: Proposal for a front support........... 258 Figure 8.2: Vehicle without CTIS (back view) ........243 Figure 9.20: Dismounting of the interior light........259 Figure 8.3: Air extraction interface on vehicle with CTIS ....243...

  • Page 290: Table Of Tables

    Figure 10.1: Chassis frame cross-section ......... 272 Table 1.1: Unimog VIN Coding ............19 Figure 10.2: Chassis frame of the U500, short wheelbase ....273 Table 1.2: Minimum bending radii of plastic lines ........24 Figure 10.3: Chassis frame of the U500, long wheelbase....274 Table 3.1: Vehicle and model designations .........56...
  • Page 291 Table 6.5: Hydraulic pumps of circuit 1 and 2........200 Table 6.6: Dealers for hydraulic couplings.........210 Table 6.7: Tema parts list for Unimog hydraulic sockets circuit 1..210 Table 6.8: Tema parts list for Unimog hydraulic circuit 2....210 Table 6.9 UNIMOG power hydraulic connections......211 Table 6.10: Power hydraulics circuit III, code H63......212...
  • Page 292 FLC/MOG-B-013(9/04PI). Specifications are subject to change without notice. Unimog is registered to ISO 9001. Copyright 2004, Freightliner LLC. All rights reserved. Unimog North America is a member of the Freightliner Group. Freightliner is a DaimlerChrysler Company.

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