Unimog Body and Implement Mounting Guidelines

BODY & IMPLEMENT
MOUNTING GUIDELINES
N O R T H A M E R I C A
Body and Implement Mounting Guidelines U500 North America
This is the 2005 Body and Implement Mounting Guideline for the Unimog New standards and amendments issued by the National Highway Traffic
U500 North America. Safety Administration will appear in the Federal Registry from time to time.
You may obtain the Federal Register through the Superintendent of Docu-
Request additional copies through your local dealer or via email:
ments, U.S. Government Printing Office, Washington, D.C. 20502
Unimoginfo@Freightliner.com (www.access.gpo.gov).
Similarly, changes in the Canadian Motor Vehicle Safety Standards are
published in the Canada Gazette (http://canadagazette.gc.ca/index-e.html).
The specifications and descriptions contained in this guide are believed to
be accurate at the time of publication. In a continuing effort toward product The final stage manufacturer is solely responsible for the final certification
improvement, changes affecting this data may be made without notice. of the vehicle and for compliance with Emission Control Standards and Mo-
tor Vehicle Safety Standards. The following recommendations are furnished
for the final stage manufacturer’s information and guidance.
Important Information Freightliner LLC neither approves nor disapproves and does not warrant
This document is provided as an aid to intermediate and final stage manu- vehicle component or chassis modifications or equipment installations ar-
facturers in determining conformity to applicable U.S. and California Emis- ranged by dealers or customers and performed by entities other than
sion Control standards, and U.S./Canadian Motor Vehicle Safety Standards Freightliner LLC, since Freightliner LLC has no control over the work being
and other applicable standards. This document is not a substitute for performed by the various vehicle body equipment builders.
knowledge of the requirements of these standards. Final stage manufactur- If dealers or customers have any vehicle modifications or equipment instal-
ers should maintain familiarity with all current Emissions Control and lations performed, to the extent these modifications or equipment installa-
U.S./Canadian Motor Vehicle Safety Standards and be aware of their spe- tions adversely affect other vehicle components or vehicle performance,
cific responsibility in regard to each standard. Freightliner LLC's shall not accept any product liability or claims under
The U.S. and Canadian Governments have established Motor Vehicle terms of the vehicle warranty. These claims become the sole responsibility
Safety Standards for various categories of motor vehicles and motor vehicle of the person performing the modifications or equipment installations.
equipment under the provisions of the National Traffic and Motor Vehicle If additional technical information or explanation concerning the contents of
Safety Act (United States) and the Canadian Motor Vehicle Safety Act this vocational reference guide is required, contact the Unimog Implement
(Canada). The Acts impose important legal responsibilities on manufactur- Manager:
ers, dealers, body builders, and others engaged in the manufacturing and
marketing of motor vehicles and motor vehicle equipment. Unimog North America, Phone: 1-877-701-3000
Unimoginfo@Freightliner.com
Questions dealing with the specific application of these Acts or the stan-
dards to your business should be discussed with your legal counsel. This is (c) 2005 Freightliner LLC
particularly so because the standards and other requirements or interpreta-
All rights reserved. Reproduction or translation in whole or in part is not
tions are subject to change by government agencies in charge, the National
permitted without written authorization from the publisher.
Highway Traffic Safety Administration (United States) (www.nhtsa.dot.gov)
or Transport Canada (www.tc.gc.ca). Fourth edition: January, 2005
Body and Implement Mounting Guidelines U500 North America Table of Contents
Table of Contents 2 Applications ................................................................. 25

2.1 Front mounted mowers.................................................. 25
1 General Information.....................................................11
2.2 Rear mounted mowers .................................................. 26
1.1 Introduction ....................................................................11
2.3 Spreaders ...................................................................... 27
1.2 Emission, Noise and Safety ...........................................13
2.4 Snow plows ................................................................... 28
1.3 Identification...................................................................15
2.5 Wing plow ...................................................................... 29
1.4 Requirements for implement mounting and operating
instructions.....................................................................16 2.6 Snow cutters / blowers .................................................. 30
1.5 Warranty rights ..............................................................16 2.7 Suction sweepers .......................................................... 31
1.6 Maintenance instructions ...............................................16 2.8 Front mounted sweepers ............................................... 32
1.7 Corrosion protection measures......................................17 2.9 Winches......................................................................... 33
1.8 Accident prevention .......................................................17 2.10 Aerial devices (man lifts) ............................................... 34
1.9 Recycling – Re-use of components ...............................18 2.11 Big cranes...................................................................... 35
1.10 Product liability...............................................................18 2.12 Drill devices ................................................................... 36
1.11 Damage prevention and safety regulations ...................19 2.13 Front end loaders .......................................................... 37
1.11.1 General notes ................................................................19 2.14 Front mounted devices .................................................. 38
1.11.2 Delivery of chassis.........................................................19 2.15 Sewer cleaning devices ................................................. 39
1.11.3 Prevention of accidents on the vehicle ..........................19 2.16 Water tanks ................................................................... 40
1.11.4 Plastic compressed-air, fuel and brake lines .................19 2.17 Front mounted 3-point hitches ....................................... 41
1.11.5 Welding operations ........................................................20 2.18 Rear mounted 3-point hitches ....................................... 42
1.11.6 Springs...........................................................................21 2.19 Fire bodies..................................................................... 43
1.11.7 Painting procedures .......................................................21 2.20 Refuse collection vehicles ............................................. 44
1.11.8 Pushing and towing .......................................................21 2.21 Box bodies ..................................................................... 45
1.11.9 Electrical system ............................................................21 2.22 Wood chipper (front mounted) ....................................... 46
1.11.10 Mobile communication systems .................................22 2.23 Concrete mixers ............................................................ 47
1.11.11 Electromagnetic compatibility (EMC) .........................22 2.24 Digger ............................................................................ 48
1.11.12 Implement drives ........................................................23 2.25 Skip loader..................................................................... 49
Page 6 of 286 January 2005

2.26 Rear mounted small cranes ...........................................50 4.9.3 Engine air intake............................................................ 74
3 Vehicle Information .....................................................52 4.9.4 Exhaust system ............................................................. 74
3.1 General Technical Data .................................................52 4.9.5 Springs .......................................................................... 75
3.2 Technical Data for implement drives .............................54 4.9.6 Brake system................................................................. 75
3.2.1 Mechanical drives ..........................................................54 4.9.7 Maintenance and repair................................................. 75
3.2.2 Hydraulic drives .............................................................54 4.10 Secure mounting of the implement / counterweight on the
vehicle ........................................................................... 76
3.3 Vehicle drawings............................................................55
4.11 Bodies with changing overall center of gravity .............. 78
3.3.1 U500 NA, wheelbase: 131.89 in / 3,350 mm .................55
4.11.1 Static check ................................................................... 78
3.3.2 U500 NA, wheelbase: 153.54 in / 3,900 mm .................57
4.11.2 Dynamic check .............................................................. 79
4 Implement / Body Installation .....................................60
4.12 Mounting of implements ................................................ 80
4.1 General Notes................................................................60
4.13 Front mounting of implements ....................................... 81
4.2 Free movement of implements/bodies on the chassis...60
4.13.1 General notes to front mounting .................................... 81
4.3 Vehicle modifications .....................................................61
4.13.2 Front mounting plate...................................................... 81
4.4 Dimensions and weight specifications ...........................62
4.13.3 Integrated implement support........................................ 85
4.5 Weight distribution .........................................................63
4.13.4 Permitted implement weights; permitted forces and .........
4.6 Suspension graph..........................................................63
torques on the front mounting plate............................... 88
4.7 Coordinate systems .......................................................66
4.13.5 Front end dimensions .................................................... 88
4.8 Center of gravity ............................................................67
4.14 Center mounting of implements and bodies .................. 89
4.8.1 General information .......................................................67
4.14.1 Bodies/implements with variable overall c.o.g. .............. 89
4.8.2 Determination of the center of gravity ............................67
4.14.2 Bodies/implements on the platform ............................... 92
4.8.3 Chassis center of gravity ...............................................72
4.14.3 Bodies/implements on the Ball points.......................... 105
4.8.4 Permissible height of center of gravity ...........................72
4.14.4 Dimensioning of implement mounting frames ............. 119
4.8.5 Anti-roll bars...................................................................73
4.14.5 Bodies/implements directly mounted at the chassis .........
4.9 General notes on vehicle components ..........................73 frame without outriggers (e.g. shelters, fire bodies,.. ). 129
4.9.1 Tires...............................................................................73 4.14.6 Bodies/implements with outriggers .............................. 137
4.9.2 Cooling...........................................................................74 4.14.7 Mounting space under the cab .................................... 156
January 2005 Page 7 of 286

4.14.8 Implement mounting between the axles ......................156 5.11.1 General information on drive shafts............................. 184
4.15 Rear mounting of implements and bodies (Code D50) 162 5.11.2 Angle of deflection/joint angle “β” of drive shafts ......... 185
5 Mechanical drive of implements...............................164 5.11.3 Forces in the drive shaft system .................................. 186
5.1 Notes on the transmission ratio ...................................164 5.11.4 Assembly of the drive shaft ......................................... 187
5.2 General notes on mechanical implement drives ..........164 5.11.5 Bearing ........................................................................ 187
5.3 Overview of available mechanical PTO’s for Unimog: .165 5.11.6 Unbalance ................................................................... 187
5.4 Safety instructions for mechanical implement drives ...165 5.11.7 Maintenance ................................................................ 187
5.5 Overview and positions of the power take-offs ............166 6 Hydraulic system ....................................................... 189
5.6 Maximum available power output at the PTO’s ...........167 6.1 Overview of codes and hydraulic circuits on the Unimog189
5.7 Engine controls and speed settings .............................167 6.1.1 Hydraulic drives ........................................................... 189
5.8 Engine dependent power take-off (code N05) .............168 6.1.2 Overview of available hydraulic equipment ................. 190
5.8.1 Technical data for N05 auxiliary power take-off...........168 6.1.3 General instructions for the use of the Unimog ................
5.8.2 Vibration absorber .......................................................169 hydraulic system .......................................................... 193
5.9 Power take-off shaft drive (code N08) .........................171 6.1.4 Oil heating ................................................................... 193
5.9.1 General ........................................................................171 6.2 Basic hydraulics........................................................... 194
5.9.2 Usable power output of the power take-off shaft .........172 6.2.1 Information on the basic hydraulic system................... 195
5.9.3 Technical data of power take-off shaft drive N08.........173 6.2.2 Information to the basic hydraulic systems.................. 198
5.9.4 Power take-off shaft profile (according to SAE J499a) 173 6.2.3 Shut-off valve............................................................... 202
5.9.5 Position of PTO shaft ...................................................174 6.2.4 Volume flows of the Unimog basic hydraulic systems . 202
5.9.6 Calculation of the PTO shaft height above ground ......175 6.2.5 Dealer for hydraulic couplings in the USA ................... 205
5.10 Auxiliary power take-off drives (code N16/N19) ..........177 6.2.6 Tema parts list for Unimog hydraulic connectors......... 205
5.10.1 General notes on auxiliary PTO’s (code N16/N19)......177 6.3 Information to the power hydraulic systems ................ 206
5.10.2 Technical data on auxiliary PTO’s (code N16 / N19) ...177 6.3.1 Power hydraulic flow rates........................................... 206
5.10.3 Hydraulic pumps for N16 auxiliary power take-off .......180 6.3.2 Drawings of the power hydraulics................................ 207
5.10.4 Direct flange mounting on auxiliary PTO N16..............183 6.3.3 Front power hydraulic connections, code H94............. 209
5.11 Drive shafts for implements .........................................184 6.3.4 Center power hydraulic connections............................ 209
6.3.5 Volume flows of the Unimog power hydraulic systems 210

6.3.6 Parts list for power hydraulic system ...........................213 8.2 Technical data of the compressed air system ............. 234
6.3.7 Dealer for power hydraulic couplings in the USA.........213 8.3 Air extraction................................................................ 235
6.4 Further information on Unimog hydraulic systems.......214 8.3.1 Air extraction on vehicles with CTIS ............................ 235
6.4.1 Hydraulic output / standard values ..............................214 9 Cab.............................................................................. 241
7 Electrical system .......................................................216 9.1 General notes .............................................................. 241
7.1 General notes on the electrical system........................216 9.2 Tilting the cab .............................................................. 241
7.1.1 Technical data of the electrical system ........................216 9.3 Cable passage into the cab ......................................... 243
7.1.2 Lighting ........................................................................216 9.3.1 Cable passage through the rear wall of the cab .......... 243
7.2 Electric cables..............................................................217 9.3.2 Cable passage through the front wall of the cab ......... 243
7.3 Current consumption - auxiliary consumers.................218 9.3.3 Pass-through plug ....................................................... 244
7.4 Electrical interfaces......................................................218 9.3.4 Important notes on cable passages into the cab ......... 249
7.4.1 Power outlet in the cab (E37) ......................................218 9.4 Mountings on the cab .................................................. 249
7.4.2 Implement socket at the front of the vehicle ................219 9.4.1 Roof loads / roof bars .................................................. 249
7.4.3 Implement socket on the battery box ...........................220 9.4.2 Aerial mounting............................................................ 254
7.4.4 Rear trailer socket........................................................222 9.5 Attaching of an implement control console in the cab . 254
7.5 Engine remote control..................................................223 10 Chassis frame modifications.................................... 263
7.5.1 Remote control functions .............................................223 10.1 Chassis frame data...................................................... 263
7.5.2 Examples for designing an external manual control ....225 10.2 Chassis frame dimensions .......................................... 263
7.5.3 Important note for engine remote controls ...................227 10.2.1 Cross-section of the chassis frame ............................. 263
7.6 W code descriptions ....................................................227 10.2.2 Chassis frame of the U500, short wheelbase.............. 264
7.7 Preparation for the installation of roof-mounted auxiliary 10.2.3 Chassis frame of the U500, long wheelbase ............... 265
headlights ....................................................................230
10.3 Chassis frame material ................................................ 266
7.8 Modification of the raised headlights code L47............231
10.4 Rear cross member ..................................................... 266
7.9 Road speed signal and travel dependent signal ..........231
10.5 Wheel chocks .............................................................. 266
7.10 Electromagnetic compatibility ......................................232
10.6 Mounting of implements .............................................. 266
8 Pneumatic Consumers ..............................................234
10.7 Drilling on the frame .................................................... 267
8.1 General notes to pneumatic consumers ......................234

10.8 Bolted connections ......................................................268
10.9 Welding on the frame...................................................269
10.9.1 General notes for welding on the frame.......................269
10.9.2 Welding preparation.....................................................270
10.9.3 Regulations for seam preparation................................271
10.9.4 Welding procedure.......................................................271
10.9.5 Seam finishing .............................................................271
10.10 Frame extensions ........................................................271
10.10.1 Design instructions for extending the frame .............272
10.11 Shortening of the frame ...............................................274
10.12 Wheelbase extensions.................................................274
11 Appendix ....................................................................276
11.1 Conversion Table.........................................................276
11.2 List of Abbreviations ....................................................277
11.3 Table of Figures ...........................................................277
11.4 Table of tables .............................................................284

Body and Implement Mounting Guidelines U500 North America General Information
change specifications or designs at any time without notice or
1 General Information incurring any obligation.
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-

ministration or issued pursuant to the Occupational Safety and
Health Act (OSHA), and/or state, provincial and local laws and
regulations may require installation of additional equipment for the
particular use intended for the vehicle. Nothing contained herein is
to be construed as a representation that such equipment required
for the particular use intended has been installed on the complete
or incomplete vehicle. If clarification regarding content of this pub-
Figure 1.1: Unimog U500 North America
lication or technical information is required, please call the Unimog
This manual is a source of basic information for body, implement and Implement Manager listed at the beginning of this guideline.
equipment manufacturers, and dealers who install their products on the
Unimog. Information on possible mounting, electrical connections and If you choose to contact us by mail our address is:
driving conditions is included. This information is not intended for use
by anyone who does not have substantial technical expertise in the de-
sign and manufacture of motor vehicles and motor vehicle equipment. Unimog North America
The information in this manual is believed to be accurate to the best of 6650 N Basin Ave, Ste. A
our knowledge at the time this manual was approved for publication. Portland, OR 97217
The accuracy is not guaranteed. The information contained in the
manual is general and nothing contained herein should be regarded as
providing specific or comprehensive instructions for the completion of a As a vehicle manufacturer, Freightliner LLC neither approves nor
particular vehicle, or as authorization by Freightliner LLC for the as- disapproves truck chassis modifications or equipment installations
sembly, modification, or alteration of any particular vehicle, whether because Freightliner LLC cannot and does not control the manu-
delivered by Freightliner LLC in complete or incomplete state of manufacturing and installation techniques of the various
facture. Freightliner LLC reserves the right to discontinue models or body/implement/equipment builders.

Implement manufacturers and companies who mount bodies, imple- • Unimog Chassis Drawings (two-dimensional data in .dwg
ments and equipment to Unimog U500 should have the following and .dxf format)
documents:
• Technical Data Book
• The current Unimog option list containing description of the Uni-
mog models and all optional equipment available • Unimog Option List
• The Unimog technical data book with all technical data and im- • Unimog Weight Calculator and Axle Load Calculations
portant additional information • Center of Gravity Calculation
• Body and Implement Mounting Guidelines including all informa- The Unimog Resource CD can be requested from the Unimog Im-
tion on mounting implements and the Freightliner LLC require- plement Manager.
ments for implement mounting.
Instructions regarding vehicle safety
These documents form the basis for the development, modification
We recommend the following:
and review of bodies, implements and equipment of all types,
which are temporarily or permanently mounted on and operated with Only use genuine Mercedes-Benz service parts and conversion
the Unimog. The development and review of implements or bodies parts and accessories, which have been explicitly approved by
for the Unimog does not, in principle, entitle claims for costs or dam- Freightliner for use with your vehicle model. Such parts have been
ages to be made against Freightliner LLC. This also applies with re- specially tested for safety, reliability and suitability.
gard to compliance with road traffic law and accident prevention as
Freightliner can give no guarantee with regard to reliability, safety
specified in the national and international regulations on road traffic
and suitability in the following cases:
and technical equipment.
• If original parts or approved conversion parts or accesso-
Particular reference is made to the responsibility of the implement
ries have been exchanged for other parts or other changes
manufacturer for his scope of delivery and to the rules of safety to
have been made to the vehicle.
be complied with in respect of the vehicle/implement interface.
The instructions given must be observed exactly to maintain the op- • If bodies are not manufactured or mounted according to
erating and road traffic safety of the chassis and to maintain war- the valid Body and Implement Mounting Guidelines or if, in
ranty rights. the event of deviations, the approval of Freightliner is not
sought.
Illustrations and drawings are examples only and serve to explain
the texts and tables. Official acceptance by public testing bodies or official approval
does not rule out safety hazards.
References to regulations, standards, directives, etc. are partially
given in key words and serve only as information. Please contact the Unimog Implement Manager listed at the be-
ginning of this guideline for further general technical data of the
A CD-ROM called “Unimog Resource CD” is available with the fol- Unimog, which is not contained in this Body and Implement
lowing documents: Mounting Guideline.
• Body and Implement Mounting Guidelines Confidential. All rights reserved. Reproduction or translation
in whole or in part is not permitted without written authoriza-
tion from the publisher.

1.2 Emission, Noise and Safety FMVSS 102 / CMVSS 102

This vehicle will conform to FMVSS / CMVSS No. 102, Transmis-
The purpose of this information and the following summarized text is to
sion Shift Lever Sequence, Starter Interlock and Transmission
assist you in interpreting the Federal Motor Vehicle Safety Standards
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
U.S. and Canada. FMVSS 103 / CMVSS 103
Unimog U500 NA manufactured by Freightliner LLC is certified for com- This vehicle will conform to FMVSS / CMVSS No. 103, Windshield
pliance with the U.S. Federal Motor Vehicle Safety Standards and the Defrosting and Defogging Systems, if no alterations are made in
Canadian Motor Vehicle Safety Standards. the windshield defrosting and defogging systems, controls, wiring,
plumbing and air flow to the windshield.
The vehicle certification is a requirement of the National Traffic and Mo-
tor Vehicle Safety Act (United States) and Canadian Motor Vehicle FMVSS 104 / CMVSS 104
Safety Act (Canada). The FMVSS and CMVSS regulations control the
This vehicle will conform to FMVSS / CMVSS No. 104, Windshield
manufacturer and sale of motor vehicles and their usage. Other laws
Wiping and Washing Systems, if no alterations are made in the
apply to the application and use of vehicles. Owners or operators using windshield wiper arms, blades, washer, controls, wiring, or plumb-
vehicles are responsible for those vehicles meeting certain legal re- ing.
quirements. The MVSS laws, by contrast, put the burden of obeying the
law on the manufacturer, dealer, or body manufacturer who sells the FMVSS 106 / CMVSS 106
completed vehicle to the end user. For this reason, it is important that all This vehicle will conform to FMVSS / CMVSS No. 106, Brake
concerned parties review information carefully to ensure compliance Hoses, if no alterations are made to the air or hydraulic brake
with the MVSS laws and related safety standards. It is recommended hoses, brake hose assemblies, and brake hose fittings including
that dealers and others concerned review this information with their legal the labeling on these components.
counsel.
FMVSS 108 / CMVSS 108
No modification or addition to the vehicle can be made which cause
noncompliance with any FMVSS or CMVSS, as applicable, as certified This vehicle will conform to FMVSS / CMVSS No. 108, Lamps,
by Freightliner LLC. Reflective Devices, and Associated Equipment, if no alterations
are made to any associated items supplied on the vehicle and no
FMVSS 101 / CMVSS 101 obstructions are installed which limit visibility of any item.
This vehicle will conform to FMVSS / CMVSS No. 101, Control Location FMVSS 111 / CMVSS 111
Identification and Illumination, if no alterations are made to the vehicle
controls including their location, means of identification and method of This vehicle will conform to FMVSS / CMVSS No. 111, Rearview
illumination. Mirrors, if no alterations are made to mirrors, mounts, locations, or
cab structure and no obstructions are installed which limit usage.

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
tem, if no alterations are made in the Hood Latch System, including the Locks and Door Retention Components, if no alterations are made
attachments for the hood latches. in the door assembly, door latches, door striker assemblies, door
hinges, door locks, door latch posts, door hinge posts, and sup-
porting cab structure.
This vehicle will conform to FMVSS / CMVSS No. 119, New Pneumatic
Tires, if no alterations are made to the pneumatic tires.
This vehicle will conform to FMVSS / CMVSS No. 207, Seating
Systems, if no alterations are made to the seats, seat adjusters,
This vehicle will conform to FMVSS / CMVSS No. 120, Tire Selection restraining devices, release and adjustment controls, seat risers,
and Rims for Motor Vehicles Other Than Passenger Cars, if no changes and supports, and the cab floor and supporting structure.
are made to the tires, rims, or labeling.
This vehicle will conform to FMVSS / CMVSS No. 208, Occupant
This vehicle will conform to FMVSS / CMVSS No. 121, Air Brake Sys- Crash Protection, if no change is made in the number of desig-
tem, if it does not exceed any of the gross axle or gross vehicle weight nated occupants seating positions provided, and if no alterations
ratings, and if no alterations or changes are made in, or affect the air are made in the cab and supporting structure, cab underbody,
system components, or circuitry, electric wire circuit or components as- seat belt assemblies, seat belt anchorages and attachments, and
sociated with the above, tire size and wheelbase. the cab structure to which the anchorages are attached.
FMVSS 124 / CMVSS 124 FMVSS 209 / CMVSS 209
This vehicle will conform to FMVSS / CMVSS No. 124, Accelerator Con- This vehicle will conform to FMVSS / CMVSS No. 209, Seat Belt
trol Systems, if no alterations are made to any components of the throt- Assemblies, if no alterations are made in the seat belt assemblies,
tle control or fuel metering system. seat belt anchorages and attachments, and the cab structure to
FMVSS 125 / CMVSS 125 which the anchorages are attached.
This vehicle will conform to FMVSS / CMVSS No. 125, Warning De- FMVSS 210 / CMVSS 210
vices, if no alterations are made to any components or items of the This vehicle will conform to FMVSS / CMVSS No. 210, Seat Belt
warning devices and no obstructions are installed which limit visibility or Assembly Anchorages, if no additional occupant seats or seat belt
usage of any item. assembly anchorages are added and if no alterations are made
FMVSS 205 / CMVSS 205 which affect the function, physical, or mechanical properties, envi-
ronmental or vital clearance of the components, assemblies or
This vehicle will conform to FMVSS / CMVSS No. 205, Glazing Materi- systems of any components of the seat belt assembly anchor-
als, if no alterations are made in the glazing material installed in the ages.
windshield and windows of the cab.
This vehicle will conform to FMVSS / CMVSS No. 302, Flammabil-
ity of Interior Materials, if no alterations are made to the materials,

including the surface of material and padding or cushioning used in the • The VIN is located on the left longitudinal member of the
interior of the vehicle’s occupant compartment including but not limited frame in the wheelhouse, below the driver’s location in the
to the following components: seat cushions, seat backs, seat belts, arm cab.
rests, all trim panels including door, front, rear, and side panels, com-
Unimog VIN Coding:
partment shelves, floor covering, headlining, sun visors and other inte-
rior materials. Example
WD6 D E1 CS ? 4 4 000001
If the body, implement or equipment manufacturer installs any of the of VIN
aforementioned items, those items must also meet the requirements of Position 1 2 3 4 5 6 7 8
this standard. Position Name Content
Summary World manufacturer
1 WD6, WD7, WD8
identifier (WMI)
The body, implement or equipment manufacturer must install the body,
2 Type of chassis D = 4x4 truck
implement or equipment to the vehicle in such a manner that it conforms
E1 = 405.210 class 6
to all standards in effect on the date of manufacture by Freightliner LLC.
Model (see also follow- E2 = 405.210 class 7
3
ing table) E3 = 405.230 class 6
1.3 Identification E4 = 405.230 class 7
CS = Mercedes-Benz OM
4 Engine
The Unimog has the following identification characteristics for clear iden- 906
tification: 5 Check digit
4 = 2004,…, 9 = 2009
• Engine identification plate: 6 Model year
A = 2010,…, F = 2015
All parts used in the respective engine series can be identified via the 7 Manufactured in 4 = Woerth, Germany
engine identification plate. This number supplements the Vehicle Identi- Sequentially assigned
8 000 001 – 999 999
fication Number (VIN) as an identification characteristic. vehicle serial number
Gross vehicle
The imprinted engine identification plate is located in the area below the Model Chassis Class Wheelbase
weight rating
left rear of the cylinder head cover, above the compressor.
131.89 inch
E1 405.210 6 26,000 lbs
• Vehicle identification plate: 3,350 mm
131.89 inch
The identification plates are intended primarily for identification and E2 405.210 7 33,000 lbs
3,350 mm
therefore contain only certain information. The identification plates on
153.54 inch
the cab are located on the B-pillar of the driver’s side. They can be seen E3 405.230 6 26,000 lbs
3,900 mm
only when the left-hand side door is open.
153.54 inch
E4 405.230 7 33,000 lbs
• Vehicle Identification Number: 3,900 mm
• The Vehicle Identification Number (VIN) contains coded informa- Table 1.1: Unimog VIN Coding
tion about the Unimog. It is composed of sub codes.

1.5 Warranty rights

1.4 Requirements for implement mounting and operating
instructions Warranty rights can only be asserted within the framework of the
purchase agreement between the purchaser and the vendor. The
Implement mounting instructions: relevant vendor of the object supplied is then obliged to the pur-
When composing mounting and operating instructions, Unimog-specific chaser as regards the warranty.
details must be included. 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 • the body and mounting guidelines have been ignored
instructions should be easy to understand so it is possible to mount the
• the chassis used does not correspond to the country-
implement without safety hazards.
specific equipment and the equipment required for the ap-
Examples of Unimog-specific details: plication.
• When mounting on the front mounting plate detail the mounting The implement or body must not affect operating and driving
location on the front of the vehicle. safety. In the case of cabs, free movement for tilting must be
guaranteed. In the case of implements and bodies, asymmetrical
• In case of heavy front mounted implement a counterweight is load on the chassis must be avoided wherever possible.
necessary otherwise the front axle will be over loaded and the
rear axle will be under loaded. Required components, ballast lo- If asymmetrical load is unavoidable (e.g. in the case of a side-
cation and amount must be shown in a mounting drawing. mounted loading crane, generator, mower, etc.) and the difference
in wheel loads exceeds 10 % of the relevant axle loads (see Sec-
• Connection of the hydraulic hoses with a note to the float position 4.8 Center of gravity, page 67), then the approval of the
tion during connecting to the Unimog. Freightliner Unimog Implement Department is necessary. In this
• Pictures showing cable and hose routing and assembly and fix- case please contact the Unimog Implement Manager listed at the
ing of the implement control console. beginning of this guideline. Driving trials may be necessary.
• Information about cable passage into the cab and use of the seal
cap (part number: A405 583 00 83). 1.6 Maintenance instructions
Implement operating instructions:
The body manufacturer must note the following prior to delivery of
Operation of the vehicle components (power take-off (PTO) switch, hy- the vehicle:
draulic control panel, etc.) and implement control consoles must be ex-
plained in the implement operating instructions. In particular, the opera- • Servicing due must be carried out at a Freightliner / Mer-
tion procedures for emergency situations must be described. cedes-Benz Service Center.
• Headlamp adjustment must be checked and, if necessary,
corrected following the mounting or attachment of an im-
plement.

• The batteries must be checked for capacity and condition and 1.8 Accident prevention
must be serviced in accordance with the manufacturer's specifi-
cations. The body and implement manufacturer is responsible for damage:
• If a wheel has been removed or changed, the wheel nuts must • Resulting from insufficient reliability or safety of the
be retightened to the tightening torque specified in the mainte- body/implement or components supplied,
nance instructions.
• Resulting from errors or omissions in the Operating In-
• Operating Instructions and directives for maintenance operations structions for the body/implement or supplied components.
on installed components or devices must be provided with the
The body and the attached or mounted implement must comply
vehicle.
with relevant laws, industrial safety or accident prevention regula-
• Instructions regarding road traffic and operating safety of the ve- tions and the safety regulations of public insurance institutions. All
hicle equipped with implement or body units are especially im- technical possibilities for the avoidance of operating risks must be
portant. exploited.
• If components have been removed and re-installed by the im- National laws and regulations must be observed.
plement or body manufacturer, the mounting must be checked to The body and equipment manufacturer is responsible for compli-
ensure that it has been fitted correctly. In the case of compo- ance with these laws and regulations.
nents, which contain liquids (coolant, lubricant, etc.), the fill lev-
els must be checked and, if necessary, topped off using the All accident prevention regulations listed in the operating instruc-
specified fluids. tions must be adhered to.
The driving speed must be appropriate to the prevailing road, traf-
fic and terrain conditions. The influence of the implement/body on
1.7 Corrosion protection measures braking, cornering, driving on a slippery road surface or unfirm
ground, on side slopes, on inclines or declines, etc. must be taken
If the original corrosion protection of the chassis has been affected by into consideration. Always drive in a defensive manner.
work carried out after the vehicle has been dispatched from the factory,
it has to be repaired according to our directives. The body manufacturer must ensure that the vehicle
owner/customer is trained and familiarized with the theory and
The following points must be observed: practice of operating the implement or the vehicle in conjunction
• Avoid welding operations close to inaccessible cavities, with the implement.
• Remove drilling and grinding swarf,
• De-burr edges,
• Remove burnt paint,
• Prime and paint all bare parts with zinc-rich paint,
• Preserve cavities with wax preservative.

1.9 Recycling – Re-use of components

1.10 Product liability
The following principles for environmentally compatible design and se-
lection of materials shall be taken into consideration from the early The body manufacturer shall bear responsibility for:
stages of development of the implement or body onwards. • Ensuring that the operating and driving safety of the entire
vehicle/implement combination and its handling, braking
• Avoid materials with potential risks such as, for example, halo-
and steering characteristics are not adversely affected by
gen additives, heavy metals, asbestos, CFCs, chlorinated hydro-
carbons, etc. the body
• Preferably use materials, which allow the implementation of ma- • Consequential damage which occurs due to fitting, installa-
terial recycling and closed material loops. tion or conversion work carried out by the body manufac-
turer
• Select material and manufacturing procedure so that only slight
volumes of waste, which can easily be recycled, are incurred. • Consequential damage which occurs due to retrofitting of
electronic systems
• In the case of plastics, particularly compound materials use mu-
tually compatible materials from one material family. • Consequential damage due to any influence on the exist-
ing vehicle electrical system
• In the case of recycling-relevant components, keep the number
of different plastics used as low as possible. • The functional safety and the free movement of all moving
parts of the chassis (e.g. axles, springs, propeller shafts,
• Check whether a component can be manufactured from recycled steering, engine control, shift linkage, brake components,
material or with recycled additives. etc.) even in the event of full axle articulation or diagonal
torsion of the chassis frame
• Ensure that recyclable components can be removed easily, e.g.
via snap connections, nominal break points, good accessibility. The body manufacturer must indemnify Freightliner LLC
against all liability for damage occurring due to
• Ensure that the removal of service fluids is simple and environ-
mentally compatible via the provision of drain plugs, etc. • Non-compliance with the Body and Implement Mounting
Guidelines
• Avoid painting and coating components wherever possible, use
colored plastic parts. • Use of the vehicle or the vehicle/implement combination
not in compliance with the regulations, particularly with re-
• Design components in areas, which are subject to accidents to
gard to the application of implements
be damage-tolerant, repairable and easily replaceable.
• Deficient design, manufacture or installation
• Only use plastics in places where they provide cost, functional or
weight advantages. • Failure to observe the appropriate basic principles in any
other regard
• Inadequate operating instructions of the implements / bod-
ies

• Lack of knowledge and training of the vehicle owner / customer /

driver 1.11.4 Plastic compressed-air, fuel and brake lines
Only basic notes regarding product liability can be provided within Before welding, drilling, grinding and working with cutting discs:
the framework of these Body and Implement Mounting Guideline.
• Cover plastic lines and brake hoses
• Remove if necessary
1.11 Damage prevention and safety regulations
The system must be checked for leaks after the lines have been
1.11.1 General notes fitted.
In all operations of the vehicle or the vehicle/implement combination, the If lines (e.g. hydraulic lines from implement or body units) have to
accident prevention directives, especially the directives and recommen- be retrofitted in the vehicle, these must not be attached to chassis
dations listed in the operating instructions of the vehicle and the lines (e.g. brake lines, electric cables, etc.). The relative move-
body/implement etc. must be complied with. ments, which occur between body and chassis in the event of
chassis diagonal torsion, and the related elongation or compres-
1.11.2 Delivery of chassis
sion of the lines, must be taken into consideration when lines are
Minimum rear axle load needs to be at least 41 % of the total vehicle routed.
weight to meet the empty failed front reservoir stopping distance.
We recommend that when routing lines, implement manufacturers
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.
mounted. Highway travel without platforms (only with platform subframe
They must not be attached to existing, highly-stressed threaded
or without platform subframe) is not allowed.
connections, such as longitudinal member frame connections, en-
1.11.3 Prevention of accidents on the vehicle gine mounting systems, anti-roll bar mountings, spring mountings,
The implement or body manufacturer is responsible for compliance with etc.
laws and regulations. This also applies to interfaces between the vehicle For additionally required holes, e.g. in the frame, see section 10.6,
and the implement and to safety when mounting or removing exchange- page 266 and section 10.7 Drilling on the frame, page 267.
able implements. Drive shafts must also be equipped with protection
Existing brackets on the chassis may be used provided that the
against accidental contact, so that shearing and crushing points are
bracket can bear the additional load.
avoided. Connectable systems must be protected against improper use
and unintentional actuation. Fans for oil radiators, etc. must be enclosed Subsequently installed lines must not rub on brake lines, electric
in such a way that access to the rotating fan is impossible. All kinds of cables, etc.; use spacers if necessary.
sharp corners and edges are to be avoided. The implement or body
Changes to the brake system (e.g. wheelbase or frame exten-
manufacturer must ensure that servicing and maintenance operations
sions) may only be carried out using the pipe connection parts and
can be carried out safely.
plastic lines, which we have approved.

Plastic loops are required for mounting. The maximum distance between • Short-circuit the positive and negative connecting cable af-
loops must not exceed 19.68 in / 500 mm. If no plastic lines are avail- ter disconnecting from the battery (to protect the vehicle
able, the installation of steel pipes with identical dimensions, which have electronic).
been electro-galvanized, both inside and out, is permissible. In regards
plastic lines, the following minimum bending radii must be adhered to: • Connect the welding unit's ground terminal directly to the
part to be welded.
Pipe diameter Wall thickness Bending radius
• Under no circumstances must the welding current be
[in] [mm] [in] [mm] [in] [mm] routed via electronic components.
0.24 6 0.04 1 1.18 30
Caution: Do not connect the welding unit's ground termi-
0.31 8 0.04 1 1.57 40 nal to components such as engine, transmission,
0.47 12 0.06 1.5 2.36 60 axles etc.
0.63 16 0.05 1.2 3.94 100
• Do not touch the housing of electronic components (e.g.
Table 1.2: Minimum bending radii of plastic lines control units) or electric cables with the welding electrode
or ground terminal of the welding unit.
Only factory lines or lines of identical quality (e.g. SAE J844 TB Tubing)
may be used. • Prior to welding, cover springs and shock absorbers to pro-
tect them from welding splatter. Do not touch springs with
Caution: In the event of modifications to the brake or air welding electrodes or welding tongs.
supply lines; a new acceptance test has to be
carried out by an authorized technician because
the modifications may have adversely affected Welding must not be carried out at the following components:
the response time of the brake system. Modifica- • At the engine, transmission, axles, etc.
tions in the brake system could result in non-
compliance to FMVSS 121 and CMVSS 121. • The chassis frame (for exceptions, see Section 10.9
Changes could also affect stopping distance Welding on the frame, page 269 onwards)
and/or vehicle stability and should be avoided. • Hydraulic fittings and components such as valves, cylin-
ders, etc.
1.11.5 Welding operations • Cavities containing electric cables and other heat-sensitive
lines.
See also Section 10.9 Welding on the frame, page 269.
Caution: In the case of welding operations at the vehicle,
In the case of welding operations with electric welding units, observe the
the ground terminal of the welding unit must
following:
never be connected to any of the above listed
• Only qualified personnel may carry out welding operations on the components or their periphery. The welding cur-
chassis. rent may cause arcing at the bearings. This can
lead to destruction of the heat-treated surfaces
• Disconnect the positive and negative battery terminals and cover and consequently lead to premature failure.
them (for protection).

Caution: Temperatures of 176°F / 80°C must not be ex-
1.11.6 Springs
ceeded for paint drying.
Only use genuine MERCEDES-BENZ springs, which have been ap-
proved for the relevant model. Modifications to springs and shock ab- 1.11.8 Pushing and towing
sorbers are not permitted.
The directives in the Driver’s Manual must be complied with when
Spring pads are only permitted in coordination with, and with the written towing or tow-starting the vehicle.
approval of, the Unimog Implement Manager listed at the beginning of
this guideline. • Only tow-start the vehicle with the battery connected.
The surface and corrosion protection of the springs must not be dam-
aged when they are fitted. Caution: If the instructions given in the Driver’s Manual
are not observed, damage may be caused to the
The protective measures described in Section 1.11.5 Welding opera- drive train.
tions, page 20 must be applied during welding operations.
1.11.7 Painting procedures 1.11.9 Electrical system
In order to avoid color variations on painted bodies, information regard- • Never start the engine unless the battery terminals are
ing the primer coats and cover coats used in manufacturing may be re- firmly connected.
quested by the Unimog Implement Manager listed at the beginning of • Incorrect supply voltage polarity may destroy the control
this guideline. units.
Before painting, cover the following areas: • Do not undo or disconnect the battery terminals while the
• Bearing surfaces between the wheel and wheel hub engine is running.
• Bearing surfaces of the wheel nuts • If the batteries are flat, the engine can be jump-started us-
ing jump leads and the battery of another vehicle running
• All bearing surfaces of high tensile threaded connections (e.g. on the same voltage. Observe the Driver’s Manual and the
engine mounting system, rear cross member, etc) Maintenance Manual. (12 V only)
• Coupling flanges of drive shafts, power take-off shafts and power • Jump-starting with a rapid charger (over voltage) is not
take-offs permitted.
• Hydraulic cylinder piston rods (platform tipping cylinder, cab tilt- • Only tow-start the vehicle with the battery connected.
ing hydraulics, etc.)
• Only charge the battery with a rapid charger if it has been
• All compressed air and hydraulic system control valves and the disconnected from the vehicle’s electrical system. The
interfaces of these components positive and negative terminals of the battery must be dis-
• Breather pipes in transmission, axles, etc. connected. Observe the Maintenance Manual.
• Brake discs • For information about the installation of additional electrical

components, see Section 7 Electrical system, page 216.
• Electrical connections

• Cables routed near exhaust systems must be protected against radio manufacturer to certify the electromagnetic compatibility of
high temperatures. the appliance.
• Cables must not be routed near the exhaust manifold or turbo- Antennas:
charger. Code E54 (preparation of two-way radio including antenna) is re-
• Install the cables in such a way that there are no chafe or shear quired for mounting two-way radio devices. Please observe the
points (in vehicle torsion and relative movement between vehicle manufacturer’s instructions and the installation guidelines of the
and implement or body parts), particularly at crossing points and devices.
sharp edges and use cable channels or conduit if necessary. 1.11.11 Electromagnetic compatibility (EMC)
• Do not attach electric cables to brake lines. The electric and electronic components of the UNIMOG are tested
• Do not carry out measurements at connector contact points us- in the factory with regard to their electromagnetic compatibility in
ing unsuitable media (test probes, wire ends, etc.). This may the vehicle.
lead to contact problems as a result of the formation of contact If additional implement or body components, which affect the elec-
resistance. Use suitable test leads. tromagnetic compatibility of the vehicle components, are fitted, the
• The ground terminal of the welding unit must be connected di- implement or body manufacturer must ensure that the operating
rectly to the part to be welded and as close as possible to the safety of the entire vehicle/implement combination is guaranteed.
welding point. A further EMC test may be necessary.
1.11.10 Mobile communication systems

The following requirements must be met to avoid subsequent interfer-
ence in vehicle operation if mobile communication systems (e.g. tele-
phone, CB radio) are retrofitted:
Device requirements:
• 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 in-
stalled external antenna.
• The transmitter must be installed separately from the vehicle
electronics.
• Protect the device against moisture, observe the permissible op-
erating temperature, and protect against strong vibration.
There may be interference with the combination of radios and implement
control panels fitted in the cab. Therefore you should always contact the

1.11.12 Implement drives
Various power take-offs (flange and shaft types) with different speeds
and power ratings are available to drive implements or attachments.
(See also Section 5 Mechanical drive of implements, page 164).
It must be ensured that the permissible torque loads are not exceeded.
The body/implement manufacturer must consider the varying types of
operation (e.g. variable loads, load factors, duration of usage, usage
profile, etc.).
It is the responsibility of the implement manufacturer to carry out
the necessary implement operation tests.
All components (mechanical, hydraulic, pneumatic, electric) must be
made compatible with one another. Therefore the following items must
be considered: Outputs, maximum oil issue quantity, rotation direction,
rotation speeds, etc. (see following Sections).
It must also be ensured that the power train does not overheat. In the
case of continuous consumers, the implement manufacturer must en-
sure that the maximum permissible temperature (engine oil, transmis-
sion fluid, coolant) is not exceeded under the expected conditions of ve-
hicle use. In the case of hydraulically driven continuous consumers, the
implement manufacturer must ensure that the maximum permissible op-
erating temperature is not exceeded under the expected conditions of
vehicle use.


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 81
(code D12)
Front PTO (code N08) → Section 5.9, page 171

Drive: Hydraulic → Chapter 6, page 189
Figure 2.1: Front mounted mower
Code E37 → Section 7.4.1, page 218

Electrical
Implement socket → Section 7.4.3, page 220
connection: Code E45
→ Section 7.4.2, page 219
Axle loads → Section 4.4, page 62

Counterweight → Section 4.10, page 76
Max. torsion moment → Section 4.13.4, page 88
Notes: Torsion frame → Section 4.9.5, page 75
Wheel loads → Section 4.5, page 63
Drive shaft angle → Section 5.11.2, page 185
Lights L47 required
Figure 2.2: Front mounted mower in transport position

2.2 Rear mounted mowers Overview of the related sections:
On platform P27 / P40 or → Section 4.14.2, page 92

Mounting: On ballpoints P60 → Section 4.14.3, pg. 105
PTO (code N05) → Section 5.8, page 168

(driven by hydraulic pump)
or
Power hydraulic → Section 6.3, page 206
Drive: (code H63, closed circuit)
or
(code H64, open circuit)
Figure 2.3: Rear mounted mower

Electrical Implement socket → Section 7.4.3, page 220
connection: Code E45 → Section 7.4.2, page 219
Mounting of the control unit → Section 9.5, page 254
Cable passage into the cab → Section 9.3, page 243

Notes: Wheel loads → Section 4.5, page 63
Roll stabilization → Section 4.14.1, page 89
Figure 2.4: Rear mounted mower in transport position

2.3 Spreaders
Overview of the related sections:
On platform P27 / P40 → Section 4.14.2, page 92

or
Mounting: On ballpoints P60 → Section 4.14.3, page 105
or
Directly on the chassis → Section 4.14.4, page 119
Hydraulic connector
Drive: - at the side (H68) → Chapter 6, page 189
- at the rear (H58/H59) → Chapter 6, page 189

Figure 2.5: Spreader mounted on ballpoints Axle loads → Section 4.4, page 62
Center of gravity → Section 4.8, page 67

2.4 Snow plows


(code D12)
Basic hydraulic → Section 6.2, page 194

Drive: Snow plow load release → Chapter 6, page 189
Electrical Code E45 → Section 7.4.2, page 219

connection: Mounting of the control unit → Section 9.5, page 254

Figure 2.6: Snow plow Counterweight or use of a → Section 4.10, page 76
Notes: Spreader → Section 4.14.2.1, pg. 101
Lights L47 required or
Roof mounted lights → Section 7.7, page 230

2.5 Wing plow

Proposal for a wing plow → Section 4.14.6.3, pg. 148

support
Via sub frame directly on → Section 4.14.6, page 137
Mounting: the chassis (code D62)
Front mounting plate → Section 4.13, page 81
(code D12)
Drive: Basic hydraulic → Section 6.2, page 194

Electrical
connection: Mounting of the control unit
→ Section 9.5, page 254

Notes: Counterweight or use of a → Section 4.10, page 76
Spreader → Section 4.14.2.1, pg. 101
Figure 2.7: Wing plow

2.6 Snow cutters / blowers


Mounting → Section 4.13, page 81
(code D12)

Drive Hydraulic → Chapter 6, page 189


Figure 2.8: Snow blower Drive shaft angle → Section 5.11.2, page 185
Notes Lights L47 required or
Counterweight or → Section 4.10, page 76
Spreader mounting → Section 4.14.2.1, page 101

2.7 Suction sweepers

Mounting: On ballpoints (code P60) → Section 4.14.3, pg. 105

(code H63, closed circuit)
Drive: or
(code H64, open circuit)

Cable passage into the cab → Section 9.3, page 243

Notes:
Figure 2.9: Suction sweeper Wheel loads → Section 4.5, page 63

2.8 Front mounted sweepers

(code D12)

or
Power hydraulic with → Section 6.3, page 206
front connection
Drive: (codes H64/H94)
or
Basic hydraulic with front → Chapter 6, page 189
connection (code H78/79)
Electrical
connection:
Figure 2.10: Front mounted sweeper

2.9 Winches

(code D12)

Drive: or
Basic hydraulic → Chapter 6, page 189
Code E37 or → Section 7.4.1, page 218
Electrical Implement socket or → Section 7.4.3, page 220
Notes: Cable passage into the cab → Section 9.3, page 243
Figure 2.11: Front mounted winch

2.10 Aerial devices (man lifts)

Via sub frame directly on

Mounting: → Section 4.14.6, page 137
the chassis (code D62)
Gearbox- PTO (code N16) → Section 5.10, page 177
Drive: and
Hydraulic pump → Section 5.10.3, page 180
connection: Implement socket → Section 7.4.3, page 220
Figure 2.12: Aerial device

2.11 Big cranes


Drive: and
Notes: Center of gravity → Section 4.8, page 67
Sub frame suggestions → Section 4.14.6.4, pg. 152
Figure 2.13: Crane with V-outriggers


2.12 Drill devices
Drive: and
Figure 2.14: Drill device


2.13 Front end loaders
Integrated implement support → Section 4.13.3, pg. 85
Code D60 (in combination → Section 4.14.8.1, pg. 160
with platform, code P60) or
Mounting: Code D62 (in combination → Section 4.14.6.2, pg. 140
with a heavy sub frame) → Section 4.14.8.1, pg. 160
Mounted between the axles → Section 4.14.8, pg. 156
Drive: Basic hydraulic → Chapter 6, page 189
Electrical → Section 7.4.2, page 219

Code E45
connection:

Figure 2.15: Front end loader Lights L47 required or
Notes: Roof mounted lights → Section 7.7, page 230
(depending on use)
Undercarriage load bar re- → Section 4.14.8, pg. 160
quired

2.14 Front mounted devices

Front mounting plate → Section 4.13.2, pg. 81

Mounting: (code D12) or
Front PTO (code N08) or → Section 5.9, page 171
Drive: Power hydraulic or → Section 6.3, page 206
Basic hydraulic → Chapter 6, page 189
Electrical Code E45 → Section 7.4.2, pg. 219
Lights L47 required or
Notes: Roof mounted lights → Section 7.7, page 230
(depending on use)
Figure 2.16: Example of a front mounted device

Front
2.15 Sewer cleaning devices - front mounting plate D12 → Section 4.13, page 81
Center
Mounting: - on platform P27 / P40 → Section 4.14.2, page 92
- on ballpoints P60 → Section 4.14.3, page 105
- directly on the chassis → Section 4.14.4, page 119
Front
- PTO (code N08) → Section 5.9, page 171
Center
Drive: - Engine-PTO (code N05) → Section 5.8, page 168
or
- gearbox-PTO (code N19) → Section 5.10, page 177
Code E37 or → Section 7.4.1, page 218

Electrical Implement socket or → Section 7.4.3, page 220

Figure 2.17: Sewer cleaning device Lights L47 required

2.16 Water tanks

On platform P27 / P40 → Section 4.14.2, page 92

Mounting: like
Spreader mounting → Section 4.14.2.1, pg. 101
Drive: Not necessary
Electrical
Not necessary
connection:

Notes: Axle loads → Section 4.4, page 62
Figure 2.18: Water tank

2.17 Front mounted 3-point hitches

Front mounting plate → Section 4.13, page 81

Mounting: (code D12) or
Electrical
Not necessary
connection:
Max. load front mounting plate → Section 4.13, page 81

Figure 2.19: Front mounted 3-point hitch Axle loads → Section 4.4, page 62
Notes: Lights L47 required or
(depending on use)

2.18 Rear mounted 3-point hitches

< 1t:
Implement mounting → Section 4.15, page 162
bracket rear (code D50)
+ undercarriage load → Section 4.14.8.1, pg. 160
bar under the rear axle → Section 4.14.8, pg. 156
1t < weight < 2.5t:

Mounting: Implement mounting → Section 4.15, page 162
and
Mounting points at rear → Section 4.14.8.1, pg. 160
stabilizer → Section 4.14.8, page 156
2.5t < weight < 4t:

Code D62 → Section 4.14.6.2, page 140
Figure 2.20: Rear mounted 3-point hitch

Electrical
Not necessary
connection:
Notes: Axle loads → Section 4.4, page 62
Minimum front axle load → Section 4.4, page 62

2.19 Fire bodies

On ballpoints P60 or → Section 4.14.3, page 105

Mounting: Directly on the chassis → Section 4.14.4, page 119
Gearbox- PTO code N19 or → Section 5.10, page 177

Engine- PTO code N05 → Section 5.8, page 168
Drive: Hydraulic connector
- at the side (H68) → Chapter 6, page 189


Figure 2.21: Fire body

2.20 Refuse collection vehicles



Hydraulic connector


Figure 2.22: Refuse collection vehicle

2.21 Box bodies



Hydraulic connector


Figure 2.23: Box body

2.22 Wood chipper (front mounted)


(code D12)

Drive: Hydraulic → Chapter 6, page 189

Figure 2.24: Wood chipper connection: Mounting of the control unit → Section 9.5, page 254

Drive shaft angle → Section 5.11.2, page 185
Notes: Lights L47 required or

2.23 Concrete mixers


Hydraulic connector


Figure 2.25: Concrete mixer

2.24 Digger

Drive: and
Figure 2.26: Backhoe

2.25 Skip loader

Hydraulic connector


Figure 2.27: Skip loader

2.26 Rear mounted small cranes
< 3.5 mt:

Implement mounting → Section 4.15, page 162
Mounting: > 3,5 mt:
Via sub frame directly on → Section 4.14.6, page 137
and
Drive: Hydraulic pump or → Section 5.10.3, page 180
Hydraulic connector:
Electrical
Trailer socket (7 pin) → Section 7.4.4, page 222
connection:
Figure 2.28: Rear mounted crane < 3.5 mt

Notes: Sub frame suggestions → Section 4.14.6.4, pg. 152
Figure 2.29: Sketch of a rear mounted crane < 3.5 mt


Body and Implement Mounting Guidelines U500 North America Vehicle Information
3 Vehicle Information
Transmission
This body and implement guideline covers the following vehicles: Type BM: G 718.840
All synchromesh MB 8-speed EPS-manual gearbox
Unimog model / Wheelbase Output With integrated permanent front wheel drive (all wheel drive).
Model
sales designation [in] [mm] [hp] [kW] Torque distribution front/rear axle 50:50
1-6 gears can be driven in reverse
U500 NA 405.210 131.89 3,350 260 193.88
(G03) 7-8 reversing gears open for rail-road application
Working gears (G20) / Working and crawler gears (G21)
U500 NA 405.230 153.54 3,900 260 193.88
Model UG 100-8 / 9,57-0,74 GPA, EPS
Table 3.1: Vehicle and model designations Overall gear Gear Forward Reverse
ratios: 1 9.570 14.569
2 6.635 10.101
3 4.375 6.660
3.1 General Technical Data 4 3.219 4.900
5 2.188 3.330
Engine 6 1.517 2.309
Emission class EPA 04 LEV 7 1.000 1.522
Manufacturer Mercedes-Benz 8 0.736 1.120
Type (LA = Turbocharger with intercooler) OM 906 LA Axles
Model 902.912 Type:
Number and arrangement of cylinders 6 (upright inline) Portal axles on trailing arm and transverse control struts
260 hp / 193.88 kW Hub reductions – identical design front and rear
Output (at rated speed)
(at 2,200 rpm) All wheel drive (Standard) with interaxle differential lock
Maximum torque (at speed) 700 lb⋅ft / 949 Nm Differential locks rear (Standard), front (optional A 52)
(at 1,200 – 1,600 rpm) Model front axle 737.591
Idle speed 600 rpm Model rear axle 747.591
Cold start ability with options M89 and All differential locks:
-22°F / -30°C
Z43 Pneumatically engage able and disengage able
Fuel tank capacity 60 gal / 227 l While in motion without traction force interruption
Width flange to flange 84.65 in / 2150 mm
Pitch circle diameter of wheel
13.19 in / 335 mm
studs
Number of wheel studs 10
Axle ratio i =5.92

Electrical System Tires: Unimog Model: Unimog Model:

Alternator 14 V, 145 A 445/70R24 XM47 405.210 405.230
Alternator with in- Angle of approach 29° 30°
14 V, 270 A
creased power Angle of departure 54° 40°
Starter 12 V, 3 kW Ground clearance 19 in / 483 mm 19 in / 483 mm
Battery 3x12 V, 96 Ah Fording ability 26 in / 660 mm 26 in / 660 mm
Lights 12 V Gross Vehicle Weights and Axle Loads
Electronics 24 V GVW 26,000 lbs 11,800 kg
Trailer socket rear 7-pin Off-road (all terrain)
FAW 11,900 lbs 5,400 kg
Implement socket front 7-pin permissible:
RAW 16,500 lbs 7,500 kg
Implement socket at On Highway and Fire- GVW 33,000 lbs 15,000 kg
16-pin
battery box Fighting (optional X18) FAW 15,900 lbs 7,200 kg
For detailed information about implement sockets and other con- permissible: RAW 18,700 lbs 8,500 kg
nection possibilities see Section 7 Electrical system, page 216.
Compressed Air System
Operating pressure 117.5 psi / 8.1 bar For further and more detailed technical information please use the
Delivery at rated engine 79.25 gal / min / 300 l / min Technical Data Book.
speed at 117.5 psi / 8.1 bar
Compressed air connec- Tire inflating valve at test connection of
tion reservoir
Reservoir, brake system 2 x 7.53 gal / 2 x 28.5 l
For detailed information about connecting possibilities to the com-
pressed air system see Section 8 Pneumatic Consumers, page
234.
Off-road relevant data
Tires: Unimog Model: Unimog Model:
395/85R20 XZL 405.210 405.230
Angle of approach 28° 29°
Angle of departure 53° 39°
Ground clearance 18.5 in / 470 mm 18.5 in / 470 mm
Fording ability 25.5 in / 648 mm 25.5 in / 648 mm

3.2.2 Hydraulic drives

3.2 Technical Data for implement drives
Basic hydraulics
3.2.1 Mechanical drives Oil tank volume 11.89 gal / 45 l
Oil issue quantity 2.64 gal / 10 l
Auxiliary power take-off (Code N05) Single circuit system (Code H02)
Gear ratio i = 0.933 Flow rate at rated engine
Speed at rated engine speed 2,200 rpm 2,356 rpm 12.68 gal/min / 48 l/min
speed 2,200 rpm
Direction of rotation (seen in direction of travel) Counter clockwise Pressure 2,900 psi / 200 bar
Max. delivered torque (continuous) 442.5 lb⋅ft / 600 Nm Application Implement actuation
Max. peak torque delivered 531 lb⋅ft / 720 Nm Front connectors Maximum 8 sockets, sep. return line
Max. continuous output 185 hp / 138 kW Rear connectors Maximum 4 sockets, sep. return line
Power take-off shaft (Code N08) Valves 2 to 4
Gear ratio i = 2.139 Dual circuit system (Code H06, H08)
Speed at rated engine speed 2,200 rpm 1,029 rpm Flow rates at rated engine Circuit 1 6.34 gal/min / 24 l/min
PTO rated speed 1,000 rpm speed 2,200 rpm: Circuit 2 12.68 gal/min / 48 l/min
Shaft speed 540 rpm or any other desired speed adjustable Pressure 2,900 psi / 200 bar
Direction of rotation (seen in direction of travel) Clockwise Application Implement actuation, constant flow
Max. peak torque (delivered at the PTO shaft) 1,030 lb⋅ft / 1,400 Nm Maximum 8 sockets, sep. return line,
Front connectors pressure line front
Max. continuous output 201 hp / 150 kW
Power take-off shaft 1 ¾” spline shaft Pressure line, separate return line (only
Middle connectors circuit 2)
High speed power take-off (Code N16) Maximum 4 sockets, sep. return line,
Gear ratio i=1 Rear connectors pressure line rear
Speed at rated engine speed 2,200 rpm 2,200 rpm Valves 2 to 4
Direction of rotation (seen in direction of travel) Counter clockwise Power hydraulics
Rated torque 479 lb⋅ft / 650 Nm Oil tank volume 13.21 gal / 50 l
Rated output 201 hp / 150 kW Oil issue quantity 2.64 gal / 10 l
High speed power take-off (Code N19) Max. flow rate circuit 3 33.02 gal/min / 125 l/min
Gear ratio i = 0.61 Working pressure circuit 3 4,351 psi / 300 bar
Speed at rated engine speed 2,200 rpm 3,607 rpm Max. flow rate circuit 4 23.78 gal/min / 90 l/min
Direction of rotation (seen in direction of travel) Clockwise Working pressure circuit 4 4,061 psi / 280 bar
Rated torque 236 lb⋅ft / 320 Nm Connectors Pressure & return line in front and/or middle
Rated output 161 hp / 120 kW Table 3.3: Technical Data for hydraulically implement drive
Table 3.2: Technical Data for mechanically implement drive For important detailed technical information about the hydraulically
For important detailed technical information about the mechanically drive of implements see Section 6 Hydraulic , page 189.
drive of implements see Section 5 Mechanical drive of implements,
page 164.

3.3 Vehicle drawings
3.3.1 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

Note:
* Dimensions marked with a * vary by
*
* [mm]. Dimensions in brackets are in [in].
Figure 3.2: Front view of U500 NA, short wheelbase

3.3.2 U500 NA, wheelbase: 153.54 in / 3,900 mm
*
*
*
* *
* Note:

* * * [mm]. Dimensions in brackets are in [in].
Figure 3.3: Side view of U500 NA, long wheelbase

* Note:
* tires and/or vehicle (axle) loads.

* [mm]. Dimensions in brackets are in [in].
Figure 3.4: Front view of U500 NA, long wheelbase


Body and Implement Mounting Guidelines U500 North America Implement / Body Installation
4 Implement / Body Installation

4.1 General Notes 4.2 Free movement of implements/bodies on the chassis
Before starting work with implements and bodies, a review must be The free movement and functional safety of all parts of the chassis,
carried out to see whether the selected chassis is suitable for the especially moving parts such as wheels, axles, pan hard rods,
planned implement or body. Also check that the chassis model and springs, propeller shafts, steering, etc. must also be guaranteed fol-
its equipment correspond with the intended application. Vehicle lowing the fitting of the implements or the bodies, even at maximum
drawings, technical data and other information are available on the axle articulation, maximum and minimum axle loads and maxi-
Unimog Resource CD or may be requested from the Unimog Im- mum steering angles (left and right).
plement Manager listed at the beginning of this guideline. The inspection for free movement and sufficient clearance at the
The Unimog chassis provides various possibilities for implement wheels and axles at full suspension travel, max steering angles and
and body mounting, see section 4.12 on page 80. axle articulation can best be carried out after removing the springs.
Verification must be provided through testing. To do this, the
diagonally opposing wheels of the front and rear axles must be
raised in such a way (min. 11.81 in / 300 mm) that the other two
wheels are only just touching the ground, see Figure 4.1.
If snow chains are to be used, the free movement tests must be car-
ried out with the chains fitted.
Caution:
Ensure that the vehicle is po-
sitioned securely before car-
rying out a chassis frame tor-
sion test. If approach ramps
are used, these must be se-
cured against slipping and
tipping. On lift platforms, the
tire contact surfaces must be
moistened to reduce drag.
Figure 4.1: Chassis frame torsion

4.3 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. moving electronic control units
Modifications to the brake assembly support / battery unit / air
drier combination part on the left hand side of the vehicle are not
permissible.
Unauthorized changes to the Unimog brake system are at the
sole risk of the person carrying out the work and could impair the
vehicle's operating safety. Inspection and approval by the techni-
cal inspection authority may be necessary.
Should modification of the original arrangement of the brake sys-
tem in the chassis be unavoidable, lines and fittings of the same
quality and dimensions must be used. It may become necessary
to check the time response of the brake system (technical inspec-
tion authority).
No modifications may be made to the vehicle's scope of delivery
without approval. In particular, Freightliner LCC must be con-
sulted if the following modifications are planned:
• Shortening or lengthening the chassis overhang
• Drilling and welding on the chassis frame or axles
• Modifications to the frame
• Modifications to the brake and steering system (e.g. modifica-
tions to the brake lines)
• Modifications to the intake and exhaust system
• Modifications to wheels, tires, springs (e.g. locking the sus-
pension)
• Modifications which impair the safety of the cab (e.g. holes in
the A- or B-pillars)
• Modifications to the hydraulic system
• Modifications to the lighting system

4.4 Dimensions and weight specifications
Dimensions and weight specifications can be found in the vehicle

drawings, this mounting guideline and the technical data book.
Unless otherwise specified, these refer to the basic vehicle without
optional equipment.
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.
Caution: Optional equipment must also be taken into ac-

count. The load values specified in the technical min. 33% min. 41%
data book and in this mounting guideline (see of the actual of the actual
Section 3.1 Gross Vehicle Weights and Axle Loads, GVW GVW
page 53)
Figure 4.2: Minimum rear axle loads
• Permissible gross vehicle weight
• Permissible front axle load Note: When designing the implements or bodies, it
• Permissible rear axle load should be noted that the chassis weight will in-
crease when special equipment is mounted (for
must be observed. example, different tires, hydraulics, power take-
offs, etc.).
To ensure sufficient vehicle steer ability, the front axle load must be Permissible axle loads and the permissible gross
at least 33 % of the total weight under all load conditions. vehicle weight may not legally be exceeded.
The minimum rear axle load must be at least 41 % of the actual
gross vehicle weight for the U500 in order to achieve sufficient
braking performance and brake traction and to guarantee sufficient
road holding in the event of full braking.

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. graph on the following pages.
Example: Actual axle load: 15,000 lbs / 6,804 kg
Permissible wheel load distribution:
6,750 lbs to 8,250 lbs / 3,062 kg to 3,742 kg
(10% of the actual axle load)
Axle load:
15,000lbs
Figure 4.4: Sketch of the upper edge frame level over the
wheel center
min. 6,750lbs max. 8,250lbs
Figure 4.3: Weight distribution (example)
The wheel and tire load-bearing capacity must be taken into

consideration.
If the wheel load difference exceeds 10 %, please contact the Uni-
mog Implement Manager listed at the beginning of this guideline.
Differences in wheel loads reduce the maximum permissible height
of the center of gravity – see Section 4.8 Center of gravity, page
67.

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

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 U.S. units

z
4.7 Coordinate systems z
One significant advantage of CAD technology is that it enables the x y

vehicle to be measured in the form of coordinates. This limits the de-
termination of relative dimensions, which previously required the de-
termination of all individual part dimensions, to the addition or sub- y
traction of spatial vectors or "direct measurement" in the CAD sys-

tem. The determination of specific points (for example the center of
the steering wheel or eye level) in the form of coordinates is signifi- x
cantly easier than relative dimensioning.
Vehicle system
Figure 4.7: Unimog frame with the zero point of the coordinate system
The following definition of chassis coordinates applies to all UNIMOG
vehicles:
x axis: Longitudinal axis with positive direction against the
direction of travel
y axis: Transverse axis with positive direction to the right side
of the vehicle
z axis: Vertical axis with positive direction to the top
Definition of the chassis coordinate system
The origin of the vehicle coordinates for the U500 NA is: z
X=0 Center front axle (longitudinal member front edge x = -

930) x
Y=0 Center chassis frame Figure 4.8: Detail drawing of zero point
Z=0 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
Note: Dimensions are mostly CAD data and partially not the U500 NA are available on the Unimog Resource CD or by the Un-
rounded. So all measures are construction dimensions imog Implement Manager listed at the beginning of this guideline.
without tolerance indication.

4.8 Center of gravity

4.8.2 Determination of the center of gravity
Note: Calculation programs are available as Microsoft® Ex-
cel® files on the Unimog Resource CD and also from Center of gravity coordinates in horizontal - direction (axle load
the Unimog Implement Manager listed at the begin- distribution FAW / RAW)
ning of this guideline. Procedure:
4.8.1 General information For weighing purposes, the vehicle must be on level ground. Weigh
The overall height of the center of gravity (vehicle with implement the individual axle loads (front and rear axle load) and the gross ve-
or body without load) must be kept as low as possible. hicle weight, then the position of the center of gravity (c.o.g.) in vehi-
cle longitudinal direction can be calculated.
Only the position of the center of gravity of the vehicle / imple-
ment combination (with the implement in statically and locked To calculate the c.o.g. use the calculation programs on the Unimog
transport position) is important for the vehicle handling. Resource CD or the formulae on the following page.
The implement / body manufacturer is responsible for the stability
of the vehicle and compliance with the maximum permissible axle
loads and gross vehicle weight in a (quasi) statically operation.
For example: Working with hydraulically operated knuckle boom
cranes, slow driving with a laterally working boom mower, loading
/ unloading of a container with a container lift etc.
Whether there is a single implement or implement combinations
(e.g. snow plow at the front mounting plate and a spreader on the
platform) the permissible loads must be observed. Use a coun-
terweight where necessary. For information on permissible axle
loads, gross vehicle weights and axle load distribution please
look up the following sections: 4.4, page 62 and 4.5, page 63.
The position of the center of gravity in the vehicle longitudinal di-
rection is given in relation to one axle. Regardless of the tires
used, the height of the center of gravity is given from the center
of the wheel.

Center of gravity distance from Wfr to front axle

lmi Center of gravity distance from Wmi to rear axle
lre Center of gravity distance from Wre to rear axle
Distance of the empty vehicle total weight c.o.g. to the
lf
Wmi front axle
Distance of the empty vehicle total weight c.o.g. to the
GVW lr
Wre rear axle
Wfr l Wheelbase
Wfr Weight of a front mounted implement
lf lr Wmi Weight of a middle mounted implement/body
Wre Weight of a rear mounted implement
lmi
lfr l lre FAW Front axle load
FAW RAW
RAW Rear axle load
Front axle load by vehicle dead weight (result of weigh-
FAWempty
ing or result of the Unimog weight calculator)
Rear axle load by vehicle dead weight (result of weigh-
RAWempty
ing or result of the Unimog weight calculator)
Vehicle dead weight (result of weighing or:
Figure 4.9: Sketch for center of gravity and axle load calculations GVWempty
GVWempty = FAWempty + RAWempty)
Table 4.1: Symbol definitions
Calculating the center of gravity for an empty vehicle:

RAWempty * l
lf = Equation 4.1
GVWempty
Calculation of the actual axle load (axle load distribution)

Wmi * l mi + GVWempty * l r + W fr * (l fr + l ) − Wre * l re
FAW = Equation 4.2
l
RAW = W fr + GVWempty + Wmi + Wre − FAW Equation 4.3 Note: For FAW use the result of Equation 4.2

Center of gravity coordinates in vertical – direction (center of
gravity height)
We recommended the following procedure to determinate the over- lf l
all height of the center of gravity:

lr
• Check tire pressure and correct them if necessary
•
cen
Determine the axle loads of the front axle (FAW) and the t
gra er of
vity
rear axle (RAW) on a level surface α
• Block the vehicle springs to avoid spring deflection influ-
ences during the measuring, (e.g. by replacing the shock
absorbers by suitable spacers)
• α
hf
Block springs of cab and fill the tank completely
• Place the vehicle-implement/body-combination in a horizon- Scale
tal and level position with one axle on the scale
QRAW
Warning: Use wheel chocks to prevent vehicle from rolling.
• Lift the other axle at least 1/3 of the wheelbase
• Weigh the existing axle load (RAW with lifted front axle or Figure 4.10: Determining the height of the center of gravity
FAW with lifted rear axle)
• Measure the exact lifting height (hf) of the front or rear axle. QFAW Front axle load by lifted rear axle
As an alternative to the lifting height, you also can determine QRAW Rear axle load by lifted front axle (see Figure 4.10)
the angle between the wheel centers to the horizontal. hf Lifting height of the raised axle
• Calculate the height of the center of gravity by using the hcog Center of gravity height above the wheel center
Equation 4.4 to Equation 4.9 hs Center of gravity above the road surface
rstat Statically loaded tire radius (see also Table 4.3)
• For confirming the height of the center of gravity, raise the α Angle between the wheel centers to the horizontal
lifted axle by further (e.g.) 4 in or 100 mm. Measure the axle
Table 4.2: Symbol definitions
load and the lifting height again and calculate the c.o.g.
height a second time.
If the vehicle suspension can’t be blocked it’s necessary to do sev-
eral calculation with different lifting heights, e.g. hf1 = 1/3 of the
wheelbase, hf2 = hf1 + 4 in, hf3 = hf2 + 4 in, hf4 = hf3 + 4 in. You can
limit the measurement errors by using the average value of all cal-
culated c.o.g. heights. Deviations of the c.o.g. height of more than
2 in or 50 mm point to measurement and/or calculation errors.

Code Tire rstat Example: Calculation of the center of gravity height

R34 395/85 R20 XZL 21.34 in 542 mm QFAW = 10,271 lbs
R40 315/80 R22.5 XDN 19.88 in 505 mm GVW = 19,200 lbs
R41 385/65 R22.5 XZY 19.65 in 499 mm FAW = 9,000 lbs
R42 445/65 R22.5 AC70 21.22 in 539 mm hf = 45 in
R42 445/65 R22.5 XZL 21.18 in 538 mm rstat = 21.34 in (tire size: 395/85 R20)
R61 445/70 R24 XM47 22.36 in 568 mm l = 131.89 in
Table 4.3:Statically (loaded) tire radius Note: Rear axle is lifted up.
⎛ l Q − FAW ⎞
hs = ⎜ * FAW * l 2 − h 2f ⎟ + rstat
hf ⎛h ⎞ ⎜h GVW ⎟
sin α = ⇒ α = arcsin⎜⎜ f ⎟⎟ Equation 4.4 ⎝ f ⎠
l ⎝ l ⎠ ⎛ 131.89in 10,271lbs − 9,000lbs ⎞
hs = ⎜ * * (131.89in) 2 − (45in) 2 ⎟ + 21.34in
⎝ 45in 19, 200lbs ⎠
hs = hcog + rstat Equation 4.5
hs = 45.39in
Equation for lifted front axle:
⎛ l Q − RAW ⎞ Caution: Practical determination of the center of gravity
hs = ⎜ * RAW * l 2 − h 2f ⎟ + rstat Equation 4.6
⎜h GVW ⎟ height may only be carried out by experienced
⎝ f ⎠ personnel using suitable lifting facilities.
Alternative equation for lifted front axle using the angle α:
⎛Q − RAW 1 ⎞
hs = ⎜⎜ RAW *l * ⎟ + rstat
tan (α ) ⎟⎠
Equation 4.7
⎝ GVW
Equation for lifted rear axle:

⎛ l Q − FAW ⎞
hs = ⎜ * FAW * l 2 − h 2f ⎟ + rstat Equation 4.8
⎜h GVW ⎟
⎝ f ⎠
Alternative equation for lifted rear axle using the angle α:

⎛Q − FAW 1 ⎞
hs = ⎜⎜ FAW *l * ⎟ + rstat
tan (α ) ⎟⎠
Equation 4.9
⎝ GVW

Calculation of the overall center of gravity simulated in the empty vehicle. Thereby the subtraction of the spring
deflection travel xSpring in the above mentioned equation is not appli-
To calculate the overall c.o.g., the positions of the center of gravity
cable.
of the chassis, implement or body relative to the chassis and the
position of the load capacity must be known. Additionally the deflec-
tion travel of the front and rear axle, induced by the implement/body Determination of the center of gravity height by a tilting test
or the load must be known.
The center of gravity height hs may also be approximated by carrying
If all the data are known, you can calculate the position of the over- out a tilting test on a stationary vehicle. As this is a static test, µ = 1 is
all center of gravity with a sufficient degree of accuracy. assumed. One side of the vehicle is lifted up by the dimension hk until
n Number of individual masses the vehicle almost falls into the prepared safety cables.
Dimension by which the center of gravity has been Secured by a crane!
xSpring lowered due to spring deflection at the front and rear

axle
⎛ n mass n * c.o.g. height of the massn above the road ⎞ Seal off
hs = ⎜⎜ ∑ ⎟⎟ − x Spring danger zone!
⎝ i =1 GVW with implement / body ⎠
Equation 4.10
hk
α
Example: Vehicle with implements in transport position

Pivot point
S
c.o.g. above the road
Description: Mass [lbs]
surface [in]
Vehicle empty 34.65 17,600 Figure 4.11: Tilting test
Front mounted implement 27.60 1,750
Central mounted body 70.50 4,410 The following applies to the axle-related tilting angle:
Rear mounted implement 29.50 1,100
xSpring 0.98 hk
sin α = Equation 4.11
s
Table 4.4: Necessary information
17,600lbs * 34.65in + 1,750lbs * 27.6in + 4,410lbs * 70.5in + 1,100lbs * 29.5in With the tilting angle determined at the axle, the height of the center
hs = − 0.98in
17,600lbs + 1,750lbs + 4,410lbs + 1,100lbs of gravity hs can be calculated with:
hs = 39.31in 0.5 * s
hs = Equation 4.12
tan α
To simplify the calculation, we determine the center of gravity of the
empty vehicle (as described in the beginning of this section) with
deflected springs. Therefore, when the vehicle is loaded to the per-
missible GVW, the spring locks must be installed and the vehicle
unloaded again, so that the compression of a fully loaded vehicle is

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
vertical is significantly greater as a result of unilat- height of the center of gravity (vehicle with all implements and/or
eral spring deflection. The static tilting test must only bodies and payload) is as low as possible.
be carried out by experienced personnel using suit-
C.o.g. height above the road surface Note
able restraining facilities of suitable dimensions. The
Permissible range
static tilting angle must be determined precisely on a up to 51 in up to 1,300 mm
of c.o.g. height
tilting stage.
between 51 in between 1,300 mm Permissible range
and 59 in and 1,500 mm with restrictions1)
between 59 in between 1,500 mm Permissible range
and 67 in and 1,700 mm with restrictions2)
4.8.3 Chassis center of gravity Not permitted
above 67 in above 1,700 mm
The following center of gravity heights of the chassis are esti- (above limit)3)
mated values with the empty vehicle in its permissible GVW Table 4.6: Permissible c.o.g. height
spring-deflected state without platform or platform subframe.
Chassis Chassis Notes:
c.o.g. (above c.o.g. (above 1)
Wheelbase Restrictions for c.o.g. height between 51 in and 59 in:
wheel center) road surface)
Vehicle Model
hcog hs * Practical road trials and approval by the Freightliner Unimog
[m department required, definition of restrictions necessary (e.g.
[in] [mm] [in] [in] [mm]
m] instruction of drivers, limited off-road-capability, reduced maxi-
U500 NA 405.210 131.89 3,350 15.75 400 36.22 940 mum speed to 55 mph or less)
U500 NA 405.210 153.54 3,900 15.75 400 36.22 940
Table 4.5: Chassis center of gravity 2)
Restrictions for c.o.g. height between 59 in and 67 in:
Practical road trials and approval by the Freightliner Unimog
*Note: The center of gravity height above the road surface is department required, definition of restrictions necessary (e.g.
calculated using the 395/85 R20 XZL (Code R34) tire. instruction of drivers, limited off-road-capability, reduced maxi-
For other tires please use data of Table 4.3, page 70 and mum speed to 35 mph or less, no off-road use!)
calculate the c.o.g. height above the road surface with
Equation 4.5, page 70 by yourself.
3)
Exceptions possible, e.g. operations in restricted areas and at
very low driving speed < 10 mph

Maximum c.o.g. height with different wheel loads

If asymmetrical load is unavoidable (e.g. in the case of a side- 4.9 General notes on vehicle components
mounted loading crane, generator, lateral boom mower, etc.) and
the difference in wheel loads exceeds 10 % of the relevant axle 4.9.1 Tires
loads then the approval of the Freightliner Unimog Implement De-
The implement or body manufacturer must ensure, that
partment is necessary. In this case please contact the Unimog Im-
plement Manager listed at the beginning of this guideline. The per- • approved wheels and tires with sufficient load-bearing capac-
missible overall height of the center of gravity must always, if the ity are used
overall position of the c.o.g. is asymmetrical, be lowered in propor-
• the permissible axle loads are adhered to
tion to the difference in wheel loads.
In the case of 10% asymmetry, the overall c.o.g height can be cal- • the tire pressure specified in the operating instructions is ad-
culated by the following equation: hered to
• there is sufficient clearance, even in the event of maximum
hmax new = 0.9 * hmax Equation 4.13
chassis frame torsion, maximum axle loads and maximum
steering lock, between the tires and chassis components (e.g.
wheel house, fender, springs etc.)
4.8.5 Anti-roll bars • there is sufficient clearance by use of tire chains, even in the
event of maximum chassis frame torsion, maximum axle loads
All Unimog´s are equipped with standard anti-roll bars on the guid- and maximum steering lock between the tire chains and chas-
ing on the front axle and rear axle. This guarantees acceptable driv- sis components (e.g. wheel house, fender, springs etc.)
ing characteristics even in the case of implements and bodies with
high centers of gravity. If the use of tire chains is not possible due to the body/implement
(e.g. positions of the rear fender), this must be pointed out in the im-
plement operating instructions.

• Use an auxiliary dust filter if the vehicle is operated in ex-

4.9.2 Cooling tremely dusty conditions, but observe the maximum permissi-
ble air intake restriction. If in doubt, contact the Unimog Im-
The cooling system (radiator, charge-air cooler, fan, hydrostatic or plement Manager listed at the beginning of this guideline.
electric driven fan, radiator grille, air ducts, coolant circuit, etc.) must
not be modified. Sufficient airflow must be guaranteed. Therefore
please consider the following points: 4.9.4 Exhaust system
• Keep the radiator air inlet free (minimum distance between Modifications to the exhaust system are not permissible since the type
radiator surface and implement parts: 8.00 in / 200 mm) and position are specified in the general certification. Relocation of the
exhaust tail pipe required for operation is permissible. For example, in
• Do not block the air outlet behind the radiator (pressure fan).
permanent crane work operation a tail pipe can be connected to an
Minimum distance between radiator surface and implement
extension pipe of the same diameter. With slow driving speeds (e.g.
parts: 8.00 in / 200 mm.
work with plate compactors, suction sweepers) the tail pipe can be
• Do not affix warning signs, badges or other trim parts in the rotated.
area in the front of the radiator For driving on public roads the original position of the exhaust tail pipe
• If possible, design the implements in such a way, that the must be restored.
radiator is not exposed to dirt
Provide auxiliary cooling facilities for major components if the Notes:
usage profile leads to the expectation of temperature problems. Do
not install an auxiliary radiator in front of the standard coolant radia- • In the case of modifications, use original parts of the Freightliner
tor or intercooler; only use complete units with their own fans, e.g. LLC.
electrically driven. • The free cross-section of the exhaust pipe behind the muffler must
not be reduced.
Disc brakes: • Bends in pipes must not be more than 90°, see Figure 4.13.
During general operation disc brake cooling must not be impaired • Additional bends in pipes are to be avoided.
by implement components, for example auxiliary wheel covers,
brake disc covers, etc. • Minimum bending radii of pipes must more than 2.5 times pipe
diameter, see Figure 4.12.
• Minimum distance to plastic lines, electric cables and spare tire:
4.9.3 Engine air intake
o 7.87 in / 200 mm in the case of exhaust systems without shields
Modifications to the engine-air intake are not permissible.
o 3.15 in / 80 mm in the case of sheet metal shields
• Protect the air intake against flying sparks by fire fighting ve-
hicles (wildfire rescue vehicles) o 1.57 in / 40 mm in the case of sheet metal shields with additional
insulation

• Additional shields may be necessary in the area of operating

An alternative supplier for torsion frames is:
components, aggregates and implement parts and installations.
Order Joe Zaloga
• If parts of the exhaust system are modified, the implement manu-
address: Saddle River Road 7222
facturer must guarantee a supply of spare parts. Corresponding
Monsey, NY 10952
notes must be included in the implement operating instructions.
Phone: +1-845-323-9231
Email: Mbilunimog@aol.com
The surface and anti-corrosion protection of the springs must not be
damaged during the installation of additional devices.
Spring / shock absorber combination
The spring / shock absorber combination must not be changed with-
out a written authorization of Freightliner LLC. Generally a practical
test (e.g. road trails) is necessary before approval.
Changing springs
Figure 4.12: Minimum bending Figure 4.13: Incorrect pipes
radius Springs must not be shortened. No shorter or longer springs or spring
pads may be installed.
4.9.5 Springs 4.9.6 Brake system
In the case of high asymmetrical loads, caused by lateral working Changes to brake lines (e.g. longer lines) influence brake timing and
implements (e.g. lateral boom mower) it may be necessary to mount must be checked by an official test center in according to FMVSS121
a spring blocking device. Please contact the Unimog implement / CMVSS121.
manager for further information. The following company offers independent testing according to
The use of a torsion frame will be necessary when bending mo- FMVSS 121 / CMVSS 121:
ments, caused by the boom of an implement, are higher than Link – Radlinski, Inc.
14,750 lb⋅ft / 20 kNm. Freightliner LLC recommends the ap- Braking Systems Consultant
proved torsion frame for U500 manufactured by MULAG®. 3143 County Road 154
East Liberty OH 43319
Order Mog Implements
(937) 666-5006
address: 171 Church Street, Suite 300
Charleston, SC 29401 ABS (anti-locking braking system) is fitted as standard on Unimog
Phone: +1-843-723-7361 vehicles. No changes may be made to any part of the system.
Fax: +1-843-723-7362 4.9.7 Maintenance and repair
www.csroads.com
Maintenance and repair of the vehicle must not be made unnecessar-
ily difficult due to the implement / body. Maintenance points and ag-
gregates must be easily accessible.

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- on the front
plements and special bodies or parts thereof must be developed mounting plate
with a quick-release design.
4.10 Secure mounting of the implement / counterweight

on the vehicle
The minimum and maximum axle loads must be considered, see

section 4.4, page 62.
The implement manufacturer is responsible for secure mounting of Figure 4.14: Front mounted counterweights
the implement, especially in transport position. When designing the
mounting components and transport locking devices, particular at-
tention must be paid to the following: Applications with front mounted implements could require the installa-
tion of counterweights on the rear of the truck to achieve the minimum
• High longitudinal, transverse and vertical accelerations rear axle load and to avoid an overloading of the front axle. Therefore
• High shock factors (e.g. driving off-road) with constantly two mounting position are possible:
changing magnitude and frequency • Mounting in the rear mounting brackets
This means that all implements / bodies must be secured against The fastening method of a counterweight in the rear mounting brack-
slipping and lifting. This also applies to loads with the exception of ets (code D50) should be preferred. Advantages of counterweight in
bulk cargos. D50:
Possible mounting positions and the right securing of counter- • Low center of gravity
weights are shown in the following drawings. In case of some rear
mounted implements it could be necessary to equip the vehicle with • Secure fastening
a front mounted counterweight (see Figure 4.14). Therefore suitable
claws that are aligned with the pocket of the front mounting plate,
should be used, see Figure 4.20, page 83.

Counterweight
(max. 1.5 t)
bolted front locking device
Plate: 6x6in, thickness: 12in

Counterweight in the rear (150x150mm, thickness: 10mm)
mounting brackets (Code D5
max. 1.5t (max. & min. axle
loads must be considered).
Figure 4.15: Rear mounted counterweights

Counterweight
The counterweight mounted on the rear mounting brackets (code (max. 1.5 t)
D50) can be fastened via plates and brackets by use of the regular
D50 bores at the end of the vehicle frame.
A second mounting position for a counterweight or an additionally
counterweight can be the platform.
bolted front Bolt: 1 1/4in,
• Mounting on the rear of the platform grade 8
locking device
In case of a platform-mounted counterweight the following require- (M30, 12.9)
ments (see also Figure 4.16) must be considered:
• The counterweight must be bolted on the platform with suffi-
ciently dimensioned bolts and mounting plates; e.g. 4x 5/8 in
(M16) or 2x 1¼ in (M30).
• Use of a bolted front locking device between the counter-
weight and the front of the platform.
Figure 4.16: Fastening of platform-mounted counterweights

The necessary testing is the responsibility of the implement /

body manufacturer.
4.11 Bodies with changing overall center of gravity
• Bodies must not move from the transport position uninten-
tionally! By use of implements, which are operated during driving and thus in-
fluence strongly the overall center of gravity (e.g. pivoting of a hydrau-
• Implements must be mechanically secured in transport posi- lic boom with a mower head) the following checks, described in sec-
tion to prevent unintentional movement! tion 4.11.1 Static check and 4.11.2 Dynamic check, are required.
• A corresponding note for transportation safety is to include The tests described are conducted with a boom mower, however the
into the instruction manual! tests can be applied to all vehicle-implement-combinations with com-
parable usage profiles (e.g. brunch and hedge cutters, tunnel washing
brushes, etc.).
Counterweights or ballast must be positioned in such a way,
that they are unable to move and they must also be secured Check conditions:
against lifting. Extend boom mower to maximum boom length, heaviest operating
tool and movement or telescopic devices fully extended. The tool
must be freely floating above the ground. If a counterweight is neces-
The transport position of the implement / body must be specified sary (e.g. use of front implements) the weighing process must be car-
unambiguously, e.g. Unimog with a snow cutter mounted to the front ried out with the counterweight installed.
mounting plate and secured counterweight on the platform. Move-
able implement parts must be secured so that they can’t move.
They must also be mechanically locked if possible.
4.11.1 Static check

In the case of cranes or backhoes the boom must either be me- The smallest wheel load must be at least 10% of the relevant axle
chanically secured to prevent it from extending (e.g. use of a load. The absolute lowest value is 882 lbs / 400 kg.
turnbuckle) or secured against unintentional movement from
the transport position (e.g. using a shut-off valve in the hydrau- If the implement is extended transverse to the direction of travel, the
lic pressure line to the crane valve manifold). sum of the opposing wheel loads must not be less than ¼ of the ac-
tual gross vehicle weight.
These are limit values and must be adhered to even if several imple-
ments are operated simultaneously. If corresponding implement com-
binations are mounted on a Unimog, the implement manufacturer is
responsible for the compliance with these limit values.

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
Right
Weighed Left front Right front Left rear
rear
wheel: (LF) (RF) (LR)
(RR)
Measured
values 5,100 7,100 1,100 8,600
[lbs]:
Limit val- 882 lbs or 882 lbs or 882 lbs or 882 lbs or
ues 10% of the 10% of the 10% of 10% of
(defini- FAW FAW the RAW the RAW
tions) 1
4 * GVW ≤ LF + LR
Limit val- 1,220 lbs 1,220 lbs 970 lbs 970 lbs
ues 1
4 * 21,900lbs ≤ 5,100lbs + 1,100lbs
(num-
bers) 5,475lbs ≤ 6,200lbs
Table 4.7: Example for a static check
4.11.2 Dynamic check

The standing stability must also be verified by suddenly stopping
at the quickest possible lowering movement, with the boom maxi-
mum extended. The wheel opposite the boom must not lift-off
the ground.

4.12 Mounting of implements
Center mounting
Platform mounting F see chapter 4.14.2
Ball points mounting F see chapter 4.14.3
Direct mounted body F see chapter 4.14.4
Mounting frame for
implements with outriggers F see chapter 4.14.6
Front mounting Mounting between axles Rear mounting

F see chapter 4.13 F see chapter 4.14.8 F see chapter 4.15
Figure 4.17: Implement mounting positions on the Unimog U500NA

4.13 Front mounting of implements

4.13.2 Front mounting plate
4.13.1 General notes to front mounting
The front mounting plate can be fixed to the integrated implement
There are two possible methods of using the front body space of
support in two different positions. Implements on the front mount-
the Unimog:
ing plate can be driven by the front power take-off (code N08), by
• Mounting on the front mounting plate (option code D12), the basic hydraulics (single and/or double circuit) or by the power
see Section 4.13.2 Front mounting plate, page 81 hydraulics (closed or open circuit).
• Mounting on the front mounting integrated implement sup- β
port, see Section 0
• *
• Integrated implement suppor, page 85
When mounting implements on the front mounting plate or the in-
tegrated implement support the following items must be consid-
ered:
• Maximum permissible front axle load Figure 4.18: Front mounting plate on the Unimog U500NA
• Axle load distribution
• Minimum rear axle load Note: * Depending on spring deflection and tires. For detailed po-
sition and approx. calculation of the front PTO to the front
• Driver’s view of vision mounting plate, see Section 5.9.5 Position of PTO shaft,
• Implement front end distance (center steering wheel to the page 174 and also Section 5.9.6 Calculation of the PTO
front edge of the implement, maximum shaft height, page 175. Angle β depends on vehicle loading
137.79 in / 3,500 mm, depends on local regulations) and varies between 0° (fully loaded vehicle) and 1.5°
(empty vehicle).
• Implement drive
It may be necessary to mount a counterweight on the platform

and/or in the rear mounting brackets (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 62.

Dimensions in [mm]
and dimensions in
brackets in [in]
Figure 4.19: Front mounting plate (code D12, part-no. A 405 550 12 38)

For implement mounting to the front mounting plate, suitable Listing of the Schmidt mounting kit for implement mounting to the
claws that are aligned with the pocket of the front mounting Unimog front mounting plate
plate, should be used, see Figure 4.20. These compatible and
screwable claws for front mounting plates, size 5 (code D12), are Schmidt
Description: Quantity:
manufactured by SCHMIDT®. Part No.:
Claw size A (compatible to Unimog
Order address 0150 026-3 2
Joe Zaloga plate)
Saddle River Road 7222
Monsey, NY 10952 0151 252-4 Block (40 mmx20 mmx140 mm) 2
Phone: +1-845-323-9231
Email: Mbilunimog@aol.com 0208 209-7 Hexagon bolt M16x70 mm 10.9 4
Hexagon socket countersunk flat
0222 075-4 4
®
The SCHMIDT identification head screw M16x70 mm 10.9
number of the zinc-plated claws 0205 474-0 Hexagon nut M16 8
is: 150 026-3 GGG 40
0150 722-7 Bolt 24 mmx315 mm 2
We recommend ordering the
complete mounting kit, listed in 0168 437-2 Washer 46 mmx25 mmx12 mm 2
Table 4.8 for implement mount-
ing to the front mounting plate 0204 710-8 Washer B 25 mmx44 mmx4 mm 2
of the Unimog.
0206 598-5 Split pin 6.3 mmx40 mm 2
0216 796-3 Eyebolt B M27x100 mm 8.8 2
0204 683-7 Washer 28 mmx60 mmx10 mm 2

Figure 4.20: Schmidt claw
size 5 0205 438-5 Hexagon nut M27 2
0155 652-1 Complete SCHMIDT® Mounting Kit

Caution: Please use only suitable claws. Grinding, cutting
or other fabrication on claws and on the front Table 4.8: SCHMIDT® mounting kit for Unimog front mounting plate
mounting plate is not permitted!

All dimensions are in [mm]
Figure 4.21: Compatible claw for front mounting plate from SCHMIDT®

Angle of the front mounting plate
The front power take-off shaft (code N08) is mounted parallel to
the longitudinal frame member. The angle between the front
mounting plate and the vertical of the longitudinal frame member is
1.5°. This angle is independent of the spring deflection condition
and thus of actual axle and vehicle loads.
Figure 4.23: Angle between front mounting plate and the vehicle
frame (optional mounting position of the front mounting plate)
4.13.3 Integrated implement support

The Unimog front
mounting plate is fit-
ted to the lowest of Standard to the Unimog is an integrated implement support in the
the three drillings. front part to which the front mounting plate is attached, for exam-
ple. The implement manufacturer can develop its own brackets on
Figure 4.22: Angle between front mounting plate and the vehicle the integrated implement support, e.g. cable winch brackets or
frame (serial mounting position of the front mounting plate) country-specific mounting plates. The manufacturer can also pre-
pare the implement for direct mounting on the integrated imple-
ment support. For necessary measurements see Figure 4.24, page
86 or also the vehicle drawings on the Unimog Resource CD.

Dimensions in [mm] and

dimensions in brackets in [in]
Figure 4.24: Integrated implement support

Removal of the front mounting plate For retrofitting the tubular cross member, the following parts are
necessary:
For vehicles without mounting plate (code D12) a tubular cross
member is fitted between the two halves of the integrated implement
Part Number Description Quantity
support at the factory. In case, that the front mounting plate has
been removed on vehicles with code D12 the tubular cross member
(part-no.: A 405 520 00 48) has to be retrofitted. A 405 525 00 17 Screen 1
A 405 520 37 41 Right Bracket 1
A 405 520 42 41 Left Bracket 1

A 405 520 0048
A 000 987 07 72 Edge Guard 1
A 405 520 00 48 Cross-member 1
N 910105 020010 Right Side Bolts 3
N 913023 020001 Right Side Nuts 3
N 910105 020025 Left Side Bolt 1
A 405 997 01 01 Bumper Plugs 2
A 405 520 10 70 Bumper 1

Figure 4.25: Integrated implement support with cross member (MB
part-no. A405 520 00 48) A 003 997 39 48 Bumper Seal Ring 1
Note: Loosen the bolt at the steering gearbox and retorque! A 405 524 13 40 Bumper Bracket 1
N 910105 010009 Bumper Bolts 2

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 contact the Unimog Imple-
ment Manager listed at the beginning of this guideline.

4.13.4 Permitted implement weights; permitted forces and 4.13.5 Front end dimensions
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- tual axle loads.
pling level of the front mounting plate. The maximum axle loads
must not be exceeded. In most cases a counterweight on the plat-
form and/or in the rear mounting brackets is necessary. Otherwise
the minimum rear axle load of 41% of the actual GVW will not
achieved.
The maximum off-set front weight (e.g. lateral boom mower
mounted on the front mounting plate) is 3,307 lbs / 1,500 kg at a
7.87 in / 200 mm distance from the coupling level and
90.59 in / 2.3 m distance to the center of the vehicle. This means
the maximum torque is 24,965 lb⋅ft / 34 kNm. For torques higher
than 14,751 lb⋅ft / 20 kNm a vehicle roll stabilization is necessary,
see chapter 4.9.5 Springs for more details.
implement c.o.g.:
max. 1,500kg / 3,307lbs
Figure 4.27: Sketch to front end dimensions
Dimension A Dimension B Dimension C

[in] [mm] [in] [mm] [in] [mm]
44.96 1,142 8.86 225 38.58 980
Table 4.10: Front end dimensions
implement c.o.g.:
max. 2,000kg / 4,409lbs

Figure 4.26: Permitted implement weights

The available vehicle wheelbases with platform and platform sub-
frame and the different mounting parts are diagramed on the follow-
4.14 Center mounting of implements and bodies
ing two pages (Figure 4.34 and Figure 4.35).
General notes to center mounting
The following mounting methods using the center body space of the 4.14.1 Bodies/implements with variable overall c.o.g.
Unimog are possible:
Implements/bodies with variable centers of gravity are, for example,
• Mounting bodies/implements on the platform, see Section boom mowers. In case of mounting such implements on the platform
4.14.2, page 92. or on the ball points it must be ensured that the implements and bal-
last etc. are sufficiently secured against sliding and lifting. For this
• Mounting bodies/implements on the platform subframe with the implement frame must be locked with wheel hub chassis sup-
ballpoints, see Section 4.14.3, page 105. ports (see Figure 4.30, page 90). The torque caused by the boom
• Mounting bodies/implements with a mounting frame on the will be directly transferred with these wheel hub chassis supports to
Unimog implement mounting points see Section 4.14.4, page the rear wheels. The supports must be unlocked during transporta-
119. tion. We recommend adding a note for unlocking of the supports into
the operating manual of the implement. The operating position of the
• Mounting bodies/implements with outriggers and a mounting boom must be counter to travel direction of the vehicle. The ex-
frame on the Unimog implement mounting points, see Sec- tended boom must not be swung over the rear of the vehicle other-
tion 4.14.6, page 137. wise the ball points of the platform will be overloaded (wheel hub
• Routing cavity above the left frame longitudinal member un- chassis supports are not effective in this position).
der the cab, see Section 4.14.6.3, page 148.
• Mounting implements between the axles, see Section 4.14.8, Mounting an implement with a variable center of gravity (e.g.
page 156. boom mower) on the platform or on the platform subframe with
See section 5, page 164 to section 8, page 234 for information on ballpoints requires wheel hub chassis supports for stabiliza-
implement drive possibilities. tion.
Important Note: The height of the center of gravity for Wheel hub chassis supports are shown in Figure 4.30, page 90 and
bodies and implements must be kept as Figure 4.31, page 91. The displayed supports are available at the
low as possible. following company:
As a rule of thumb, the upper edge of a Order Mog Implements
spreader must not be higher than the address: 171 Church Street, Suite 300
roof of the cab, see also section Charleston, SC 29401
4.14.2.1, page 101 and following pages. Phone: +1-843-723-7361
Governing factor is the actual height of Fax: +1-843-723-7362
c.o.g. www.csroads.com
The supports are not available for Accuride rims (code R54).

The wheels are fastened on the wheel hubs with 10 nuts and bolts
(M22x1.5). The wheel bolts are arranged in a circle with a diameter
of 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 4.29 and Figure 4.28. The
shown figures apply for the following rims:
• 22.5 x 9.0
• 10.00V20
• 13 x 24
• 22.5 x 14
• 22.5 x 11.75
Dimensions without brackets are in [mm]. Dimensions in brackets are in [in].
Figure 4.29: Standard fastening of wheels on the Unimog
Figure 4.30: Fastening of the MULAG wheel hub chassis support

Figure 4.28: Fastening of wheels and wheel hub chassis supports

Figure 4.31: Drawing of the wheel hub chassis support

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
operating load and transportation (on-road and off-road) can be • At the two (2) front ball half shells use bolts (9/16 in x 5.5 in /
transferred safely. For bodies/implements on the platform, mount- M14x130) and self-locking nuts (9/16 in / M14) instead of
ing points are available in certain platform models. pins. Fastening torque: 37 lb·ft / 50 Nm.
Consider the following important notes:

The body/implement must be fastened free from play, so that it
can’t move on the platform and is secured against lifting. The
transportation position must be clearly specified; movable imple-
ment parts must be secured against moving and should be me-
chanically locked if possible. The height of the center of gravity of
bodies/implements must be kept as low as possible over the road
surface. For securely mounting on the platform, the forces (static
and dynamic) must be calculated. If necessary, mounting points of
adequate dimensions must be created on the floor of the platform.
Figure 4.32: Ball half shell assembly
The body/implement on the platform must only have point shaped
support at those points where the ballpoints of the platform sub- • Remove lever from shut-off valve of tipper cylinder or lock
frame are located. In this way, the weight of the implement can be (using cable ties) in “off”-position.
directly transferred to the subframe and bending of the platform is
prevented. The platform is only designed for an area load such as
when transporting sand.
Warning: Risk of serious injury or death may result from

tipping cylinder. Dissemble the platform only with
the tipping cylinder fully extended, otherwise the
cylinder can extend suddenly when removing the
platform.
Use code P01 (quick change platform) if the plat-
form is removed often. Dismount or lock lever
of shut-off valve in
Caution: Risk of vehicle damage! “off”- position.
The implement / body support on the aluminum Figure 4.33: Securing platform against tipping
platform side walls is not permitted!

Figure 4.34: Overview of the platform and subframe mounting parts at the U500 with a short wheelbase

Figure 4.35: Overview of the platform and subframe mounting parts at the U500 with a long wheelbase

Available platforms for the U500 NA Platform dimensions
Two different platforms are available for the U500 NA: Outer dimensions Inner dimensions
Code Dimension
[in] [mm] [in] [mm]
• Platform Code P27 available for short and long wheelbase.
Platforms P27 for long wheelbase are loosely delivered. Length 109.05 2,770 105.79 2,687
Width 89.80 2,281 87.20 2,215
• Platform Code P40 available for long wheelbase P27
Height front 25.20 640 19.68 500
Height rear 21.65 550 15.75 400
Length 139.76 3,550 136.85 3,476
Width 89.80 2,281 87.20 2,215
P40
Height front 25.20 640 19.68 500
Height rear 21.65 550 15.75 400
Table 4.11: Platform dimension
Every platform has eight fastening points and four additional bores.
For detailed measurements of the platforms and the attachment
points look at the drawings on the following pages (Figure 4.37 and
Figure 4.38) and also in the vehicle drawings on the Unimog Re-
source CD.
Figure 4.36: Overview of available platforms

Holes for
implement
fastening

Figure 4.37: Platform P27

Holes for implement fastening
Dimensions without brackets are in [mm].

Dimensions in brackets are in [in].
Figure 4.38: Platform P40

Note: Please consider the stops on the rear corner stakes and
the front platform wall for the left and right platform
Tipping cylinders
gates (see also Figure 4.39).
Two different tipping cylinders are available for the Unimog U500NA:
Stop for the • 4 stages for short wheelbase, part-no.: A 002 553 73 05
platform gate
• 4 stages for long wheelbase, part-no.: A 002 553 74 05
Tipping cylinders for U500NA

Rear tipping Side tipping
Wheelbase: Part-No.:
angle: angle:
131.89 in /
A 002 553 73 05 47° 50°
3,350 mm
153.54 in /
A 002 553 74 05 47° 50°
3,900 mm
Table 4.12: Tipping cylinders for U500NA
Implement / body fastening on the platform

Implements and bodies can be fastened on the platform by use of
Stop on the front platform wall Stop on the rear corner stake the holes in the platform, see Figure 4.40.
Figure 4.39: Platform gate stop
Hole for implement
fastening
Rear platform gate catches
The “Kinne-Grip” system is used for the rear platform gate catches.
So the rear platform gate can be opened by use of the upper or
lower catches. Advantages of this system are:
Only for fastening of pay-
• Maximum inner width with given outer width
load, not for fastening of
• Smooth outer surface (catch does not protrude) implements
• Side platform gates are held on the stake without rear plat-
form gate (ideal for implement operation, e.g. spreader)
Figure 4.40: Fastening points
• Stakes can be removed using simple grab handles

The tie-down eyes are not suitable for securing implements, only
for fastening payload. The maximum permissible force affect to the
towing point must not be higher than 4,500 lb⋅ft / 20 kN or
4,410 lbs / 2,000 kg. For heavy implement fastening on the plat-
form use ring nuts in the mounting holes like diagramed in Figure
4.45, Figure 4.46, page 100.

Figure 4.41: Tie-down eye Figure 4.42: Tie-down eye label

The positions of the tie down eyes can be seen in Figure 4.43 and
Figure 4.44 or in the vehicle drawings on the Unimog Resource
CD. 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. We rec-
ommend fitting a 7/8 in ring nut together with two reinforcing plates
(see Figure 4.47 and Figure 4.48) to attach spreaders or bodies. For
fitting a spreader at the rear we recommend the use of approved
chains, which are secured diagonally using at least 7/8 in ring nuts in
the rear mounting brackets, code D50. For fastening of spreaders
and other heavy implements additional drillings on the platform
should be fitted.
Important Note: Generally two locking bolts and two
bolts (see Figure 4.32, page 92) must be
used for non-tipping implements, which
are mounted on the platform. The cor-
rect position of the cutoff valve of the
tipping cylinder (closed position) must
be ensured.
Figure 4.43: Positions of the towing eyes on platform P27


Holes for
implement
fastening

Figure 4.47: Reinforcing plate

KENFORGING, Ohio
Figure 4.45: Positions of the fastening holes in platform P27 Eye Nut Style B C1030
Stock No. EN-9-HD
plate 3“ x 3“,
thickness ¼“
Holes for implement fastening
screw 7/8“
length 4“
Figure 4.48: Implement fastening with ring eyes
The holes in the platform bottom can be sealed for transporting bulk
materials.
Note: To mount the 7/8 in eye nut the serial 17 mm – holes in
Figure 4.46: Positions of the fastening holes in platform P40 the platform have to be enlarged to 1 in!

4.14.2.1 Spreaders on the platform o Stipulated mounting method

How to prevent the implement from sliding to the front
General: note: In case of a crash the spreader mounting The implement must be secured against sliding to the front using two
must not fail! mechanical stops (a and b). One of them has to be adjustable in
length. The implement fastening must be dimensioned in such a
n Prohibited mounting methods way, that, even in case of an accident, it does not slide to the front.
It is not permitted to brace the implement (grit spreader) against the a) Implement support at the rear edge of the floor or at the
sidewalls of the body. For this reason, the implement should not be cross beam of the subframe (preferred) (see Figure 4.51).
equipped with bracing devices. b) Adjustable stop at the front of the body (see Figure 4.50).
• It is not allowed to use the serial platform towing eyes. Rear view Side view
• It is not allowed to reinforce the implement by using the plat-
form’s sidewall.
ENKL ENKL
Implement a
Section A-A b
Bolts must not

Stops at the rear edge of the floor be exposed to
plate combined width must be at shear load!
least 32 in / 80 cm.
Figure 4.50: Rear mechanical locking

Side view Top view
A-A
Body Not per-
side mitted!
panel ENKLE
ENKL
At least 40 in / ENKL
100 cm wide
Figure 4.49: Prohibited mounting

Length
adjustable
Figure 4.51: Front mechanical locking

How to prevent lift-off and slipping of the implement (grit
min. Ø ¾“
spreader)
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. The spreader must always be fixed at the front first.
Front view
chains or straps ENKLER
4 x 5/8“, min. length 3“

Figure 4.54: Tie-down eye (option 2)
Note: The existing tie-down eyes must not be the sole anchor
points for fastening heavy implements, but shall be used for
additional fastening.
Tie-down eye
Figure 4.52: Front end mounting with chains or belts Rear mounting
The rear of the implement has to be fastened using option code D50
brackets or alternatively using the holes in the chassis frame and
KENFORGING, Ohio
suitable eye bolts, chains and turnbuckles to avoid lift-off and slip-
Eye Nut Style B C1030
Stock No. EN-9-HD ping of the implement.
plate 3“ x 3“, Side view

thickness ¼“
ENK
screw 7/8“
length 4“
Figure 4.53: Tie-down eye (option 1) Figure 4.55: Rear end mounting

Additional fastening between the support points
rear view Heavy implements (more than 11,000 lbs / 5,000 kg) must also be
secured to the central tie down eyes at each side of the floor plate,
using straps or chains.
ENKLER min. ¾“
ENKLER
plate
swivel plates
Figure 4.57: Center mounting of heavy implements
p Alternative solutions
ENKLER Alternatively, the implement may be bolted directly to the floor of the
ENKLER body. If you prefer this kind of mounting, please contact the Unimog
KENFORGING, Ohio
Eye Nut Style B C1030
Implement Manager for approval (submit an engineering drawing).
Stock No. EN-9-HD
eye nut 7/8“
grade 8 without D50
with D50
Figure 4.56: Rear end mounting with additional plate

Design of gritter implements
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).
The diagram can be used to remind designers, and makes it easy for visual checking by anyone.
The following rule applies: The height of the center of gravity for a (heavy) body must be kept as low as possible.
Figure 4.58: Correct and incorrect gritter design

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. If an implement is mounted on the chassis in the same
manner (ball points on the platform subframe and ball half shells
Tipping shell
on the implement) it must be ensured that there is sufficient clear- must not lay on
ance between the ball half shell and the ball yoke; see also Figure the ball yoke!
4.59.
The load on the ballpoints must not exceed the load, which results
from a platform, which is loaded to its maximum permissible value
of 15,400 lbs / 7,000 kg (depends on the maximum permissible
axle loads and the GVW). When tipping, each ballpoint must only Figure 4.59: Mounting diagram on the platform subframe
be loaded vertically with maximum 5,070 lbs / 2,300 kg.
For implement mounting on the platform ballpoints the original ball
mounting parts must be used. The necessary mounting parts are Available platform sub frames for the U500 NA
listed in Table 4.13 and can be ordered by any authorized Freight- Four different platform sub frames are available for the U500NA:
liner Unimog dealer.
• Low platform subframe (code P60) available for short wheel-
Parts designation: Part number: Note: base
Tipping shell A 405 610 00 35 2 pieces required
Tipping shell A 405 610 01 35 2 pieces required • Low platform subframe (code P60) available for long wheel-
base
Ball half shell A 405 610 00 75 4 pieces required
Locating bolt A 405 619 00 74 1 piece required* • High platform subframe (code P80) available for short wheel-
Locating bolt A 405 619 01 74 1 piece required* base
*Two, if the body cannot be tipped!
• High platform subframe (code P80) available for long wheel-
Table 4.13: Necessary mounting parts for ballpoint mounting base
The low platform subframe is the standard subframe for the
Note: A unilateral load on the subframe must be avoided. U500NA. Unimog vehicles with power hydraulics and/or live P.T.O.
The permissible axle loads are to adhere to. (code N05) will be equipped with high platform sub frames (code
P80).
Caution: Risk of damage to the platform subframe. The tip- Note: The power hydraulic components protrude approxi-
ping shell must not lay on the ball yoke (see mately 2.48 in / 63 mm above the upper edge of the plat-
Figure 4.59)! form subframe.


Figure 4.60: Overview of the available platform sub frames

Platform sub frames dimensions
Low platform subframe High platform subframe
Part-No.: A405 610 04 03 Part-No.: A405 610 05 03

Figure 4.61: Platform sub frames for short wheelbases

Low platform subframe High platform subframe

Part-No.: A405 610 06 03 Part-No.: A405 610 07 03

Figure 4.62: Platform sub frames for long wheelbases


Figure 4.63: Ball half shell, Part-No.: A405 610 00 35


Figure 4.64: Ball half shell, Part-No.: A405 610 01 35

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.
Figure 4.66: Diagonally mounting of the ball half shells
Four identical ball half shells can be used on bodies / implements

that do not tilt. Non-tilt able bodies / implements must always be se-
cured with four locating bolts! The shut-off valve of the tipping cylin-
der must be closed at vehicles equipped with tipping cylinder and
Dimensions in brackets are in [in]. non-tilt able bodies or implements. These notes must be included in
the implement / body installation manual.
Figure 4.65: Ball point, Part-No.: A405 991 00 20
Warning: Risk of vehicle and body / implement damage!

Improper use of locating bolts and shut-off valve
will cause damages to the implement / body and
the vehicle.

The height of the implement / body frame above the platform sub- Position of the contact points
frame longitudinal members must be designed in such a manner that of the polyamide plates
four plastic plates can be fitted at the implement / body frame. There
should be a distance of 0.06 in / 1.5 mm between the plastic plates
and the subframe (see Figure 4.67). In case of heavy bodies / im-
plements or dynamic loads (e.g. driving over uneven surfaces) the
body can be supported above the plastic plates directly against the
platform subframe longitudinal members. This method will prevent
overloading the platform subframe tubular cross members or ball
points which must only be vertically loaded with maximum 5,070 lbs
/ 2,300 kg. Use polyamide plates (nylon fiber) for best results.

Figure 4.68: Contact points of the plastic plates on the subframe
Figure 4.67: Correct mounting of the plastic plates

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
The front platform subframe - chassis frame - interface must be rein-

forced, if a demountable deposit skip should be mounted on the
ballpoints.
This can be done using the hole pattern of the chassis frame with a
fastening part (Figure 4.76, page 118). Therefore a holding plate
must be cut off of the platform subframe and holes must be inserted
(see Figure 4.71, page 114). These kind of implements / bodies
must be attached at the cross members of the platform subframe to
avoid overloading of the ballpoints when the vehicle will be raised by
the implement. To reduce the forces at the ballpoints U-bolts can be
used (see Figure 4.70).

Low platform subframe and short wheelbase Low platform subframe and long wheelbase
High platform subframe and short wheelbase High platform subframe and long wheelbase
Figure 4.71: Strengthened mounting of the platform subframe

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. These light up as soon as a small magnet is no
longer in the immediate vicinity of the tilt control sensor. The tilt con-
trol sensor is mounted directly on the platform subframe (see Figure
4.73).
If an implement is mounted on the ball points of a vehicle equipped
with a tipping cylinder, the magnet (Part-no.: A000 546 07 88; see
Figure 4.72) on the implement frame must be mounted in the exact
position so that the tilt warning lamp is not permanently lit. The mag-
net must not be attached on the side of the chassis under any cir-
cumstances as this could cause a collision (damage to the magnet)
when the platform is mounted.
Figure 4.73: Position of the magnet and the tilt control sensor
Further drawings with the position of the magnet and the tilt control
sensor are shown on the following two pages.
This side to the tilt

control sensor
0.48 in / 12,2 mm
0.87 in / 22 mm
1.28 in / 32.4 mm
Figure 4.72: Magnet of the tilt-warning lamp

Figure 4.74: Position of the magnet for the tilt control sensor on the short wheelbase

Figure 4.75: Position of the magnet for the tilt control sensor on the long wheelbase

ABSETSKIPPER
Figure 4.76: Suggestion for reinforcing of the front fastening interface

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
mounting frame are to fit flush on the upper frame flange of the Implement
chassis frame. Wood sill between the implement mounting frame sub frame
and the upper frame flange are not permitted. The use of U-bolts
and other clamping devices is not permitted.
The dimensions of the longitudinal members can be determined
Unimog frame
from the second moment of area for mounting and chassis frame
charts (see, page and, page). The displayed information applies only
for evenly loaded longitudinal members.
A smooth transition at the front end of the longitudinal members
should be designed. Two different solutions are possible:
Code D70
• Mounting frames with a maximum height of 6.3 in / 160 mm:
Figure 4.78: Front end of a mounting frame higher than 6.3 in
Drawings with detailed measurements are shown in Figure 4.102,

page 141.
Heavy bodies / implements need mounting frames with a high sec-
tion modulus. Such a high section modulus can be reached by use
of high or closed longitudinal members. Closed C - profiles should
be preferred to reduce the height of the center of gravity. The follow-
ing Figure 4.79 shows some possible profiles for mounting frames:
A = Open C – profile
Closed C – profile (Section modulus x 1.25 higher than at an
B = open C-profile)
Nested C – profile (Section modulus x 1.75 higher than at an
C = open C-profile)
Figure 4.77: Front end of a mounting frame with a max. height of
6.3 in Nested C – profile (Section modulus x 1.9 higher than at an open
D = C-profile)

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.
Figure 4.81: Possible transition from closed to open profiles
Figure 4.80: Possible transition from closed to open profiles

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. The following sketches display the possibilities of sub
frame dimensioning and the different designs of cross members.
Figure 4.83: Suggestion for design of cross members
Figure 4.82: Suggestion for design of cross members

Figure 4.84: Suggestion for a custom-manufactured low mounting frame


Figure 4.85: Suggestion for a custom-manufactured high mounting frame

Mounting frame Mounting frame with

with a C-profile a rectangular tube
Mounting
frame Mounting
frame
Vehicle Vehicle
frame frame
Figure 4.86: Sketches with dimensions of the subframe-frame-combination for the following section modulus diagrams

Figure 4.87: Section modulus of the frame-subframe-combination for a mounting frame with C-profiles (U.S. units)

Figure 4.88: Section modulus of the frame-subframe-combination for a mounting frame with C-profiles (metric units)

Figure 4.89: Section modulus of the frame-subframe-combination for a mounting frame with rectangular tubes (U.S. units)

Figure 4.90: Section modulus of the frame-subframe-combination for a mounting frame with rectangular tubes (metric units)

4.14.5 Bodies/implements directly mounted at the chassis frame without outriggers (e.g. shelters, fire bodies,.. )
Console fastening with Console fastening without

belleville spring washer belleville spring washer
package, package,
see pages 131 and 136 see pages 136
Fastening plate Fastening plate

A405 611 01 11 (U500 short wheelbase), see page 133 A405 611 00 11,
A405 611 03 11 (U500 long wheelbase), see page 134 see page 135
Figure 4.91: Overview of fastening plates for directly mounting (this figure shows a U500 with long wheelbase)

Figure 4.92: Tightening torques for mounting bodies/implements without outriggers directly to the chassis frame

1 x bolt M14x1.5x120,
grade 10.9
MB-No. N 910105014022
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
MB-No. N 913023014003
Figure 4.94: Arrangement of

Figure 4.93: Console with belleville spring washers
belleville spring washers

Implements like fire bodies, shelters, spreaders etc. can be

mounted via a mounting frame directly on the chassis. Therefore • Suitable fastening material for attaching a mounting frame on
the following parts are necessary and can be ordered by any au- a Unimog with long wheelbase:
thorized Freightliner Unimog dealer: Fastening material:
Suitable for part:
Part Wheelbase U.S. units Metric units Quantity
Part – No.: Quantity Bolt Diameter 9/16” UNF, Bolt M14x1.5x120
description: 131.89 in 153.54 in 4 Consoles
Length: 5”, Grade: 5 Grade: 10.9 4
A405 520 10 33 Console 4 X (N 910 105 014 022)
(Mounting with
A405 520 10 33 Console 6 X Belleville spring
Belleville spring washer
80 washer)
Table 4.14: Necessary mounting parts (A 000 993 05 26)
Support plates
8
(A 387 619 00 97)
Nut Diameter 9/16” UNF Nut M14x1.5
• Suitable fastening material for attaching a mounting frame on (N 913 023 014 003)
4
a Unimog with short wheelbase: Bolt Diameter 5/8“ UNF, Bolt M16x1.5x90 2 Consoles
2
Fastening material: Length: 3.5“, Grade: 5 Grade 10.9
Suitable for part: Nut Diameter 5/8“ UNF Nut M16x1.5 2
U.S. units Metric units Quantity
Support plates
Bolt M14x1.5x120 4
Bolt Diameter 9/16” UNF, 4 Consoles (A 387 619 00 97)
Grade: 10.9 4 Fastening plate
Length: 5”, Grade: 5 (Mounting with Bolt Diameter 9/16” UNF, Bolt M14x1.5 *
(N 910 105 014 022) 6 (middle)
Belleville spring Length: *, Grade: 8 Grade 12.9
Belleville spring washer A405 611 03 11
80 washer)
(A 000 993 05 26)
Support plates
8 Nut Diameter 9/16” UNF Nut M14x1.5 6
(A 387 619 00 97)
Nut M14x1.5
Nut Diameter 9/16” UNF 4 Fastening plate
(N 913 023 014 003)
Fastening plate Bolt Diameter 9/16” UNF, Bolt M14x1.5 * (rear)
8
Bolt Diameter 9/16” UNF, Bolt M14x1.5 * Length: *, Grade: 8 Grade 12.9 A405 611 00 11
4 (middle)
Length: *, Grade: 8 Grade 12.9
A405 611 01 11
Nut Diameter 9/16” UNF Nut M14x1.5 4 Nut Diameter 9/16” UNF Nut M14x1.5 8
Fastening plate * Bolt length depends on the sub frame thickness.

Bolt Diameter 9/16” UNF, Bolt M14x1.5 * (rear)
8
Length: *, Grade: 8 Grade 12.9 A405 611 00 11
Nut Diameter 9/16” UNF Nut M14x1.5 8
* Bolt length depends on the sub frame thickness.

t=8mm

Figure 4.95: Fastening plate (only short wheelbase; Part-No.: A405 611 01 11)

t=8mm

Figure 4.96: Fastening plate (only long wheelbase; Part-No.: A405 611 03 11)

t=10mm

Figure 4.97: Fastening plate (Part-No.: A405 611 00 11)

For more details, see Figure 4.34
Figure 4.98: Console (Part-No.: A405 520 10 33)

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 Figure 4.100, page 138 and Figure 4.102, page 141).
ENKLER
Figure 4.99: Sub frame with outriggers mounted on D62 brackets

The mounting frame must be designed in such a way, that it reaches Note: Limited accessibility to holes on fastening plate D70:
under the cab to avoid abrupt changes of frame stiffness between
Access to the holes of the fastening plate (code D70)
the mounting frame and the chassis frame. It should run out at an
mounted on the left hand side longitudinal support of the
angle of 20 degrees to the longitudinal member (see Figure 4.77,
chassis frame is limited by installation of the mounting frame.
page 119).
Therefore it is allowed to use only two holes (see Figure
Note: Disassembly of the complete power hydraulic system for 4.100) of the D70 plate. All three holes of the fastening plate
implement mounting on the mounting parts is neces- (D70) mounted on the right hand side are accessible for in-
sary. stallation.
When the power hydraulics have been removed, the electrical con-
nector must be protected against moisture and dirt. The electrical
interface is electronically monitored for malfunctions. The hydraulic
control panel must be parameterized to prevent error messages in
the electronics system of the Unimog (see the relevant service in-
formation).
Warning: All permanently mounted, heavy implements (e.g.
cranes, aerial devices, backhoes, etc.) must be at-
tached with a sub frame on the Unimog frame. The
mounting frames must of sufficient size and be
properly mounted to the chassis frame (see also
pages 119 - 120).
Figure 4.100: Limited accessibility to holes on plate D70
4.14.6.1 Code D70 (included in code D62):

The fastening plates (code D70, see Figure 4.101, page 139) are
mounted ex factory under the cab. The plates are mounted instead
of spacer between the chassis frame and the consoles of the rear
cab bearing. The front end of the sub frames should be bolted with
the D70 fastening plates.
An overview and the positions of the available mounting points and
hole patterns is shown in Figure 4.101.

A405 550 01 39

Figure 4.101: Fastening plate code D70 (included in D62), Part-No.: A405 550 01 39 (left), A405 550 02 39 (right)

4.14.6.2 Code D62: (Code D70 included)

The heavy implement mounting supports (code D62, see Figure Proposal for an implement mounting support using D62:
4.104, page 143) fit to the serial hole pattern for implement brack- The implement mounting frame can be fastened using the heavy
ets on the chassis frame. These supports should be used for mounting brackets (code D62) as shown in Figure 4.105, page 144
heavy implements (e.g. backhoes, cranes, all implements which shown. This mounting support can pass high forces through the
can raise the vehicle, etc.) and also in cases of multiple applica- bushing (diameter 1.77 in / 45 mm) into the chassis frame. The
tions, which need both the implement brackets hole pattern (e.g. projecting end of the mounting bracket above the vehicle frame
front end loaders with an under carriage load bar and a crane with provides lateral guidance of the implement-mounting frame. Using
mounting frame, etc.). one M24x300 mm bolt (alternative one bolt with diameter of 1 in
and 12 in length, grade 8) in combination with a spacer (Length:
Note: Combination of ex factory mounted platform sub 4 in; inner diameter: 1.1 in; outer diameter 2 in) ensures secure
frames code P60 and heavy mounting brackets (code mounting of the implement-mounting frame. The length of the bolts
D62) is not possible because of collision with welded and spacers depends on the dimensions of the mounting frame.
consoles on the sub frames. The bolts should be fastened with a torque of 260 lb⋅ft / 350 Nm.
Note: Retrofitting of the heavy mounting brackets (code D62)

For retrofitting of the heavy mounting brackets the following parts
will be needed:
• One bolt M14 x 1.5 x 50 mm (part no.: N910 105 014 011)
• One nut M14 x 1.5 (part no.: N913 023 014 003)
• Two bolts M12 x 1.5 x 50 mm (part no.: N910 105 012 021)
• Two nuts M12 x 1.5 (part no.: N913 023 012 002)
Warning: Risk of vehicle damage!

Fastening of mounting frames using U-bolts and
other clamping devices is not permitted!
Use of wood sills between implement mounting
frame and upper frame flanges is not permitted!

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)
Code D70 Code D62
Console
Figure 4.102: Overview of the different mounting points and fastening plates

Figure 4.103: D60/D62 hole pattern in the vehicle frame

Figure 4.104: Heavy implement mounting support, code D62 (Part-No.: A405 552 04 18)

Dimensions with a * depends on the subframe height.

Figure 4.105: Proposal for fastening of a mounting frame by use of heavy mounting brackets (code D62)


Figure 4.106: Subframe tolerance when using code D62

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 loose platform (code P27) is available ex
factory.
Figure 4.108: subframe body on implement mounting ball points
If, for example, the P27 tipping platform for a wheelbase of 3900 mm
is to be fitted to the implement subframe, the relevant ball points
should be ordered as original replacement parts. The ball point has
the part number MB 405 991 01 20.
Figure 4.107: Code D62 mounted on the frame

Figure 4.109: Welding of the ball points into to cross members
When fitting platforms on the implement mounting sub frame, a

loosely delivered platform (code P27) available ex factory. This plat-
form can be fitted on the implement-mounting frame by use of a
loading crane or similar implements. 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). Attention should be paid to
the correct position of the cross members on the mounting frame. Dimensions without brackets are in [mm].
The measurement of the center of the ball point to the upper edge of
the mounting frame must be 2.64 in / 67 mm otherwise the 0.06 in /
1.5 mm distance between the polyamide plates of the platform to the Figure 4.110: Ball point, Part-No.: A405 991 01 20
upper edge of the mounting frame (see Figure 4.67, page 112) will
not be adhered to.

#
4.14.6.3 Mounting frame for a wing plow support

The following graphics and sketches show a concept for fastening of
a wing plow on a Unimog U500.
All figures, sketches and recommendations are without obligation.
All dimensions without brackets are in [mm] and all dimensions in
brackets are in [in].
The Unimog must be equipped with a self-supporting mounting
frame. Therefore the mounting frame must be fastened on the Uni-
mog chassis by use of heavy implement brackets (code D62) and
front fastening plates (code D70 included in code D62).
The entire forces resulting from the wing plow must be directly pref-
aced into the mounting frame. A force flow through the chassis
frame is prohibited and results in vehicle damage.
Unilateral (asymmetrical) weight distribution between wheel posi-
tions must be avoided (see Section 4.5, page 63). 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-

support Figure 4.113: Example 2 for a wing plow on a Unimog

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)

Figure 4.121: Mounting frame with cross member and vertical frame
member (top view)
Figure 4.122: Wing plow-support mounted via code D62 and D70 on
the chassis frame (side view)
Figure 4.119: Cross member (top view)
Figure 4.120: Mounting frame with cross member and vertical frame Figure 4.123: Wing plow-support mounted via code D62 and D70 on
member (side view) the chassis frame (side view)

Figure 4.124: 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
plow-support

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
in case of small cranes, without a sub frame is not permitted and will • Minimum axle loads
cause vehicle damages. The sub frame must be dimensioned ac- • Standing stability
cording to section 4.14.4, page 119.
• C.o.g. height
The crane mounting frames on common trucks are attached to the
frame with U-bolts or other clamping devices. These mounting
methods cannot be used on Unimog´s and will cause damages to Mounting positions of cranes
the chassis frame. Use only the fastening brackets and plates, which
are recommended in this Unimog mounting guideline. Cranes can be mounted on three different positions on the Unimog:
• Front mounting of cranes:
o Cranes up to 20 mt can be mounted directly behind
the cab.
o Advantages: Trailer use possible, Mounting of plat-
form possible
Mounting methods • Center mounting of cranes:

not permitted! o Cranes up to 30 mt (in special cases up to 40 mt) can
be mounted on the center of mounting frame.
Figure 4.128: Attachment of mounting frames with a U-bolt
o Advantages: Plenty of space between the cab and
the crane
• Rear mounting of cranes:

o Cranes up to 16 mt can be mounted at the rear of the
vehicle.
o Advantages: Quick attach and detach possible, tilt
able crane attachment possible and allows trailer use,
mounting of a platform possible
All three mounting positions are located behind the cab. The differ-
Figure 4.129: Mounting via clamping devices ent positions are shown in the following figures.

Figure 4.132: Rear mounted cranes
Figure 4.130: Front mounted crane Dimensioning of mounting frames for cranes
It is recommended the following materials or materials with a higher
yield stress be used for manufacturing the mounting frames
Tensile strength Yield stress
Material
106 Pa [N/mm2] 106 Pa [N/mm2]
E 460 TM > 560 > 560 460 460
E 500 TM > 610 > 610 500 500
Table 4.15: Material data
Equivalent materials:
SAE: 480 XLK or ASTM: A607 Grade 65
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.
Figure 4.131: Center mounted cranes

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
Leveling jacks can be mounted on the front mounting plate in con-

sideration of the following conditions:
• No further force transmission into the chassis frame between
the leveling jack on the front mounting plate and the first out-
rigger of implement, i.e. front axle must be lift up and the tire
Figure 4.135: Single V-outriggers, Figure 4.136: Single V-outriggers,
front rear must not touch the ground.
• The following maximum force flow of the front leveling jack
into the front mounting plate must not exceed the limit other-
wise the vehicle can be damaged!
• The maximum support force of the front leveling jack must be
calculated and in case of exceeding the limit, the crane load
and/or the slewing angle must be limited.
Max. permissible force Max. permissible force
Unimog type flow into the front flow into the front
mounting plate in [lbf] mounting plate in [kN]
Figure 4.137: Double V- outriggers U500NA 9,000 40

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)
• Bending moment of the crane is evenly distributed to both longitudinal frame members
Crane Lifting Moment Crane Subframe Dimensions
Profile width Profile height Profile thickness

[mt] [kNm] Profile
[in] [mm] [in] [mm] [in] [mm]

up to 5 up to 49,05 C- Profile 2.56 65 6.30 160 0.354 9
5 - 10 49,05 - 98,1 C- Profile 2.56 65 7.87 200 0.354 9
10 - 15 98,1 - 147,15 Rectangular- Profile 2.56 65 8.07 205 0.354 9
Table 4.16: Suggestions for mounting frame dimensions
Important Note: The implement manufacturer is responsible for crane subframe dimen-
sions. The suggestions above are for information only.
Note: Subframe dimensioning according to section 4.14.4, page 119. The subframes must be mounted via heavy implement mounting
brackets (code D62, see section 4.14.6, page 137.

4.14.8 Implement mounting between the axles
4.14.7 Mounting space under the cab The implement mounting brackets (code D60 or D62) should be
used for fastening implement supports by implements, which must
There is a square cross-sectional area with 2.17 in x 2.17 in (55 mm
be fitted between the axles (e.g. inter-axle road sweepers, road
x 55 mm) clearance above the left longitudinal member of the chas-
scrapers etc.). Additionally it is possible to replace the bearing cover
sis frame under the cab. This installation space can be used, for ex-
on the rear stabilizer arm (see Figure 4.139 and Figure 4.140) with
ample, for a cable of a mid-mounted winch or water hoses etc.
an implement mounting support. An example of such a mounting
Note: When code H94 (front connectors of the power hydraulic support is shown on the following pages.
system, circuit 4) is specified, the space under the cab
The support on the rear stabilizer arms must not be loaded with
above the longitudinal frame member is used and cannot
vertical forces (implement weight, self weight of mounting bars
used for other applications
etc.). These bearings may only be loaded with horizontal
forces!
Figure 4.139: Serial bearing Figure 4.140: Proposal for a

cover of the rear stabilizer arm mounting support


Figure 4.141: Proposal for a implement mounting support on the rear stabilizer arm


Figure 4.142: Counterpart of the implement mounting support on Figure 4.143: Proposal for fastening of an inter-axle implement
the rear stabilizer arm

Note:
Bolts and nuts used to attach the
rear axle to the chassis frame
brackets may only be used once
and have to be replaced before
reassembly.
Torque to:
• 520 Nm or
• 383 lb·ft
Part Numbers:
Nuts:
N 913 023 020 001
Nut, Hex.,
FLGD M20 x 1,5 -10 i.a.w
MBN 10112 – M20 x 1,5 - 10
Bolt:
N 000 000 000 620
Bolt Hex., FLGD
M20 x 1,5 x 300 – 10.9 i.a.w.
DBL 9440
Figure 4.144: Implement mounting support manufactured by SCHMIDT® (for an order address of SCHMIDT® - parts see page 83)

4.14.8.1 Code D60:

The implement mounting supports (code D60, see Figure 4.147,
page 161) are available for the frame hole pattern shown in Figure
4.103, page 142. On vehicles with short wheelbase there are four
D60 hole pattern and on the long wheelbase are six D60 hole pat-
tern bored.
Examples for the use of code D60 and code D62:
Code D60 Code D62
• Under carriage load bar by • Cranes
use of front end loaders • Aerial devices (man lifts)
• Cleaning devices between • Drillings
the axles
(All implements, which can
• Grader between the axles raise the vehicle)
Table 4.17: Examples for using codes D60 and D62 Figure 4.145: Example for use of code D60
• Bracket D62 is not mountable in combination with the plat-

form subframe code P60 and can therefore not be used in
combination with platforms (code P27 or P40).
• Bracket D60 must be used when using subframe P60 in
combination with implements mounted between the axles,
such as suction sweepers or undercarriage load bars of
front end loaders (see Figure 4.145 and Figure 4.146).
• Bracket D60 can also be used for combination of platform
subframes (code P60) and
Figure 4.146: Example for use of code D62
o Protection bars (mowers)
o Side protectors (snow cutter / blower)
o Implement supports (suction sweepers, etc.)
Page 160 of 286 December 2004

Figure 4.147: Implement mounting support, code D60 (Part-No: A427 551 03 21)

The exact position of the rear mounting brackets can be determined
from the vehicle drawings on the Unimog Resource CD.
4.15 Rear mounting of implements and bodies (Code
D50) Implements or implement mounting frames can be quick-release fas-
tened to the rear mounting brackets (code D50) using bolts with a di-
Rear frame mounting supports (code D50) for implement mounting ameter of 0.98 in / 25 mm. Heavy implements must additionally fas-
are available for the Unimog. They are friction-locked installed with tened with plates to the left and right of each mounting bracket. The
positive locking to the right and left in the longitudinal frame mem- hydraulic supply for rear-mounted implements can be provided via
ber. rear connectors of the single/dual municipal hydraulic system or the
power hydraulic system of the Unimog. The electrical connection can
Spare part number: be provided via the implement socket near the battery unit (see Figure
Code No.:
Right version: Left version: 7.5, page 220) or the rear trailer socket (see Figure 7.8, page 222).
D50 A405 552 01 18 A405 552 0118
Table 4.18: Part numbers of the rear mounting brackets (code D50)
Implements or counterweights must ensure that the two mounting
brackets have a balanced load in the event of longitudinal and vertical
acceleration.
The maximum rear implement weight in D50 mounting points (on road
use) is 3,300 lbs / 1,500 kg with a distance of 19.68 in / 500 mm from
the attachment points.
The maximum axle load and the minimum front axle load must be
considered. Counterweights must not be positioned above the mount-
ing brackets.
In case of a quick release mounted rear crane that mounts in the rear
mounting brackets, the maximum crane torque shall be 25,324 lb⋅ft /
34.34 kNm (3.5 mt).

Figure 4.148: Drawing of the rear mounting bracket (code D50)


Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements
5 Mechanical drive of implements

This means: For transmission ratios higher than one (i > 1), the PTO –
Drive facilities speed is lower than the engine speed (step down).
There are various possibilities to drive implements fitted to Transmission ratios lower than one (i < 1) cause higher PTO – speed
Unimog´s. than engine speed (step up).
See Section 3.2 Technical Data for implement drives, page 54, for
details. 5.2 General notes on mechanical implement drives
The following power take-offs are available:
The following applies to all mechanical implement drives:
• Auxiliary power take-off (Code N05)
In comparison with other power transfer systems, a mechanical power
• Power take-off shaft drive (Code N08) transfer is the most efficient system!
• High speed power take off (Code N16)
• High speed power take-off (Code N19) Important Notes:
The following chapter contains important and detailed information • Either option code N16 or N19 can be installed, not
about the different power take-offs (PTO’s) of the Unimog. A tech- both.
nical overview of the PTO’s is shown in Table 5.1, page 165.
• N16 and N19 PTO’s must only be used while stationary
or while driving without shifting gear, as the drag torque
5.1 Notes on the transmission ratio of the attachment connected to the auxiliary power
take-off prevents synchronization of the manual trans-
mission. Therefore shifting must not take place be-
General definition of the transmission ratio “ i ”:
cause the synchronizer rings will get damaged.
i=
(Transmission ) Input Speed i=
nengine • The current Unimog code list on the Unimog Resource
(Transmission ) Output Speed n power take−off CD provides information regarding the availability or
possible combinations of the optional equipment.
• Please contact the Unimog implement manager listed
Note: Definition of input and output is according to the direc- at the beginning of this guideline in the event of uncer-
tion of power flow! tainty regarding the suitability of an auxiliary power
The speed of the PTO – drive in relation to the power take-off / take-off for the planned use.
auxiliary power take-off speed is derived from the engine speed as
follows:
nengine
n power take −off =
i

5.3 Overview of available mechanical PTO’s for Uni-

mog: Retrofitting possibility of code N18
Note: Transmission with retrofitting option for high speed auxiliary
Auxiliary engine power take-off (Code N05) PTO’s (code N16/N19). Transmissions with code N18 are already
Ratio i = 0.933 equipped with a suitable drive shaft for the PTO N16/N19 install.
Speed at rated engine speed (2,200 rpm) 2,356 rpm
Gearbox high speed power take-off (Code N19)
Direction of rotation Counter clockwise
(viewed in direction of travel) Ratio i = 0.61
Max. torque delivered (continuous) 442.5 lb⋅ft / 600 Nm Speed at rated engine speed (2,200 rpm) 3,607 rpm
Max. torque delivered (intermittent) 531 lb⋅ft / 720 Nm Direction of rotation (seen in direction of travel) Clockwise
Max. continuous power output 185 hp / 138 kW Rated torque 236 lb⋅ft / 320 Nm
Note: Engine dependent PTO, driven via dog clutch located at Rated power output 161 hp / 120 kW
rear side of engine Note: Transmission dependent PTO,(flange drive).
Engine power take-off shaft drive (Code N08) Table 5.1: Technical Data of mechanically implement drive
Ratio i = 2.139
PTO rated speed 1,000 rpm
Shaft speed range (adjustable) 500 – 1,000 rpm 5.4 Safety instructions for mechanical implement drives
Direction of rotation Clockwise
(viewed in direction of travel) The implement manufacturer is responsible for protection
Max. torque delivered (intermittent) 1,030 lb⋅ft / 1,400 Nm against unintentional actuation or improper use of all attach-
Max. continuous power output 201 hp / 150 kW ments connected to any of the PTO – facilities of the Unimog.
Power take-off shaft 1 ¾” spline shaft (consider suitable mechanical/electrical protective measures,
Note: Shaft speed 500 - 1,000 rpm can be set using cruise control warning notices etc.).
Gearbox high speed power take-off (Code N16) Rotating parts, such as implement drive shafts etc., must be
Ratio i=1 covered or enclosed in accordance with the currently valid acci-
Speed at rated engine speed (2,200 rpm) 2,200 rpm dent prevention directives, OSHA requirements and local regula-
Direction of rotation tions.
Counter clockwise
(viewed in direction of travel)
Rated torque 479 lb⋅ft / 650 Nm
Rated power output 201 hp / 150 kW
Note: Transmission dependent, drive is directly coupled to the
transmission input shaft.

5.5 Overview and positions of the power take-offs
Figure 5.1: Overview of the available power take-offs

Applications See also a calculation example in Section 5.9.2 Usable power output
N05 hydraulic pumps (shaft driven), generators, winches of the power take-off shaft, page 172.
N08 front mounted snow equipment, mower, wood chipper
N16 hydraulic pumps (directly mounted or via adapter)
N19 motor pumps (fire trucks), winches, generators 5.7 Engine controls and speed settings
Table 5.2: Examples of PTO applications
Engine speed control
The Diesel engine OM 906 LA is equipped with an electronic engine
The position of the power take-offs relative to the chassis coordi- control system.
nates is the same for all U500NA. The dimensions can be deter-
mined from the CAD chassis drawings on the Unimog Resource CD. In normal driving mode, only the idling speed and max. speed are
controlled. With manual throttle setting applied and the auxiliary
Coordi- x y z power take-off engaged, the variable speed control is automatically
nates [in] [mm] [in] [mm] [in] [mm] activated.
N05 54.68 1,389 - 6.38 - 162 14.96 380 Variable speed control means that the engine speed is proportional
N08 - 38.74 -984 - 5.71 - 145 8.50 216 to the accelerator pedal setting in all engine load conditions. The
N16 97.29 2,471.2 0.93 23.65 0.36 9.2 engine governor independently sets the injection volume from zero
N19 101.90 2,588.2 0.53 13.53 4.91 124.8 up to maximum injection volume in order to maintain the specified
Table 5.3: Position of PTO´s N05 thru N19 speed.
Intermediate speed limit
Max. governed engine speed settings for the auxiliary power take-
5.6 Maximum available power output at the PTO’s offs N16 and N19 can be ordered ex factory or can be programmed
into the engine ECU at authorized Freightliner Unimog dealers. The
The maximum available power output can be approximately deter-
following programmed governed speeds can be ordered ex factory:
mined as follows:
• Code W14; maximum engine speed of 1,400 rpm
• Determination of the required PTO – speed and calculation
of the engine speed (e.g. PTO shaft speed: 1,000 rpm; ratio: • Code W18; maximum engine speed of 1,800 rpm
2.139; result: engine speed of 2,139 rpm).
Other W-codes and speeds are available, therefore see section 7.6
• Determination of the engine power output at this engine W code descriptions on page 227.
speed from the engine power output diagram (Technical
The speed limits are automatically activated when the power take-off
Data book, see Unimog Resource CD).
is switched on.
• Reduction of engine power output due to the driven auxilia- It is a standard feature that the engine speed, and thus the auxiliary
ries (fans, hydraulic pumps, alternator, A/C compressor etc.). PTO – speed, can be adjusted via the cruise control to any setting
• Consideration of the drive train efficiency (approx. 90 – 95%). between low idle and max. governed speed.
Multiplication of the reduced engine power output with this
factor.

5.8 Engine dependent power take-off (code N05) Important Notes: Freightliner Unimog Division approved
the N05 auxiliary power take-off only for
The power hydraulic system (Code H63 and H64), available ex fac- the drive of the power hydraulic system,
tory, is driven via a drive shaft by the N05 auxiliary power take-off. as available from the factory. Written
permission should be obtained from
In applications where neither H63 nor H64 are installed, the N05
Freightliner Unimog Division for all
auxiliary power take-off can be used to drive hydraulic pumps, water
other applications.
pumps etc. It is however necessary to install a vibration absorber
(damper) in the driveline (see Section 5.8.2 Vibration absorber, page
169).
Drawing of the N05 flange
The use of N05 for mechanical applications (e.g. drive of a rear PTO
- shaft for implement drives etc.) is not permitted!
N 05 - flange
5.8.1 Technical data for N05 auxiliary power take-off
The N05 auxiliary power take-off is driven via spur gears off the en-
gine camshaft. At the rear end of the engine there is a PTO flange
that is driven via a dog clutch. The PTO can only be engaged when
the engine is at standstill and the ignition is switched on.
Auxiliary power take-off (Code N05)
Gear ratio i = 0.933
Direction of rotation (viewed in direction of travel) Counter clockwise
Max. delivered torque (continuous) 442 lb⋅ft / 600 Nm
Max. torque delivered (intermittent) 531 lb⋅ft / 720 Nm
Max. continuous power output 185 hp / 138 kW
Max .moment of inertia w. rigid PTO drive 0.01 kgm2
Max. moment of inertia w. elastic PTO dr. 0.02 kgm2 Dimensions without brackets are in [mm].
Note: Engine dependent PTO, actuated via dog clutch
Table 5.4: Technical data of N05 auxiliary PTO
Figure 5.2: Drawing of the N05 flange

5.8.2 Vibration absorber
A Vibration absorber (Part-No. A 906 250 00 01) must be installed

into the driveline if auxiliary power take-off N05 is used for applica-
tions other than H63 or H64.The absorber can be ordered at author-
ized Freightliner Unimog dealers.
Figure 5.5: Use of the N05 with a vibration absorber
Figure 5.3: PTO N05 with vibration absorber and hydraulic pump
Note for installation of the vibration absorber:
Refer to Figure 5.6 drawing of absorber.
The left side represented on the cut in the drawing must be bolted
with the device-sided consumer (e.g. hydraulic pump). The right side
(soft side) must be bolted with the prop shaft to the auxiliary power
take-off N05.
Observe installation directives
Figure 5.4: Installation of a vibration absorber on N05 Warning: Risk of damage to the vibration absorber!
Maximum thread engagement 0.59 in / 15 mm.

Figure 5.6: Drawing of the vibration absorber (part-no. A906 250 00 01)

5.9 Power take-off shaft drive (code N08)
5.9.1 General
The engine power take-off drive shaft is installed in front of the en- • The drive shaft joint angle must not exceed 15° (short periods
gine. It is actuated electrically and can be engaged under load of time up to max. 30°) in continuous operation.
when the vehicle is stationary or moving. It is driven by the front
end of the engine crankshaft via a torsion-vibration-damper and a • The drive shafts are to be arranged so that irregular running is
drive shaft through a gearbox to the PTO output shaft. An inde- impossible in all operating positions.
pendent oil supply and a hydraulic multi-disc clutch with slip brakes • The sliding parts of the drive shafts must be selected such that
(for slip compensation) are also part of the PTO drive code N08. easy movement is possible at maximum torque transfer. In
An oil/water heat exchanger cools the PTO gearbox. case of high torques, telescopic type ball bearing traveler pro-
For safety reasons, the power take-off shaft can only be engaged files are preferable.
when the engine is running. • Protection devices must be provided by the implement manu-
The safety and monitoring instruments include a digital rev facturer for all accessible rotating parts.
counter in the display (true PTO shaft speed) as well as elec- • The direction of rotation of all rotating parts of the PTO-drive
tronically monitored safety precautions (starter interlock, must be marked clearly (risk of accident!).
torque limit).
• For operation of a power take-off shaft, it must be ensured that
The one-step power take-off transmission was designed for a PTO the rotating shaft is sufficiently protected.
shaft speed of 1,000 rpm. A PTO shaft speed of 540 rpm can be
realized by setting the engine speed via hand throttle to approx. • Wear tightly fitting clothing when working near rotating drive
1,155 rpm. At a PTO shaft speed of 540 rpm there are at least shafts and other rotating components.
67 hp / 50 kW available at the power take-off shaft. • During stationary operation the vehicle must be secured
against rolling away (parking brake, wheel chocks)
Safety instructions for power take-off shaft operation: • Only connect and disconnect implements when the engine is
at standstill and the power take-off shaft is disengaged.
• The rated load must not be exceeded, taking the type of
operation (shock coefficients, duration of use, ambient con- • The engine must be switched off prior to performing any ser-
ditions etc.) into consideration. vice on implements which are driven by power take-off shafts,
and no work must be carried out until the implement has come
• The implement manufacturer is responsible for carrying out to a standstill.
practical tests with the implement to verify the operation of
the drive. • Only connect and disconnect the drive shaft to the PTO drive
using the appropriate coupling and never by joining / pulling
the drive shaft splines apart.

Power take-off shaft guards
Example:
Rotating shafts and other PTO – components, which could cause
accidents, must be equipped with protection devices. The guards M PTOshaft = i *η * (M engine − M auxiliaries ) = 2.139 * 0.97 * (590 − 82.6)lb ⋅ ft
for rotating parts shall be provided by the implement manufacturer.
M PTOshaft = 1,053lb ⋅ ft
The power take-off shaft drive must never be operated without
n PTOshaft 1,000
shaft guards. The standard / original power take-off shaft guard PPTOshaft = 2 * π * * M PTOshaft = 2 * π * *1,053lb ⋅ ft
must not be removed. Following the removal of the drive shaft from 60 60s
the PTO-drive, the protective cap must be placed on the stub end lb ⋅ ft
of the PTO output shaft at the vehicle. PPTOshaft = 110,270 = 200.5hp
s
5.9.2 Usable power output of the power take-off shaft Maximal permissible Maximal power output at
Drive shaft the PTO shaft at 1,000 rpm
engine torque
angle β
The permissible power output at the PTO shaft depends on appli- [lb⋅ft] [Nm] [hp] [kW]
cation conditions, e.g. operating duration, temperatures and kind of β ≤ 15° 590 800* 201 150
application. The usable power output at the power take-off shaft 15° ≤ β ≤ 20° 502 680 166 124
further depends on the engine speed, engine power output etc. 20° ≤ β ≤ 25° 428 580 137 102
(see Section 5.6 Maximum available power output at the PTO’s, 25° ≤ β ≤ 30° 369 500 113 84
page 167) and also on the angle β of the drive shaft from the PTO
Table 5.5: PTO shaft power output
to the implement (see Figure 5.7 and Table 5.5). The maximum
*Note: Ex factory adjusted engine torque with PTO shaft engaged.
continuous PTO shaft power output is 201 hp / 150 kW. This is lim-
ited realized with the electronic engine control and cannot be
changed. The limitation of the engine torque output (not PTO shaft
torque!) with engaged PTO shaft is 590 lb⋅ft / 800 Nm. β β
Calculation of the usable PTO shaft power output:
n PTOshaft
PTO shaft power output: PPTOshaft = 2 * π * * M PTOshaft
60
PTO shaft torque output: M PTOshaft = i *η * (M engine − M auxiliaries )
Torque of auxiliaries:
Figure 5.7: Drive shaft angle β
M auxiliaries = M fan + M hydraulic + M alternator + M ACcompressor + M tractiondrive
Min. torque of auxiliaries: Mauxiliaries = 112 Nm / 82.6 lb⋅ft
Efficiency factor of the PTO transm.: η = 0.97 Further conditions:
PTO shaft speed: nPTOshaft = 1,000 rpm • Drive shaft in W or Z arrangement (see page 185 and the fol-
Ratio of the PTO transmission: i = 2.139 lowing)
• Drive shaft angles larger than 30° are not permitted

5.9.4 Power take-off shaft profile (according to SAE J499a)
5.9.3 Technical data of power take-off shaft drive N08
Power take-off shaft (Code N08)

Ratio i = 2.139
PTO rated speed 1,000 rpm
Shaft speed range (adjustable) 500 – 1,000 rpm
Direction of rotation Clockwise
Max. torque delivered at the power take-
1,030 lb⋅ft / 1,400 Nm
off shaft (intermittent)
Max. continuous power output 201 hp / 150 kW
Power take-off shaft 1 ¾” spline shaft
Note: Shaft speed 500 – 1000 rpm can be set using cruise con-
trol. Figure 5.8: PTO shaft profile
Power take-off shaft:

Dimension [in] [mm]
• 1 ¾” spline shaft (at output side of PTO - transmission) A* 3.03 77
B 1.50 38
• Spline according to SAE J499a (6 splines)
C 1.745 44.32
• Shaft can be hand-turned when clutch is open D R 0.33 R 8.3
(for coupling implements) E 1.417 +0.01 36 +0.25
F 1.465 +0.008 37.2 +0.2
• Max. moment of inertia on shaft at n = 1,000 rpm:
593 lbs*ft2 / 25 kg*m2 G 0.431 +0.002 10.95 +0.05
H 0.343 8.7
Power take-off transmission: α 30° 30°
• Oil capacity: 1.06 gal / 4 l (engine oil SAE 10 W 40) Table 5.6: PTO shaft dimensions
G 77 *A: Usable length

• Transmission ratio: i = 1 = = 2.139
G2 36

5.9.5 Position of PTO shaft
Note:

Note:
Vehicle equipped with tires 315/80R22.5
Figure 5.9: Position of the PTO shaft in relation to the front mounting plate

∆tire* = (rstatFA − rstatRA ) *

b
l
Formula 5.2: Calculation of the tire part
∆h = (e FA − e RA ) *
b
l
Formula 5.3: Calculation of the suspension part
h = Height of power take-off shaft above the road surface

rs = Static tire radius; measure at the loaded truck or see Table
tat 4.3, page 70.
e = Spring height at the front axle (dimension, center of front
F wheel to lower edge of chassis frame). This value can be de-
A termined from Figure 4.5, page 65. The suspension graphs
display the upper edge of the chassis frame, so consider
the frame height of 9.76 in / 248 mm!
e = Spring height at the rear axle (dimension, center of the rear
Dimensions in brackets are in [in]. R wheel to lower edge of chassis frame). This value can be de-
Figure 5.10: Position of the N08 shaft in relation to the front A termined from Figure 4.5, page 65. The suspension graphs
display the upper edge of the chassis frame, so consider
mounting plate
the frame height of 9.76 in / 248 mm!
a = Distance between lower edge of chassis frame and the cen-
Note: Please consider the angle between the front mounting plate ter of the PTO shaft: 8.66 in / 220 mm
and the vertical of the longitudinal frame member by design- b = Distance between the center of the front wheel and front face
ing implements accordingly (see also Figure 5.11, page 176). of PTO shaft
5.9.6 Calculation of the PTO shaft height above ground Example: U500 short, wheelbase 131.89 in, fully loaded
(FAW:15,100 lbs, RAW: 17,900 lbs), tires: 395/85R20
Dimension “h” (height of the power take-off shaft above the road sur- a = 8.66 in rstat = 21.34 in
face) can be approximately calculated by use of Formula 5.1. The b = 37.83 in eFA = 13.69 in
height depends on tire size and suspension spring compression l = 131.89 in eRA = 15.24 in
(axle loads, vehicle weight). A tolerance of +/- 3% of “h” must be al-
∆h = (e FA − e RA ) * = (13.69in − 15.24in ) *
b 37.83in
lowed for. = −0.44in
l 131.89in
h = rstat + e FA + a + ∆h + ∆tire *
h = rstat + e FA + a + ∆h = 21.34in + 13.69in + 8.66in + (−0.44in) = 43.25in
Formula 5.1: Calculation of the PTO shaft height

Figure 5.11: Effect of suspension travel on dimension “h”

5.10.2 Technical data on auxiliary PTO’s (code N16 / N19)

5.10 Auxiliary power take-off drives (code N16/N19)
High speed power take-off (Code N16)
5.10.1 General notes on auxiliary PTO’s (code N16/N19) Ratio i=1
Auxiliary power take-offs (N16 and N19) can only be engaged and Direction of rotation
disengaged when the vehicle is stationary (electronic lock). The Counter clockwise
PTO’s can be used to drive hydraulic pumps (e.g. to drive cranes, Rated torque output 479 lb⋅ft / 650 Nm
backhoes etc.), water pumps installed in fire trucks.(stationary op- Rated power output 201 hp / 150 kW
eration) generators etc. The hydraulic pumps etc. can be mounted Note: Transmission dependent, drive is directly coupled to the
directly to the transmission housing (with code N16) or connected transmission input shaft.
via a drive shaft to the flange of the PTO output shaft (with code High speed power take-off (Code N19)
N19). Ratio i = 0.61
The power flow to the transmission input shaft and therefore also to Speed at rated engine speed (2,200 rpm) 3,607 rpm
the auxiliary PTO´s is interrupted when the clutch is engaged. In Direction of rotation Clockwise
case of use of the auxiliary PTO during driving, it is necessary to (viewed in direction of travel)
stay in the previously selected gear. Shifting gear while the auxiliary Rated torque output 236 lb⋅ft / 320 Nm
PTO is engaged is not possible as the drag torque of the driven im- Rated power output 161 hp / 120 kW
plement impedes synchronization in the transmission. Therefore, Note: Transmission dependent, drive is directly coupled to the
gear shifting with the auxiliary PTO engaged is electronically dis- transmission input shaft.
abled. Table 5.7: Technical data of auxiliary PTO’s

Drawings of the N16 and N19 flanges
N 16 - flange


N 19 - flange


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:
• Hydraulic pump model F1 in different variations and
sizes; manufactured by Parker Hannifin Corporation.
An adaptor is required for fitting this pump to the N16
flange (see Figure 5.15). This adapter is also available
from Parker Hannifin.
o Adapter: Parker Part-No.: 370 57 50
Figure 5.16: Pump F1 with adapter for N16
Figure 5.14: Hydraulic Figure 5.15: Adapter for Parker

pump model F1 hydraulic pumps
Figure 5.17: PARKER® part numbers

1300
1250 F1-41
F1-61
1200 F1-81
Engine speed [rpm]
1150
1100
1050
1000
950
0 5 10 15 20 25 30
Flow [gallons/minute]
Figure 5.18: PARKER® hydraulic pumps

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-

draulic pumps
In case of hydraulic pumps mounted directly to the N16 flange,
the static load on the flange surface due to the pump must not
exceed Mmax= 29.5 lb⋅ft / 40 Nm.
The mass torque / bending moment can be calculated with the
following data:
G = Pump weight including fittings in [lbs] or [kg]
Distance of the pump’s c.o.g. from the mounting flange Figure 5.19: Permissible mass
s = torque at N16 flange
in [ft] or [m]
Warning: Risk of vehicle damage!

The auxiliary power take-off or the transmis-
sion may get damaged if the permissible
mass torque / bending moment is exceeded.

Length compensation is realized with a 1.57 in / 40 mm travel
5.10.4 Direct flange mounting on auxiliary PTO N16 slip joint. The rear flange (see Figure 5.21) can be used for
connecting drive shafts, pumps, generators etc.
Direct flange mounting on the auxiliary power take-off N16 is
possible. The maximum drive shaft angle must not exceed 6°.
Flanges for direct mounting can be ordered with the following
part-no. 500 019 099 from:
Werner Forst- und Industrietechnik GmbH
Ehranger Strasse 101
D – 54293 Trier – Ehrang
GERMANY
Phone: 0049-651-68670
Fax: 0049-651-64146
Email: Werner@t-online.de

Figure 5.21: Sketch of the connecting flange
Figure 5.20: Directly mounted flange drive on auxiliary PTO N16

Relevant vehicle safety components (e.g. brake, hydraulic and

5.11 Drive shafts for implements
fuel lines) must be routed and protected in such a way that
they cannot get damaged in the event of a drive shaft failure.
5.11.1 General information on drive shafts
At continuous operation the temperature at joints, splines and
Drive shafts must be positioned in such a way to avoid uneven bearings shall not exceed 176°F / 80°C in order to avoid dam-
rotation, misalignment and vibration in all implement-operating ages to the plastic coating of the spline, (slip yoke) and also to
positions. avoid leakage of grease from the universal-joints. It could be
necessary to install heat shields.
The torque capacity and ease of movement of the sliding
parts (slip yoke), even during maximum torque transfer,
must be considered. Ball track profiles should be used in the
case of high torque. The direction of rotation in the vehi-
cle/implement combination must be considered.
Caution: Risk of accident and serious injury!

Fig. 5.22: Drive shaft, length compensation
The implement/body manufacturer must pro-
vide safeguards against rotating parts in the
vicinity of the drive shaft connection to the The splined portion of the shafts must not be painted. Drive
vehicle. Drive shafts that are located in areas shafts must be balanced before they are installed. Existing
in which personnel pass or work must be en- balancing weights must not be removed. The installation ar-
cased or covered. Failure to do so can cause rangement in the vehicle must be identical to that used on the
property damage, personnel injury or death. balancing machine. The phasing of yokes on the splines must
not be changed. The specified grade of fasteners and the
Installing of drive shafts tightening torque must be adhered to. The tightening of the
bolts must by happen cross-wise. Shaft assemblies with center
Pay attention to the installation guidelines of the drive shaft
bearings must first be attached to the in- and output flange /
manufacturers. If the application makes it necessary, use sev-
yoke / spline. Thereafter the intermediate (center) bearing can
eral drive shafts with intermediate bearings. The flange sur-
be installed properly aligned and tension-free with consoles on
faces must be completely flush. The joint shaft angle must be
the chassis frame.
the same at both ends of the shaft (β1 = β2) and must not be
larger than 15° (except for N08 the drive shaft between the
PTO shaft and the front implement. Refer to section 5.9 for
details). Angle β must also be not smaller than 1°.

Plane deflection
Correct design and installation of the drive shaft (length, tube
diameter, speed, etc.) prevents premature failure, damage,
noise and vibrations.
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 of up to 30° can be tolerated, however not in high Figure 5.23: Z-deflection of a drive shaft
power/torque transfer applications. The angle of deflection β
between the PTO shaft (code N08) and the front mounted im-
plement may be up to 30° only in combination with low
power/torque transfer rates (Ref. sect. 5.9). Joint angles larger
than 15° and flange misalignment (β1 ≠ β2) will result in critical
vibrations in the drive train. It affects the durability of auxiliaries
and can cause damages to vehicle and implement/body.
Different kinds of deflection:
• Plane deflection (2D):” W” or “Z” deflection
• Three-dimensional deflection (3D): In case of 3D-
deflection the centerlines of input and output shafts in-
tersect with a compound angle (angles in horizontal
and vertical plane). Figure 5.24: W-deflection of a drive shaft
The joint angles at both ends of the drive shaft must be equal.
The forks of the connecting shaft must be in the same plane.
A combined drive shaft assembly with Z deflection in one and
W deflection in the other plane should be avoided. This would
be the case if input and output shaft were not on one plane.

Three-dimensional deflection tan β h1 An infinite number of possible positions
tan 2 µ1 = may be created by the combination of the
A three-dimensional tan β v1
vertical and horizontal angle of deflec-
deflection is an in-
tan β h 2 tion. In order to better determine the off-
tersection of the tan 2 µ 2 =
centerlines of input tan β v 2 set angle, the pro shaft manufacturer
should be involved in an advisory capac-
and output shaft with µ = µ1 + µ 2 ity.
spacious offset. A
common plane just
like with W or Z de- 5.11.3 Forces in the drive shaft system
flection does not ex-
ist. In order to com- Forces are introduced as a result of the angle of deflection in
Figure 5.25: Three-dimensional deflec- pensate the speed the drive shaft. Additional forces are created if the drive shaft
tion oscillation, the inner is laterally displaced under the concurrent effect of force and
forks of the univer- torque. The type, magnitude and direction of the additional
sal-joints of the connecting shaft must be offset. This offset forces are dependent on the relevant operating status and the
angle is designated with µ (see Figure 5.25). type of drive shaft arrangement.
The following applies to determine the offset angle µ:
β1 = Three-dimensional angle of shaft 1
β2 = Three-dimensional angle of shaft 2
β3 = Three-dimensional angle of deflection
The 3D angle of deflection β3 can be determined with:

tan 2 β 3 = tan 2 β 1 + tan 2 β 2
βv = Three-dimensional angle of shaft 1
β = Three-dimensional angle of shaft 2
h
µ = Offset angle
The offset angle µ can be determined with the horizontal and
vertical angles of deflection of the two shafts:

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 • Due to worn-out universal-joint shafts or bearing
dynamically balanced in order to avoid vibrations. mountings
They are marked accordingly. • Due to drive shafts that are incorrectly assembled fol-
Each drive line assembly is comprised of several universal- lowing repair as a result of the marks not being noted
joints and shafts. The synchronization of each driveline is sub- or the absence of the marks
ject to optimization (compensation of the differences in angular
velocity of the universal-joints between input and output). This 5.11.5 Bearing
synchronization optimization is coordinated exactly to the
phasing of the joints and the overall length of the driveline. The bearings of the input and output shafts are radial and axial
Early in design the specified universal-joint offset must be heavily loaded due to statically and dynamically forces and
considered in order to compensate for irregularities due to torques. Therefore the bearings must be adequate designed.
slight differences in the joint angles of the drive shafts.
5.11.6 Unbalance
Important Note: During assembly of a drive shaft or a
After each repair the drive shaft must be new balanced.
driveline, the marks at the universal-
joints, yokes and splines must be
aligned. 5.11.7 Maintenance
Depending on the design of the drive
When using non maintenance-free drive shafts, easily acces-
shaft, one of the two marks can be lo-
sible lubrication service points should be considered. Mainte-
cated underneath the rubber sleeve.
nance-free drive shafts have one-time grease ex factory and
needn’t be serviced. Inspection and maintenance instructions
of the manufacturer, depending on the operating conditions
Noises and vibrations
must be considered. Only authorized dealers may repair fail-
Noises and vibrations may occur: ures or damages on the drive shafts using original spare parts.
• If the speed of an implement is too high or too low
• Due to vibrations originating from the implement/body


Body and Implement Mounting Guidelines U500 North America Hydraulic system
6 Hydraulic system
Dual circuit system (Code H06, H08)
Flow rates at rated Circuit 1 6.34 gal/min / 24 l/min
6.1 Overview of codes and hydraulic circuits on the engine speed
Unimog 2,200 rpm: Circuit 2 12.68 gal/min / 48 l/min
Up to four hydraulic circuits are available for the Unimog Pressure 2,900 psi / 200 bar
U500NA: Application Implement actuation, constant flow
Maximum 8 sockets, sep. return line,
6.1.1 Hydraulic drives Front connectors
pressure line (front)
Basic hydraulics Pressure line, separate return line
Middle connectors
(circuit 2)
Oil tank volume 11.89 gal / 45 l Maximum 4 sockets, sep. return line,
Rear connectors
Oil SAE 10 W pressure line (rear)
Valves 2 to 4
Oil issue quantity 2.64 gal / 10 l
Power hydraulic system (closed or open circuit)
Single circuit system (Code H02) Oil tank volume 13.21 gal / 50 l
Flow rate at rated Oil SAE 10 W
engine speed 12.68 gal/min / 48 l/min Oil issue quantity 2.64 gal / 5 l
2,200 rpm
Pressure 2,900 psi / 200 bar Max. flow rate circuit 3 at
rated engine speed 33.02 gal/min / 125 l/min
Application Implement actuation 1,800-1,900 rpm:
Front connectors Maximum 8 sockets, sep. return line Working pressure circuit 3 4,351 psi / 300 bar
Rear connectors Maximum 4 sockets, sep. return line Max. flow rate circuit 4 at
rated engine speed 23.78 gal/min / 90 l/min
Valves 2 to 4
1,800-1,900 rpm:
Working pressure circuit 4 4,061 psi / 280 bar
Pressure & return line in front
Connectors
and/or middle
Table 6.1: Technical data of available hydraulic circuits

6.1.2 Overview of available hydraulic equipment
Code Designation Comment

Simplest form of the UNIMOG hydraulic system, enables actuating
H02 Single circuit hydraulic system
movements for an implement
Enables the operation of two independent implements (actuating
H06 Dual circuit hydraulic system
movements and continuous consumers)
H08 Dual circuit hydraulic system, proportional As H 06 but with proportional valve control (in circuit 1)
H12 2 valve hydraulic system For use with implements with max. 2 actuating movements
H43 Tipping cylinder for platform Multistage tipping cylinder situated in the center under the platform
H51 Hydraulic connection, rear, 2 lines on valve 1 2 flush-face couplers
H55 Hydraulic connection, rear, 4 lines on valves 1 and 2 4 flush-face couplers
H57 Hydraulic connection, rear, 4 lines on valves 2 and 3 4 flush-face couplers
H58 Pressure line rear for dual circuit hydraulic system Connection for circuit 2 rear, return via H59
H59 Separate rear return line Return for H 58 or single circuit hydraulic system
H61 Hydraulic snow plow release Weight transfer to the vehicle via hydraulic pressure
H63 Power hydraulics, closed circuit (circuit 3) Integrated in platform subframe, couplers above the battery box

Code Designation Comment
H64 Power hydraulics, open circuit (circuit 4) Integrated in platform subframe, couplers above the battery box
Additional pressure line for dual circuit hydraulic sys- For operation of a built-in continuous consumer, couplers above the
H68
tem, middle, inc. separate return line gas tank
H71 Hydraulic connection, front, 2 lines on valve 1 2 flush-face couplers
H73 Hydraulic connection, front, 2 lines on valve 3 2 flush-face couplers
H75 Hydraulic connection, front, 4 lines on valves 1 and 2 4 flush-face couplers
H76 Hydraulic connection, front, 4 lines on valves 3 and 4 4 flush-face couplers
H78 Pressure line front for dual circuit hydraulic system Connection for circuit 2 front, return via H79
H79 Separate front return line Return for H 78 or single circuit hydraulic system
H94 Add. lines for power hydraulics, circuit 4 at the front

Table 6.2: Available hydraulic options for the Unimog

Available hydraulic packages for the Unimog U500NA:
H 02 Single pump hydraulic package
H02 Single circuit hydraulic system
H12 2 valve hydraulic system
H55 Hydraulic connection, rear, 4 lines on valves 1 and 2
H59 Separate rear return line
H75 Hydraulic connection, front, 4 lines on valves 1 and 2
H79 Separate front return line
H 06 Dual pump system hydraulic package
H06 Dual circuit hydraulic system
H58 Pressure line rear for dual circuit hydraulic system
H68 Additional pressure line for dual circuit hydraulic system, middle, inc. separate return line
H73 Hydraulic connection, front, 2 lines on valve 3
H78 Pressure line front for dual circuit hydraulic system
H 08 Dual pump system hydraulic package with proportional valves
H08 Dual circuit hydraulic system, proportional
H58 Pressure line rear for dual circuit hydraulic system
H61 Hydraulic snow plow release
H68 Additional pressure line for dual circuit hydraulic system, middle, inc. separate return line
H78 Pressure line front for dual circuit hydraulic system
Table 6.3: Available hydraulic packages

6.1.3 General instructions for the use of the Unimog hy- • "Lower" connector hose on "lower" port (circuit 1; lower
draulic system left, port 1 or 5, lower right, port 2 or 6)
Implements to be used in conjunction with the vehicle hydraulic • Only load the hydraulic system when the engine is at op-
system shall be reviewed in respect to the following items: erating temperature
• Maximum fluid volumes which can be extracted from the • Prior to initial operation, note fluid level and permissible
vehicle system volume, which may be consumed.
• Necessary flow cross-sections (nominal line diameters
etc.) corresponding to the maximum flow rate
Note: The hydraulic power steering system may not be used
• Available system pressure (primary pressure relief). for the actuation or drive of implements.
• Necessary oil quality
• Permissible degree of oil heating 6.1.4 Oil heating
• Compatibility of connections (couplers, nipples) In the case of continuous consumers, the implement manufac-
turer must ensure that the maximum oil temperature (approx.
• Prevent sudden cylinder movement (actuating speeds) 194°F / 90°C) cannot be exceeded under the expected condi-
• Design cylinder movement and if necessary control tions of usage. Further details should be obtained from the oil
valves in such a way that the implements cannot move manufacturer.
suddenly when actuated (risk of accident, implement and The power hydraulics radiator, which is integrated in the plat-
vehicle strain) form subframe, has a cooling performance of approx. 15 kW
• Do not connect implements that are mounted at the front (20 hp). If a higher cooling performance is required, the imple-
and rear of the Unimog to the same valve cell ment must be equipped with an additional radiator. Basically, it
must be guaranteed that unnecessarily high loss of output is be
• Preventing faulty operations, all implements which work avoided via the coordination of all hydraulic components with
in float position must be connected single-acting, i.e. re- regard to the relevant use or operating point. In case of using
turn via the separate return line flow regulators the maximum flow rate must under no circum-
• "Lift" connector hose on "lift" line (circuit 1; port 3 or 7) stances be exceeded.

6.2 Basic hydraulics

Sym- Symbol
Circuit Cell Port
bol color
Sym- Symbol
Circuit Cell Port
bol color
Coupler (female) ISO
5 Yellow
16028 Size 12.5 (1/2”)
1 Red
16028 Size 12.5 (1/2”)
3
1
6 Yellow
16028 Size 12.5 (1/2”)
2 Red
16028 Size 12.5 (1/2”)

7 Blue
16028 Size 12.5 (1/2”)
3 Green
16028 Size 12.5 (1/2”)
4
2
8 Blue
16028 Size 12.5 (1/2”)
4 Green
16028 Size 12.5 (1/2”)
Pressure Plug (male) ISO 16028
Blue
line Size 19 (3/4“)
Separate Coupler (female) ISO
Black
return 16028 Size 19 (3/4”)
Table 6.4 UNIMOG basic hydraulic connections

6.2.1 Information on the basic hydraulic system

6.2.1.2 Hydraulic control unit
Electrically controlled 4/3-way valves with neutral settings, two
Note: Care should be taken when connecting implements to pressure settings and float setting are used for circuits 1 and 2.
circuit 1 to ensure that implements cannot be connected Circuit 1 can be equipped with up to 4 double-acting valve cells
to the same cell (color) at the front and side. Each dou- (optionally black/white or proportionally controlled). These valve
ble acting cylinder may only be connected to one cell cells with their possible settings can be used for the functions:
(color), so that its actuation is analogous with the move- Lifting, lowering, neutral and floating setting.
ments of the operating unit (lifting: pull hydraulic actuat-
ing lever, lowering: push hydraulic actuating lever). The hydraulic circuit 1 can also be equipped with up to 8 con-
nections at the front and up to 4 connections at the rear of the
Unimog.
A cell indicates the hydraulic valve (Example: Connections 3
and 4 are pressurized by a cell, the connections on a cell always
have the same color!)
6.2.1.3 Dual circuit hydraulic system

The flow rates of circuit 1 and circuit 2 can be easily switched
6.2.1.1 Hydraulic pumps of circuit 1 and circuit 2
with the hydraulic control unit in the cab. For example, imple-
Hydraulic ment-actuating speeds can be accelerated by use of the higher
Hydraulic pump data flow rate of circuit 2.
system
Casappa gear pump; 16.6 cm3/turn; It is also possible to combine the flow rates of circuit 1 and cir-
Single circuit cuit 2, but the consumer must be connected to circuit 2.
driven via belt by the engine
Dual circuit Circuit 1: Cassappa gear pump;
8.3 cm3/turn; 0.506 cu in/turn
Circuit 2: Cassappa gear pump;
16.6 cm3/turn; 1.013 cu in/turn
Table 6.5: Hydraulic pumps of circuit 1 and 2

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.
So, implements with a high self-weight could
fall without restriction to the ground by actuat-
metered
ing of the float position.
implement orifice
Figure 6.1: Braked lowering function with a metered orifice

Implements, which require a braked lowering function, must be
equipped with a flow restrictor. These flow restrictors should be
coordinated with implement weight.
Power-operated lifting equipment must be set up in such a way
that the implements cannot be lowered in free fall. This is ful-
filled, for example, if the flow cross-section of the hydraulic sys-
tems is designed accordingly (flow restrictor, aperture).
Adjustable flow restrictors are available in combination with code
H08.
The Figure 6.1 and Figure 6.2 show two possibilities for a braking
the lowering function. adjustable flow restrictor with
implement non-return valve (bypass)
Figure 6.2: Braked lowering with a flow restrictor

6.2.1.5 Basic hydraulic sketch
3 Hydraulic tank (basic hydraulics) and hydrostatic fan drive 4 Hydraulic cylinder, tipper body P3 Hydraulic pump hydrostatic fan drive
1 Oil filter 5 Hydraulic oil cooler Z1 Cell 1 in circuit I, connector 1 and 2
1a Valve block SR Return line Z2 Cell 2 in circuit I, connector 3 and 4
2 Snow-plow load release valve P1 Hydraulic pump circuit I Z3 Cell 3 in circuit I, connector 5 and 6
2a Shut-off valve for tipper cylinder P2 Hydraulic pump circuit II Z4 Cell 4 in circuit I, connector 7 and 8
Figure 6.3: Basic hydraulics circuit I and II – 4 cells

6.2.2 Information to the basic hydraulic systems
6.2.2.1 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).
8 7 6 5
4 3 2 1
Figure 6.5: Front hydraulic connections (drive direction: right)
Figure 6.4: Front hydraulic connections (drive direction: left)
Note: Only one cell / valve can be used at the same time

Figure 6.6: Overview of hydraulic connections at the vehicle front

6.2.2.2 Center basic hydraulic connections

H68 connections are located above the fuel tank, on the right-
hand side of the vehicle (seen in drive direction) behind the
cab. These two circuit 2 connections can be used for driving
continuous consumers. As in the front, the pressure line is a
female plug and the return line is a male socket. 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

Figure 6.7: Position of the H68 hydraulic connections

6.2.2.3 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.
Figure 6.10: Hydraulic connections on right hand side
1 3 2 4
Figure 6.9: Hydraulic connections on left hand side

6.2.3 Shut-off valve 6.2.4 Volume flows of the Unimog basic hydraulic sys-
tems
The figures on the following pages show the flow rates of
available Unimog hydraulic circuits with and without combina-
tion. Combination means, adding the flow rate of circuit 1 and
circuit 2. The flow rates of these two circuits can also be inter-
changed (see Section 6.2.1.3 Dual circuit hydraulic system,
page 195).
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. This valve locks the tipping cylinder and
the platform against inadvertent use.
Note: If an implement is mounted, the shut-off valve has

to be closed!

C i rcu i t I + II w i t h co mb i n a t i o n s
2 5 ,0 0
circuit I
circuit II
circuit I + circuit II
2 0 ,0 0
Volume flow [gal/min]
1 5 ,0 0
1 0 ,0 0
5 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e sp e e d [rp m]
Figure 6.12: Flow rates of hydraulic circuits I + II with combinations in [gal/min]

C i rcu i t I + II w i t h co m b i n a t i o n s
1 0 0 ,0 0
c irc uit I
9 0 ,0 0 c irc uit II
c irc uit I + c irc uit II
8 0 ,0 0
7 0 ,0 0
Volume flow [l/min]
6 0 ,0 0
5 0 ,0 0
4 0 ,0 0
3 0 ,0 0
2 0 ,0 0
1 0 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e sp e e d [rp m]
Figure 6.13: Flow rates of hydraulic circuits I + II with combinations in [l/min]

6.2.5 Dealer for hydraulic couplings in the USA
PARKER® PCI Suitable plugs/sockets for Unimog hydraulic circuit 2 (¾”) are
PARKER® Hannifin PCI Pressure Components Inc. listed in the following table:
Quick Coupling Division 5101 Naiman Parkway
Description Part-No.:
8145 Lewis Road Solon, Ohio 44139
UNF – Inside thread ¾” – 16
Minneapolis, MN 55427 Phone: 800-322-9527 IF7510UNF
(Socket for pressure line)
Phone: 763-525-4240 Fax: 440-349-3653
NPT – Inside thread ¾” – 14
Fax: 763-544-3418 IF7510NPT
(Socket for pressure line)
Rectus / Tema Stucchi UNF – Inside thread ¾” – 16 (Socket for
Rectus-Tema Corp. Stucchi USA Inc. IF7511UNF
pressure line with pressure elimination)
34 Wilson Drive 1525 Elmhurst Road NPT – Inside thread ¾” – 14 (Socket for
Sparta, NJ 07871 Elk Grove Village, IL 60007 IF7511NPT
pressure line with pressure elimination)
Phone: 973-383-0095 Phone: 847-956-9720 UNF – Inside thread ¾” – 16
Fax: 973-579- 5485 Fax: 847-956-9723 IF7520PUUNF
(Plug for separate return line)
Table 6.6: Dealer for hydraulic couplings NPT – Inside thread ¾” – 14
IF7520PUNPT
(Plug for separate return line)
UNF – Inside thread ¾” – 16 (Plug for
separate return line with pressure elimi- IF7521PUUNF
nation)
NPT – Inside thread ¾” – 14 (Plug for
6.2.6 Tema parts list for Unimog hydraulic connectors
separate return line with pressure elimi- IF7521PUNPT
Suitable plugs for Unimog hydraulic circuit 1 (½”; ports 1 to 8) nation)
are listed in the following table: Table 6.8: Tema parts list for Unimog hydraulic circuit 2
Description Part-No.:
UNF – Inside thread ½” – 20 IF5020PUUNF Note: The hydraulic couplings listened above comply with
NPT – Inside thread ½” – 14 IF5020PUNPT ISO 16028
UNF – Inside thread ¾” – 16 IF5020-75PUUNF
UNF – Inside thread ½” – 20 (with pressure IF5020PUUNF
elimination)
NPT – Inside thread ½” – 14 (with pressure IF5020PUNPT
elimination)
UNF – Inside thread ¾” – 16 (with pressure IF5020-75PUUNF
elimination)
Table 6.7: Tema parts list for Unimog hydraulic sockets circuit 1

6.3 Information to the power hydraulic systems
6.3.1 Power hydraulic flow rates
Symbol
Circuit Cell Symbol A constant capacity is often necessary for the operation of a
color
Pressure HS 20 screwed joint, continuous consumer. This is why the Unimog has electrically
Red controlled variable displacement pumps for the power hydrau-
line plug
lic systems (circuit 3 and circuit 4). Before operating an imple-
Closed Separate HS 20 screwed joint, ment the driver must adjust the necessary flow rate for the cor-
Red
Circuit return socket responding circuit on the hydraulic control unit in the cab. The
Pressure HS 20 screwed joint, flow rate can be adjusted continuously variable between 0 and
Green
line plug the maximum capacity (circuit 3: 33.02 gal/min / 125 l/min; cir-
Open Separate HS 20 screwed joint, cuit 4: 23.78 gal/min / 90 l/min) in both circuits. It is controlled
Green
Circuit return socket independent of the engine speed in the context of basic val-
Table 6.9 UNIMOG power hydraulic connections ues. If the engine speed is changed during operation, the flow
rate of the variable displacement pump remains constant. The
maximum flow rate is reached with engine speeds of approx.
1,800 rpm. Above 1,800 rpm the flow rate remains constant
(see Figure 6.14).
Note: Care should be taken when connecting implements
to circuit 4 to ensure that implements cannot be
connected to at the front (code H94) and the side at
the same time.
Figure 6.14: Flow rate over engine speed

6.3.2 Drawings of the power hydraulics
1 Hydraulic tank P Pressure port circle III

2 Hydraulic oil cooler circuit III L Oil leakage pipe
3.1 Oil filter for feeding pump R Return line
3.2 Valve P4 Variable pump circuit III
5 Bypass P5 Feeding pump
Table 6.10: Power hydraulics circuit III, code H63

1 Hydraulic tank P Pressure port circle IV

2 Hydraulic oil cooler circuit IV L Oil leakage pipe
3 Oil filter circuit IV R Return line
4 Proportional valve P6 Variable pump circuit IV
5 Bypass
Table 6.11: Power hydraulics circuit IV, code H64

6.3.3 Front power hydraulic connections, code H94 6.3.4 Center power hydraulic connections
There are 13 hydraulic connections available at the front of the The connections for the power hydraulic circuits 3 and 4 are
Unimog. In addition to the basic hydraulic system (circuit 1 and integrated in the platform subframe. They are located on the
circuit 2) connections of the power hydraulics (only open cir- left longitudinal subframe member above the battery box. The
cuit) at the front could be ordered (Code H94). The connec- positions of the center connections of the power hydraulic cir-
tions of the power hydraulic circuit 4 are labeled with green cuits are labeled with red covers shown in the following fig-
covers (see Figure 6.15). ures.
pressure line closed circuit; plug return line closed circuit;

with cap nut and inside thread socket with outside thread
Figure 6.16: Center power hydraulic connections circuit 3
return leakage oil pressure

line connection line
Figure 6.15: Front connections of the power hydraulics circuit
4
leakage oil con- return line, pressure line,

nection, open open circuit, open circuit,
circuit, socket socket plug
Figure 6.17: Center power hydraulic connections circuit 4

Note: Circuit III

• Maximum oil flow for continuous use 80l/min
(21.13 gal) at 250 bar (3625 psi)
• Temporary oil flow 125l/min (33.02 gal) at 300
bar (4350 psi)
Figure 6.18: Hose laying of the H94 lines above the battery box Circuit VI
• Maximum and temporary oil flow 90l/min (23.77
Figure 6.18 shows the laying of the hoses and lines of the front gal) at 280 bar (4060 psi)
power hydraulic connections (code H94). These three lines are
connected at the side of the subframe longitudinal member
above the battery box with the serial connections of the power
hydraulic circuit 4. When code H94 is specified, the space un- 6.3.5 Volume flows of the Unimog power hydraulic sys-
der the cab above the longitudinal frame member is used and tems
cannot used for other applications (see also 4.14.7, page 156).
The figures on the following pages show the flow rates of
available Unimog power hydraulic circuits.
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). The power hydraulic system and the
basic hydraulic system are separate
systems!

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
Volume flow [gal/min]
2 0 ,0 0
1 5 ,0 0
1 0 ,0 0
5 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e sp e e d [rp m ]
Figure 6.19: Flow rates of hydraulic circuits III + IV without combinations in [gal/min]

C irc u it III + IV
1 4 0 ,0 0
c irc u it III c irc u it IV

1 2 0 ,0 0
1 0 0 ,0 0
Volume flow [l/min]
8 0 ,0 0
6 0 ,0 0
4 0 ,0 0
2 0 ,0 0
0 ,0 0
700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700
E n g in e s p e e d [r p m ]
Figure 6.20: Flow rates of hydraulic circuits III + IV without combinations in [l/min]

6.3.6 Parts list for power hydraulic system 6.3.7 Dealer for power hydraulic couplings in the USA
Voswinkel HS 20 Hatec
Hatec - Metric Hydraulic Components
10821 Train Ct.
Houston, Texas 77041
Phone: 713.466.6678
Fax: 713.466.8030
Email: sales@hatec-metric.com
www.hatecinc.com
Table 6.13: Dealer for power hydraulic couplings
Port A Plug Connector
G 3/4” HS20-1-IGF12 HS20-2-IGF12
G 1" HS20-1-IGF16 HS20-2-IGF16 Note: Port “A” to be used for connection to implement
NTPF 1-11 1/2 HS20-1-INF16 HS20-2-INF16
Voswinkel HS 10
Port A Connector
G 3/8” HS10-2-IGF06
G 1/2" HS10-2-IGF08
NTPF 1/2-14 HS10-2-INF08
Table 6.12: Parts list for high working pressure power hydraulic
system

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: Q* p
P= *η total
Q* p 600
P= *ηtotal P = Output [kW]
1714.29 Q = Flow rate [l/min]
P = Output [hp]
p = Pressure [bar]
Q = Flow rate [gal/min]
Total degree of efficiency (depends on pressure, flow
p = Pressure [PSI] η =
rate/speed, temperature, leakage etc.)
Total degree of efficiency (depends on pressure, flow
η =
rate/speed, temperature, leakage etc.)
Note: Qmax * p ratedn
PE = with htotal = 1
Due to the range of the degree of efficiency, only the output is 600
calculated from the hydraulic standard values Qmax (at rated en-
Examples:
gine speed) and prated (rated pressure) in order to estimate the
required output. Power hydraulics, closed circuit:
The standard output is thus: 125 l/min, 300 bar P = 62.5 kW
Qmax * pRated Power hydraulics, open circuit:
PE = with htotal = 1
1714.29 90 l/min, 280 bar P = 42 kW
Examples:
Power hydraulics, closed circuit:
33.02 gal/min, 4350 PSI P = 83.8 hp
Power hydraulics, open circuit:
23.78 gal/min, 4060 PSI P = 56.32 hp
The engine output to be applied for driving purposes is therefore

always higher than the standard value. The hydraulic output pro-
vided is always lower than the standard value.


Body and Implement Mounting Guidelines U500 North America Electrical system
7 Electrical system
Trailer socket rear 7-pin
Implement socket at battery box 16-pin
7.1 General notes on the electrical system Permanent power socket with speed signal in cab 3-pin
Implement socket front (optional, Code E45) 7-pin
The U500NA has a 12 V vehicle circuit voltage and a serial bat- Table 7.2: Electrical interfaces
tery-isolating switch.
Important Note: The vehicle has also 24 V in some loca- Option
Descriptions:
tions in the electrical system. codes:
E44 12 V jump start terminals
Preparation for CB / mobile telephone (12 V), incl.
E53
antenna
7.1.1 Technical data of the electrical system E54 Preparation for two-way radio (12 V), incl. antenna
Alternator 14 V, 145 A E55 Antenna and two loudspeakers
Alternator with increased power (option Table 7.3: Optional electrical equipment
14 V, 270 A
code M37)
Starter 12 V, 3 kW
Batteries 3x12 V, 96 Ah 7.1.2 Lighting
Lights 12 V Following the mounting of implements/bodies on the Unimog the
Electronics (except FR1 and MR2) 24 V adjustment of the headlights should be checked.
Table 7.1: Technical data of the electrical system In case of attaching an implement/body, the implement/body
manufacturer is responsible for compliance with regulations to
Note: lighting of a vehicle.
1
ECU for chassis (12V)
2
ECU for engine (12V)

7.2 Electric cables • Do not change standard connections, e.g. ground con-
nections.
Conductor cross sections
• When changing the length of cables or on installing fur-
When determining cable cross-sections, the loss of voltage in ther cables, waterproofed connectors must be used.
the conductors must be considered. If the voltage drop is too
great, it may lead to the conductors becoming heated and, under • If the installation position of electric or electronic compo-
certain circumstances, to a cable fire. Conductor cross-sections nents is changed, the length of the electric cable must be
of less than 18AWG / 1 mm2 are to be avoided due to the low adapted. Routing may compensate for slight excess in
stability of the conductor. The positive and negative cables must the cable length. Excess length must not be routed in
have the same cross-section. Technical literature provides in- rings or loops.
formation regarding the cross-sections of electric conductors that When routing cables from one side of the frame to the other, use
are to be used or which are suitable. No more than 5 A should existing holes. An additional hole may only be drilled if there is
be carried per mm² cable cross-section. no other possibility for passing the cable through the frame. Re-
The necessary cross-section must be calculated by the im- ferring to section 10.6 Mounting of implements on page 266. The
plement manufacturer and must be tested under concrete, hole must be provided with edge protection (grommet), so that
practical conditions. the cables are protected against damage.
For extending electric cables, note the following:

• Only use cables with the same cross-section and same
basic and identification color as the standard cables.
• The cables must be sheathed with a protective insulating
sleeve to prevent chafing and abrasion.
• Only attach original connectors or connectors of equiva-
lent quality to the cable end.
• Electric cables may only be connected via junction
boxes.

seat. Fuse F2/14 is located on the left module (Module E), at the
right hand side at the bottom.
7.3 Current consumption - auxiliary consumers
If auxiliary electrically driven components are installed, batteries

or alternators with higher outputs (code M37) may be necessary.
Retrofitting of larger batteries by the implement or body manu-
facturer is possible. If, despite these measures, the output of the
vehicle electrical system is insufficient, a vehicle-independent
power supply must be installed.
If the implement or body manufacturer subsequently installs
electrical consumers, the following must be noted:
• Do not connect additional consumers to assigned fuses.
• Do not connect additional cables to existing cables (e.g. Figure 7.1: Power outlet and grommet behind the driver seat
with insulation displacement connectors).
• Provide consumers with sufficient protection via addi- Further information to grommets and laying of cables into the
tional fuses. cab are included in Section 9 Cab, page 241.
7.4 Electrical interfaces
7.4.1 Power outlet in the cab (E37)

Socket out- 3-pin
let
Data 12 V / 25 A
Location Behind the driver seat
Suitable Part-No.: A 022 545 90 28
plug
Ports +12 V: Terminal 30 (steady plus); 0 V: Ground;
Road speed signal “C3”.
Table 7.4: Power outlet in the cab
The power outlet in the cab is fused with fuse number F2/14.
This fuse is located in the fuse box behind the right passenger

7.4.2 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.
Figure 7.4: Suitable plug for socket E45

Figure 7.2: Left front bumper Figure 7.3: Socket E45
Pin assignment:
A suitable plug (part-no.: A 004 545 21 28) can be ordered at Pin num-
any authorized Freightliner Unimog dealers. The cables are fas- Function
ber
tened in the plug with screw connectors. 1 Ground (Terminal 31)
2 Left hand side tail light (Terminal 58L)
3 Turn signal lamp, left
4 12 V, 15 A
5 Turn signal lamp, right
6 Right hand side tail light (Terminal 58R)
7 Not connected
Table 7.5: Pin assignment of front implement socket E45

7.4.3 Implement socket on the battery box Note: EPS is an abbreviation for electro-pneumatic gear
shifting.
This implement socket is intended as electrical interface for im-
plements and bodies. It is located at the right hand side of the
battery box (at the left hand side of the vehicle). It is a 16-pin Current up to 40 A can be tapped from the implement socket.
socket with the following pin assignment: For this purpose the pins 1, 2 and 3 (+12 V) must be con-
Pin nected. The same applies to ground connection pins 4, 5 and
Function: Description: 6.
number:
1 Terminal 30 +12 V; steady plus; fused (15A)
4 Terminal 31 Ground
7 Terminal 15 Ignition
8 Terminal 58 Parking light / side marking lamps
9 Terminal W Alternator speed signal
10 WB Warning beacon closed opened
11 BUL Back up light
12 C3 Road speed signal Figure 7.5: Implement socket
13 C4 Distance signal
Not con-
14 -
nected
15 UI* Universal input to EPS control unit
16 UI ground EPS - Ground for universal signal
Table 7.6: Pin assignment of implement socket 16-pin
Note: UI (Universal input) is suitable for different functions,

for example, remote control engine speed including
start/stop function. Figure 7.6: Suitable plug Figure 7.7: Pins of the plug
See section 7.9 Road speed signal and travel dependent signal,
page 231 for further description of the road speed and travel dis-
tance signals (C3 and C4).

Two different types of suitable plugs are available for the con- Part numbers for plug with screw connectors:
nection of implements/bodies to this implement socket.
Description AMP Part-No.: MB Part-No.:
Housing, Plug:
51.42.42.16.07 A 043 545 15 28
The plug is available with crimp connectors and also with HB-K.16.STS-GR.1.21
screwed connectors. In both cases the necessary plug (size 6) Cartridge, screw:
66.12.16.40 ---
can be ordered at AMP or at any authorized Freightliner Unimog HX.16.Sti.S
dealer. Terminal, screw
--- ---
for pins 1 thru 6
AMP order address: Terminal, screw
--- ---
AMP Regional Center for pins 7 thru 16
Harrisburg, PA, USA Table 7.8: Part numbers for plug with screw connectors
Phone: +1.717.564.0100
Fax: +1.717.986.7575
Part numbers for plug with crimp connectors:

Description AMP Part-No.: MB Part-No.:
Housing, plug:
51.42.42.16.07 A 043 545 15 28
HB-K.16.STS-GR.1.21
Cartridge: HE.16.Sti.C 43.12.16.41 A 043 545 19 28
Terminal, crimp for pins
1 thru 6: HE/HA-C- 43.15.00.22 A 000 545 21 63
Sti.Ag. 2.5 mm2
Contact, crimp for pins
7 thru 16: HE/HA-C- 43.15.00.21 A 000 545 22 63
Sti.Ag. 1.5 mm2
Table 7.7: Part numbers for plug with crimp connectors

7.4.4 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.
lid closed lid open

Figure 7.8: Rear trailer socket
Pin assignment:
Cable
Pin-no.: Lamp and Signal Circuit
Color1
1 white Ground return to towing vehicle (31)
Clearance, side marker and identifica-
2 black
tion lamps (58LI)
3 yellow Left turn signal and hazard lamps (L)
4 red Stop lamps a antilock device (54)
5 green Right turn signal and hazard lamps (R)
6 brown Tail and license plate lamps (58RE) Dimensions in [mm]
Continuous ABS power / auxiliary
7 blue Figure 7.9: Pin and color assignment
(AUX + 54G) 12V, 20A (steady plus)
Table 7.9: Pin assignment of the rear trailer socket
1 A suitable plug (part-no.: A 004 545 21 28) can be ordered at

Trailer side any authorized Freightliner Unimog dealers. The cables are fas-
tened in the plug with screw connectors.

7.5 Engine remote control Note: Since connecting pin 15 and pin 16 stops the engine, the
implement socket should always be kept clean and the
An engine remote control system is available for the Unimog. lid should be closed when ever no connector is attached.
Such remote controls systems can be primarily used in conjunc-
tion with N16 / N19 auxiliary PTO applications like cranes, back-
hoes, aerial devices, emergency stop switches on implements • Engine speed remote control:
etc.
o Operation code W04
Remote controls use the implement socket (at the battery box).
o Carried out via UI (pins 15 and 16)
Prerequisite is the activation of operation codes “W” (see section
7.6, page 227). o Change in resistance between UI and signal ground
Before enabling the engine remote control system, the engine
variable speed governor must be activated using the manual
• Other functions (refer also to W-codes):
throttle control switch at the gearshift console (take place auto-
matically when an auxiliary power take-off is switched on). o Warning buzzer W06
Important Note for following descriptions: o Limitation of max. engine speed W09 thru W20
Necessary resistor power 1 Watt. All Pin numbers refer o Transmission lock W30
to the implement socket at the battery box.
o Useful as a safety feature to prevent driving off
when support legs are extended (e.g. cranes)
7.5.1 Remote control functions o Speed limit W35
• Engine Start/Stop: o Useful as a safety feature with waste disposal
trucks
o Operation code W01, W02 or W05 (refer to page 229)
must be activated
o Carried out via UI (pins 15 and 16) A cable runs to the cab from pin 14 of the socket. Other func-
tions can be directly wired or programmed at the request of the
o Engine stop via connection between pin 15 and pin 16
implement manufacturer. Contact the Unimog Implement Man-
(signal ground)
ger listed at the beginning of this guideline.
o Engine start with 470 Ohms resistor (1 W) between pins 15
and 16

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). circuit between pin 15 and pin 16, the engine runs at idling
speed. If the speed function switch is closed (2,200 Ohm resis-
The engine is started when a resistance of 470 Ohms is con-
tance between pins 15 and 16), the engine speed increases
nected between pins 15 and 16 for 5 seconds.
slightly (to 750 rpm) and the engine speed control system is ac-
tivated. Higher speeds can be reached using an additional resis-
Engine stop tor, which is switched in series to a resistance of 2,200 Ohms
(Additional resistances: 0 Ohm = approx. 750 rpm, 800 Ohm =
The engine can be stopped at any time, for example, in case of approx. 1,000 rpm, 4,000 Ohm = approx. 2,200 rpm).
an emergency. The ignition circuit (terminal 15) will remain
switched on.
The engine can only be stopped via short-circuit between pin 15
and pin 16 at the implement socket on the battery box, if the Procedure:
parking brake is applied and the code W05 is parameterized.
• Apply the parking brake
Note to auxiliary PTO N16 / N19:
• Shift to Neutral
N16/N19 can be switched on when the clutch pedal is depressed
and the transmission (EPS) is in neutral or any gear up to 4th • Switch on the variable-speed governor (switch "n" on the
gear. If a gear is engaged and N16/N19 is switched on, no fur- instrument panel between the seats)
ther gear changes can be carried out (except engaging neutral). • Press the engine start button on the remote control and
hold it for five seconds (470 Ohm circuit). The engine will
be started after five seconds
• Activate engine speed control (2,200 Ohm circuit) and
allow the engine speed to increase to approx. 750 rpm
Their after connect additional resistors in series to the
2,200 Ohm resistor to reach higher engine speeds.

7.5.2 Examples for designing an external manual control
Figure 7.11: Suggestion for a variable engine speed limiting

Figure 7.10: Suggestion for an engine speed remote control circuit
circuit
Note: Potentiometer R1 may be replaced with a (fixed value) re-

sistor if only one engine speed limit is required

Circuit suggestion for a fixed speed of 1,200 rpm:
Figure 7.12: Suggestion for an engine speed remote control

unit
value
4000
3000
resistor
Figure 7.14: Suggestion for an fixed engine speed of 1,200 rpm

2000
Operating states:
1000 Basic state: S1 open, S2 closed
Increased idle speed: approx. 750 rpm: S1 and S2 closed
500 1000 1500 2000 2500

Speed approx. 1,200 rpm: S1 closed and S2 open
These states must be implemented one after the other with
engine speed (RPM) approx. 1sec intervals.
Figure 7.13: Resistor R1

7.5.3 Important note for engine remote controls 7.6 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).
Code W30 and code W35 can therefore not be combined. It is
also not possible to use code W30 or code W35 in conjunction
with option code N09 (PTO shaft speed limiter 540 rpm).
The following factory settings are possible for the implement

socket at the battery unit:
Code Description
Engine stop function via implement socket at the
battery box:
Immediate engine stop (emergency shutdown func-
tion) if a signal is present at the implement socket,
W01
which complies with specifications (see 7.5 Engine
Figure 7.15: Important note for remote controls remote control, page 223). This function is only pos-
sible when the vehicle is stationary (parking brake
applied).
In case an electronic component (e.g. transistors etc) is used to Engine start-stop function via implement socket
operate the engine remote control it is necessary to disconnect at the battery box:
the remote control circuit from the implement socket by means of Immediate engine stop (emergency shutdown func-
a switch or a relay. tion) if a signal is present at the implement socket,
W02 which complies with specifications. Engine start if a
Failing to comply will cause malfunction of the transmission due
signal is present for at least 5 seconds which com-
to leakage currents of the electronic components.
plies with specifications, (see 7.5 Engine remote con-
trol, page 223). This function is only possible when
the vehicle is stationary (parking brake applied).

Variable engine speed limit via the implement Limitation of engine speed to 1,000 rpm when
socket: transmission PTO (option code N16, N19) is ac-
Variable engine speed limit if a signal, which complies tivated.
W03 with specifications (see 7.5 Engine remote control, W10 Engagement of transmission PTO will automatically
page 223) is present at the implement socket (see limit the engine speed to 1,000 rpm. In case of over
Figure 7.11). speeding on a down-hill run the warning buzzer will
Note: limits max. achievable engine speed sound at 1,000 rpm +/- 10%.
Variable engine speed function via the implement Limitation of engine speed to 1,100 rpm when
socket: transmission PTO (option code N16, N19) is ac-
Variable engine speed function if a signal. which com- tivated.
W04 plies with specifications (see 7.5 Engine remote con- W11 Engagement of transmission PTO will automatically
trol, page 223) is present at the implement socket. limit the engine speed to 1,100 rpm. In case of over
Note: when activated engine speed will increase to speeding on a down-hill run the warning buzzer will
set limit sound at 1,000 rpm +/- 10%.
Variable speed function and engine start-stop via Limitation of engine speed to 1,200 rpm when
the implement socket: transmission PTO (option code N16, N19) is ac-
Variable speed function if a signal is present at the im- tivated.
plement socket, which complies with specifications, W12 Engagement of transmission PTO will automatically
W05 (see 7.5 Engine remote control, page 223). Engine limit the engine speed to 1,200 rpm. In case of over
start or stop if a signal, which complies with specifica- speeding on a down-hill run the warning buzzer will
tions is present at the implement socket. The engine sound at 1,200 rpm +/- 10%.
stop function is only possible when the vehicle is sta- Limitation of engine speed to 1,300 rpm when
tionary (parking brake applied). transmission PTO (option code N16, N19) is ac-
Controls warning buzzer at the instrument panel: tivated.
Controls central warning buzzer at instrument panel in W13 Engagement of transmission PTO will automatically
the driver's cab if a signal, which complies with specifi- limit the engine speed to 1,300 rpm. In case of over
W06
cations is present at the implement socket. speeding on a down-hill run the warning buzzer will
(Signal: sort circle between pins 15 and 16, activated sound at 1,300 rpm +/- 10%.
by implement/body manufacturer) Limitation of engine speed to 1,400 rpm when
Limitation of engine speed to 900 rpm when transmission PTO (option code N16, N19) is ac-
transmission PTO (option code N16, N19) is acti- tivated.
vated. W14 Engagement of transmission PTO will automatically
W09 Engagement of transmission PTO will automatically limit the engine speed to 1,400 rpm. In case of over
limit the engine speed to 900 rpm. In case of over speeding on a down-hill run the warning buzzer will
speeding on a down-hill run the warning buzzer will sound at 1,400 rpm +/- 10%.
sound at 900 rpm +/- 10%.

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. vated.
W15 Engagement of transmission PTO will automatically W20 Engagement of transmission PTO will automatically
limit the engine speed to 1,500 rpm. In case of over limit the engine speed to 2,000 rpm. In case of over
speeding on a down-hill run the warning buzzer will speeding on a down-hill run the warning buzzer will
sound at 1,500 rpm +/- 10%. sound at 2,000 rpm +/- 10%.
Limitation of engine speed to 1,600 rpm when Electrical preparation for safety circuit, crane in-
transmission PTO (option code N16, N19) is acti- stallations:
vated. Pull-away lock when crane supports are extended.
W16 Engagement of transmission PTO will automatically Start blocking is activated by controlling pin 14 on the
limit the engine speed to 1,600 rpm. In case of over implement socket, provided the parking brake has
W30
speeding on a down-hill run the warning buzzer will been applied and neutral has been selected. This is
sound at 1,600 rpm +/- 10%. deactivated again once the control is removed.
Limitation of engine speed to 1,700 rpm when Signal: +12 V at pin 14, activated by the imple-
transmission PTO (option code N16, N19) is acti- ment/body manufacturer. A cable bridge must be retro-
vated. fitted in the switch box in front of the cab rear wall.
W17 Engagement of transmission PTO will automatically Electrical preparation for safety circuit, waste dis-
limit the engine speed to 1,700 rpm. In case of over posal vehicles:
speeding on a down-hill run the warning buzzer will Limit speed to 18.6 mph / 30 km/h, reverse-gear inter-
sound at 1,700 rpm +/- 10%. lock. Typical application: If waste disposal workers are
Limitation of engine speed to 1,800 rpm when on board, the road speed is restricted to 18.6 mph /
transmission PTO (option code N16, N19) is acti- W35 30 km/h. A reverse-gear interlock is also activated (no
vated. rollback lock!).
W18 Engagement of transmission PTO will automatically Signal: +12 V at pin 14, activated by the imple-
limit the engine speed to 1,800 rpm. In case of over ment/body manufacturer. Add a wire from terminal cab
speeding on a down-hill run the warning buzzer will junction box (XT1/18-10) to transmission junction box
sound at 1,800 rpm +/- 10%. (X4/15-1).
Limitation of engine speed to 1,900 rpm when Table 7.10: W-code description
transmission PTO (option code N16, N19) is acti-
vated.
W19 Engagement of transmission PTO will automatically
limit the engine speed to 1,900 rpm. In case of over
speeding on a down-hill run the warning buzzer will
sound at 1,900 rpm +/- 10%.

7.7 Preparation for the installation of roof-mounted

auxiliary headlights Pin assignment:
On large front mounted implements, e.g. large snow plows with Pin: Description:
wind deflectors, the auxiliary driving lamp (code L47) may get 1 12 V ground (terminal 31), right
covered by the implement in transport position. The implement 2 Side marker lights (terminal 58), right
manufacturer must draw attention to this in the operators 3 Low beam light (terminal 56), right
instruction manual. 4 High beam (terminal 56), right
5 Turn signal light, right
6 Not connected
Code L49: Preparation for Roof-mounted headlights may be or- 7 12 V ground (terminal 31), right
dered ex factory. The auxiliary driving lights (code L47) may not 8 Side marker lights (terminal 58), left
be ordered together with code L49. 9 Low beam light (terminal 56), left
Code L49 includes the main headlamp switch and an electrical 10 High beam (terminal 56), left
interface, which is located in the switch box in the area behind 11 Turn signal light, left
the power outlet (behind driver seat) in the cab. 12 Not connected
Table 7.11: Pin assignment of code L49 connector
To connect your roof-mounted headlamp support you will need:
• 1x Housing, socket; part-no.: A 013 545 62 26 (12-
pin housing)
• 10x Terminal, clamp for 14AWG / 1.5 mm2 cable cross-
section; part-no.: A013 545 78 26
Figure 7.16: Example for a roof-mounted headlights

7.8 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-
If high front implements are to be mounted, it can be useful tude 8 V, Imax = 1 mA.
to increase the height of the additional raised headlights The distance signal (C4) provides 4 pulses per meter of travel,
code L47. The electrical cables are long enough; it is only amplitude 8 V, Imax = 1 mA.
necessary to make a new bracket, mounted between the
serial holder and the lights. voltage
8V
T time
t=1/f
Figure 7.18: Speed signal C3

Max. height
h < 2350 mm voltage
U(V)
Figure 7.17: Example for raised headlights 4

1 2 3 4
2
0
7.9 Road speed signal and travel dependent signal
distance travelled
1.0 m s (m)
The road speed signal and travel dependent signal comply with
ISO 16844-2.
The road speed signal (C3) can be taken from the power supply Figure 7.19: Travel distance signal C4
socket in the cab (behind the driver’s seat) and also from the
implement socket at the battery box.
The travel distance signal (C4) can only be taken from the im-
plement socket at the battery box.

7.10 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-
tromagnetic compatibility of the vehicle components are in-
stalled, the implement or body manufacturer must ensure that
the operating safety of the entire vehicle/implement combination
needs the EMC requirements lad down by law or specified by
the application.
Important Note: A further EMC test may be necessary.


Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers
8 Pneumatic Consumers
8.2 Technical data of the compressed air system
8.1 General notes to pneumatic consumers Operating pressure 117.5 psi / 8.1 bar
Delivery at rated engine 79.25 gal / min / 300 l / min
The Unimog is serially equipped with a air brake system. When speed at 117.5 psi / 8.1 bar
attaching pneumatic consumers on the Unimog the following Tire inflating valve at test con-
Compressed air connection
items must be considered: nection of reservoir
Reservoir, brake system 2 x 7.53 gal / 2 x 28.5 l
• Only small air extraction values are permitted, for exam-
Table 8.1: Technical data of the compressed air system
ple implement actuations
• Pneumatic consumers with high air consumption must
not be attached to the Unimog air system
• Continuous consumers with constant air flow must not be
attached to the Unimog air system
The implement/body can be equipped with an additional air tank.
In this case the time limit for filling the air tanks to reach the nec-
essary brake pressure must be considered (FMVSS 121 /
CMVSS 121).
Applications, which require a high airflow, must be equipped with
an external mechanically, hydraulically or electrically driven air
compressor. For additional or larger air compressors engine
mounting is not possible.
To protect the air brake system, the air may only be tapped be-
hind an pressure protection valve. Figure 8.1: Location of the compressed air system
The air extraction interfaces are different for vehicles with CTIS
(central tire inflating system, code A30) and vehicles without
CTIS. Pneumatic consumers may only be connected to the fol-
lowing described interfaces.

8.3 Air extraction
On vehicles with CTIS dried air can be extracted behind an pro-

tection valve (part-no.: A005 429 55 44) at the ½ in interface
(see Figure 8.3). The air extraction can be realized like shown in
Figure 8.4 to Figure 8.7.
On vehicles without CTIS the connection (part-no.:
A405 990 09 71) should be replaced with the parts shown in
Table 8.2.
Purge tank Wet tank

Air extraction
interface
Figure 8.3: Air extraction interface on vehicle with CTIS
Note: All connecting parts with thread must be mounted with

sealing compound Loctite Vibra Seal®516.
The locations on Figure 8.2 and Figure 8.3 called air extraction
interface are detailed described on the following pages.
8.3.1 Air extraction on vehicles with CTIS
Figure 8.4 shows the serial mounting parts on vehicles with op-
tion code A30 (CTIS). Connecting of additional pneumatic con-
sumers can be realized by retrofitting the serial parts with addi-
Reservoir circuit 1 Reservoir circuit 2 Air extraction tional parts. An overview of the retrofitted interface is shown in
(primary reservoir) (secondary reservoir) interface Figure 8.7. All necessary parts are described on page 239.
Figure 8.2: Vehicle without CTIS (back view)

Serial mounting parts on vehicles w/o CTIS (code A30):
Connected to secondary
supply reservoir
Figure 8.4: Serial mounting parts on vehicles w/o CTIS
Serial mounting parts on vehicles with CTIS (code A30):
Connected to secon-
dary supply reservoir
CTIS
interface
Figure 8.5: Serial mounting parts on vehicles with CTIS

Serial and additional mounting parts for pneumatic consumers on vehicles w/o CTIS (code A30):
Connected to secondary
supply reservoir
Interface for
additional
pneumatic
consumers
Figure 8.6: Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS

Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS (code A30):
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
Air extraction on vehicles without CTIS

The L-fitting shown in Figure 8.2 (called air extraction interface) must be replaced with all parts like displayed in Figure 8.7. All nec-
essary parts are described on page 239.

Necessary parts for air extraction

Serial amount w/o CTIS Serial amount with CTIS
PARKER® Hannifin
w/o with w/o with Part MB Part-No.:
Part-No.:
air extraction air extraction air extraction air extraction
0 1 1 2 A405 997 00 67 VS 2225P-8
0 1 1 1 A405 997 07 71 VS 68NTA-10-8
0 1 1 1 A405 990 08 70 VS 209P-8-6
0 1 1 1 A405 997 06 71 VS 1204P-6
Meritor Wabco
0 1 1 1 A005 429 55 44
Part-No.: 934 899 0207
0 1 1 1 A405 997 08 71 66NTA-8-8
0 0 0 1 A405 990 07 71 VS269NTA-8-8
1 0 1 0 A405 900 09 71 VS269NTA-10-8
0 0 0 1 A005 431 01 07 934 099 0010
Table 8.2: Necessary parts for air extraction


Body and Implement Mounting Guidelines U500 North America Cab
9 Cab Warning: Risk of becoming trapped or crushed!

Do not stand in tipping area during tipping
procedure. Never stay or move in front of,
9.1 General notes behind or under the cab during tipping, and
avoid the tipping area. 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. cab.
Warning: Risk of damage to the hood!

9.2 Tilting the cab
Always open the front flap before tipping. Tilt-
The tilting ability of the cab must not be impaired as a result of ing the cab forward with closed hood will
an implement / body on the Unimog chassis. cause damage to the hood.
Lines and cables, which are routed from the implement or In order to avoid damages to the cab, ensure that sufficient
body into the interior of the cab or which are fixed up to that space is available in front of the vehicle. Depending on its de-
point, must have disconnection points or, like the vehicle wir- sign and size, a front mounted implement must be removed
ing harness, must be routed via the cab pivoting point. prior to tilting.
The connector for an electric cable that must be disconnected
prior to tilting must be easily accessible. The connectors must
be adequately protected against dirt and water, in order to en-
sure that they function even when driving off-road or through
water.
Control cables and the corresponding control consoles can
also be passed into the cab through the cable passage in the
rear wall of the cab or to the front wall of the cab and also
through the rear-sliding window. For further information to ca-
ble passages into the cab see 9.3 Cable passage into the cab,
page 243).
Before tilting the cab:
Pay attention to the Maintenance Manual!
Figure 9.1: Tilting of the cab

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” (in Figure 9.3) measured from the rear wall of the
Any roof loads must be removed before the cab is tilted. Cor-
cab to the center mounted body, must not be less than 2.76 in
responding instructions must be included in the implement /
/ 70 mm.
body operating instructions.
The design of an implement or body must ensure that the cab
is able to tilt unimpaired. In an already existing body the ease
of movement when tilting must be checked practically. When
raising the cab it must be ensured that the vehicle is standing
on an even surface. Even slight unevenness leads to unilateral
spring deflection, thereby increasing the amount of space,
which is required. The body must only be located within the
shaded area in Figure 9.3.
Figure 9.3: Free movement of the body and the cab

Figure 9.2: Cab tilting curve

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. The cable passages are
closed with seal caps (part-no. A405 583 00 83, see Figure
9.6). The seal caps can be cut in for cable passages into the
cab.
9.3.1 Cable passage through the rear wall of the cab
The cable passage in the rear wall of the cab is provided in the
area behind the driver seat near the power outlet (see Figure Dimensions without brackets are in [mm].
9.4). Since the Unimog cab can be tilted, plug-connections Dimensions in brackets are in [in].
must be provided for the cables so the lines are not damaged Figure 9.4: Cable passage through the rear wall of the cab
when the cab is tilted.
9.3.2 Cable passage through the front wall of the cab
A similar cable passage in the front wall of the cab is located in
the area of the right (passenger) footwell (see Figure 9.6). This
is intended for front implement cables or cables which are
passed over the pivot point and therefore need not be taken
apart when the cab is being tilted (in particular with perma-
nently mounted implements / bodies).
For the exact position of the front cable passage, see vehicle
drawings on the Unimog Resource CD.
Figure 9.5: Cable passage through the front wall of the cab

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. The pass-through plug can also ordered at au-
thorized Freightliner Unimog dealers (part-no.
A405 583 00 83). The exact mounting position can be seen on
the previous sections and can also be determined with the ve-
hicle drawings on the Unimog Resource CD.
The fitted ports on the pass-through plug have four different
diameters, which can be cut so that different cable diameters
are possible. If the cable passage on the implement cable is
already converted, the two attached port plugs can be cut. If
the cable passage is connected on the existing cable, it can be
cut along the cable slits.
Figure 9.7: Caps for pass-through plug
Figure 9.6: Pass-through plug for four different cable diame-

ters

Figure 9.8: Drawing of the pass-through plug

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):
The best method for routing the cable into the cab is by se-
curely attaching the rubber part (material: EPDM) to the im-
plement cable. Use the pass-through plug (part-no.
A405 583 00 83) available at authorized Freightliner Unimog
dealers.
The plug may be cut to the cable diameter and the plug ports
can removed. Ensure that the strap for removal from the cab
remains intact. A plug / socket can be attached on the cable as Figure 9.10: Removing of the plug ports
soon as the cable has been put through the plugs. It is rec-
ommended to fix the cable using a cable tie. The pass-through
plug, which is fitted ex factory, should not be used for convert-
ing of the plug, as it must be available when the implement
cable is removed. If the implement / body is removed, the rub-
ber is removed from the cab using the strap and the hole in the
cab is closed with the original pass-through plug using talcum
powder.
Figure 9.11: Pass-through plug with removed port

Figure 9.9: Cutting of the plugs

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. Following the cut-in of
the pass-through plug, the cable can be inserted and fixed with
a cable tie. If the pass-through plug always remains on the im-
plement cable, the plug ports can be removed.
Figure 9.14: Fastening of the cable with a cable tie
Figure 9.12: Cut-in of the plug
Figure 9.13: Cable mounting

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.
If the same pass-through plug is used for several implements, A 409 583 0 83 can be used to close the hole in the cab.
you should generally cut-in along the cable slit (see Option 2).
Once the implement cable has been removed, the plug port
can be used to close the open port on the pass-through plug
(see Figure 9.15).
Figure 9.16: Use of seal cap (part no. A409 583 00 83)
Figure 9.15: Use of the plug ports

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.
they are continuously able to endure the strain of being used
under on-road and off-road conditions. Attention should be Important Risk of damage to the cab!
paid to following items: note:
The maximum possible load for roof-mounted
• Good accessibility devices or roof bars must not exceed 44 lbs /
20 kg.
• Good corrosion protection with regard to de-icing salt
(winter service)
All roof-mounted devices must be attached on the revolving
• Protection from mud and stone impact roof beacon stands at the rear of the cab. The stands are fitted
in tubes, which are laminated into the rear wall of the cab.
• Shocks incurred in off-road use must not cause dis- These tubes have an inside thread (M28 x 1.5). Mounting of
connection of the connectors devices like a light bar or similar implements could be attached
• Connectors, which are not routed via junction boxes, with a tube that fits on the left and right hand side of the cab to
must be enclosed, equipped with strain-relieves and the inside thread of the stands.
fixed to the vehicle with cable ties.
laminated
tube
Figure 9.17: Mounting possibility on the roof of the cab

The center of gravity of the roof-mounted device must be as

close as possible at the laminated stands.
A-A
A proposal for mounting of
• Emergency lighting
• Light bars
• Light heads
A-A
• Strobe lights etc.
is displayed on the following pages.
In all cases the roof-mounted devices must be designed in
such a way that it’s possible to attach beacon lights either on
the laminated stands of the cab or on the roof bar.
Roof-mounted devices can be attached additionally at these
front supports:

Figure 9.19: Proposal for a front support
These supports can be mounted on the roof of the cab by dis-

mounting the two interior lighting (see Figure 9.20).
Figure 9.18: Front support for roof-mounted devices

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

Figure 9.21: Fastening of the roof-mounted front support
Figure 9.23: Reinforcement plate for the inside of the cab
The front support shall be mounted via two bolts and a suitable
reinforcement plate. Additionally a seal must be attached be-
tween the front support and the roof of the cab. This seal can

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)
This sleeve must be screwed into the inside thread (M28) of

Dimensions without brackets are in [mm]. the stand.
Figure 9.24: Reinforcement plate for the inside of the cab
As described of the beginning of this section the rear supports

for roof-mounted devices are the laminated stands of the bea-
con lights. Therefore the beacon lights must be removed from
these stands and fastened securely on the roof bar.

Electrical connection of roof-mounted devices Routing of the cable

Roof-mounted devices can be connected to the electrical sys- The cable should be routed through the cable passage in the
tem of the Unimog on different ways. rear wall of the cab and behind the funnel of the air intake to
the roof of the cab (see the following figures).
1. Preparation kit for roof-mounted light bar (code L49):
This preparation kit contains a short cable (in the fuse box be-
hind the co-driver’s seat) and a switch in the center console.
The implement manufacturer must connect a cable of the roof-
mounted device to the short cable at the fuse box. The cable
can be routed to the roof of the cab and connected to the addi-
tional roof-mounted headlights. By activating of the switch the
regular headlights will turn of and the additional headlights on
the roof of the cab will turn on. This preparation kit is fused
with 10 amps per headlight (12 V).
2. Support for rotating beacon (road side, code L58)
If code L58 is ordered, the Unimog will be delivered with a
switch in the center console and a support for a beacon light
with cables at the rear end of the roof of the cab (see Figure
9.17). The switch in the console will turn the power for the ro- Figure 9.26: Cable passage through the rear wall of the cab
tating beacon on or off. The rotating beacon is fused with
15 amps (12 V).
3. Support for rotating beacon (road and curb side, code L59)
By ordering of code L59 the scope of delivery will include all
features of code L58 plus a support with cables for the curb
side. Both rotating beacons are fused with 15 amps (12 V).
4. Power outlet in the cab (code E37)
For higher electrical power the power outlet in the cab behind
the driver’s seat must be used. This outlet is fused with
25 amps (12 V). See also section 7.4.1, page 218.
Figure 9.27:Routing of the cable behind the chimney of the air intake

9.4.2 Aerial mounting 9.5 Attaching of an implement control console in

A preliminary setup for CB / mobile telephone (code E53), two the cab
way radio (code E54) and radio aerial with speakers and con-
trol units are available as an option. The preliminary setup for Two different installation positions for the gearshift console are
the CB / mobile telephone is fitted on the right, the radio aerial available:
is n the center and the two-way setup is fitted on the left of the • Left mounted gearshift console in case of two-seat cab/
cab roof. In code E55 the radio aerial is fitted in the factory. three-seat cab
National laws and regulations must be taken into considera- • Center mounted gearshift console in case of vehicles
tion. Special caution is required when passing railroad cross- equipped with VarioPilot (changeable steering)
ings. If the aerial comes into contact with the overhead power
lines, the lives of the vehicle passengers are placed in danger.
Figure 9.28: Left mounted Figure 9.29: Center mounted

gearshift console gearshift console

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. and the VarioPilot (changeable steer-
ing).
A support can be fitted to four threaded holes in the gearshift
console with a weight of up to 6.61 lbs / 3 kg. There are two The clearance must be checked after the installation of sup-
M6 thread holes on the sides and two M8 thread holes on top port bails and the implement control console to the gearshift
of the gearshift console. panel (see Figure 9.31).
Control consoles that weigh more than 6.61 lbs / 3 kg must be
attached with three additional securing points under the flood
mat of the cab. For more information and dimensions see
Figure 9.30, page 255 and the following pages.
4 fastening points
on the gearshift
console for light-
weight control
panels
3 additional fas-
tening points for
heavy control
panels
Figure 9.30: Fastening points for mounting control consoles
Figure 9.31: Clearance between steering and gearshift con-

sole

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

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

control unit
mounting frame control unit
mounting frame
Figure 9.34: position of the frame for center mounting (use Figure 9.36: position of the frame for left mounting
with VarioPilot)
Figure 9.35: 3D view of the frame for center mounting (use with Figure 9.37: 3D view of the frame for left mounting
VarioPilot) RK 999 000 P 207 RK 999 000 P 245

Figure 9.38: 3D view of the frame for left mounting

Figure 9.39: 3D view of the frame for left mount



Body and Implement Mounting Guidelines U500 North America Chassis frame modifications
10 Chassis frame modifica-

10.2 Chassis frame dimensions
tions
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.): 31.85 in 809 mm
Longitudinal member pro-
9.76x2.17x0.35 in 248x55x9 mm
file:
DIN: E460 TM or E500 TM
Material:
(ASTM: A 607 Grade 65)
100 mm x
1st frame cross member: 3.94 in x 0.20 in
5 mm
90 mm x
2nd frame cross member: 3.54 in x 0.30 in
7.5 mm
3rd frame cross member: U cross member
100 mm x
4th frame cross member: 3.94 in x 0.20 in
5 mm
5th frame cross member: Welded closed profile
6th frame cross member: U cross member
Approx. Approx.
Torsion stiffness of the
1,844 lb⋅ft per 2.5 kNm per
frame:
degree degree
Max. bending moment
25,815 lb⋅ft 35 kNm
over the front axle:
Bending resistance mo- Dimensions without brackets are in [mm].
16.48 in3 270 cm3 Dimensions in brackets are in [in].
ment over the front axle
Bending resistance mo-
10.50 in3 172 cm3 Figure 10.1: Chassis frame cross-section
ment over the rear axle
Table 10.1: Chassis frame data

10.2.2 Chassis frame of the U500, short wheelbase

Figure 10.2: Chassis frame of the U500, short wheelbase

10.2.3 Chassis frame of the U500, long wheelbase

Figure 10.3: Chassis frame of the U500, long wheelbase

10.3 Chassis frame material 10.4 Rear cross member
In case of frame extensions the quality and dimensions of the The chassis frame of the Unimog must always be equipped
extension material must be equivalent to the standard chassis with a rear cross member, even in non-trailer use. Otherwise
frame. The chassis frame material is E460 TM or E500 TM on the frame will be damaged.
the Unimog U500 NA.
A 47.24 in / 1,200 mm long piece of factory frame material is
10.5 Wheel chocks
also available as a spare part (part-no.: A405 311 08 01) and
can be ordered at authorized Freightliner Unimog Dealers.
The wheel chocks must be mounted without play in suitable
brackets. They must be easily accessible, secured against
loss and removable without risk of injury.
10.6 Mounting of implements
Drilling/welding is prohibited when mounting bodies or imple-

ments. Use additional brackets to mount the body/implement.
For further information, see 4.12.


10.7 Drilling on the frame
The chassis frame may be drilled in special cases. The spac-

ing dimension “a” (see Figure 10.4) 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. The maximum hole diameter may
not larger than 0.59 in / 15 mm. After drilling, the holes must
be deburr and reamed.
Drilling must not be carried out on the following locations Figure 10.4: Drilling dimension on the chassis frame
of the chassis frame:
• On the upper and lower flange of the chassis frame
(see Figure 10.5).
• In the area of profile modifications on the frame longi-
tudinal member such as:
o Frame cranking
o Frame supply
o Tubular cross ports
o Frame reinforcements
o Frame flanges
• On load induction points (e.g. spring supports)
• Factory-made drillings in the upper and lower flange of Figure 10.5: Drilling on the frame flange is prohibited
the chassis frame must not be modified.

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.
Observe prescribed tightening torque.
Following items should be considered by using bolt connec-
tions:
• Use fit bolts, headless bolts or flange head bolts (grade
8 and if available SAE fine thread) and flange nuts or
flange lock nuts for bolt connections on the Unimog Figure 10.6: Use of clamping sleeves
(see Figure 10.8).
• Use existing drillings and drill new holes only if it is es-
sential.
• Adapt the number of bolts to the load, if necessary re-
move paint down to the primer to minimize setting
symptoms.
• Use sufficiently strong washers for clamping sleeves
and anti-fatigue sleeves.
Examples for bolted connections:
In case of transferring lateral forces with positive locking bolted
connections a clamping sleeve should be used (see Figure
10.6). For minimizing the loss of preload force caused by sub-
sidence sufficiently long bolts or anti-fatigue sleeves should be
used (see Figure 10.7).

10.9 Welding on the frame
10.9.1 General notes for welding on the frame

Trained personnel must only carry out welding opera-
tions on the frame.
Prior to welding, the frame must be in its normal position and
free of pre-tension due to external forces. This means that all
mounted implements must be lowered to the ground and the
floating position of all hydraulic circuits must be activated.
Additional weights and bodies must be removed. The corre-
sponding area must always be exposed before welding is
commenced.
Further measures:
• Disconnect the battery
Figure 10.7: Use of anti-fatigue sleeves
• Remove the springs or cover them
• Remove or cover plastic lines and electric cables
The weld seam must be checked at regular intervals. After
welding, the welded joint must be thoroughly cleaned and
protected against corrosion. All slag must be removed.
Welding must not be carried out on the upper and lower
flange of the chassis frame (except in the event of wheel-
base modifications and frame extensions).
Connect the ground terminal of the welding unit directly
to the part of the vehicle which is to be welded.
Figure 10.8: Use flange head bolts and flange nuts

10.9.2 Welding preparation
Further measures: It is recommended that a double-V seam (see Figure 10.10)
be used on the upper and lower flange of the frame. The use
• Only use well-dried out electrodes with lime-based
of a V-seam is sufficient in the area of the web.
coating with an electrode diameter of 1/8 in or 5/32 in.
• Electrodes must only be welded with direct current via
the positive terminal.
• Inert gas shielded arc welding is preferable to manual
arc welding.
• In order to avoid notching effects due to fusion penetra-
tion, grind seams with direction of grinding in direction
of torsion (see Figure 10.9) and, if necessary, reinforce
the welding section with angle steels. Weld seams are
not permitted in bending radii (radius ≤ 0.59 in /
15 mm). The distance between seams and the outer
edge should be at least 0.59 in / 15 mm.
Figure 10.10: Welding preparation

Serious defects in and the failure of welded constructions is
often caused by a lack of seam preparation. The protective
paint must be completely removed from the area of the weld.
On creation of the seam form, ensure that no furrows are
caused in the frame (e.g. due to slipping on creation of the
joint). These become notches and thereby reduce the service
life of the chassis.
If carefully welded, butt seams may be equivalent to the basic
material. These seams enable force to flow in a largely unin-
Figure 10.9: Grinding of the weld seam terrupted manner.

10.9.3 Regulations for seam preparation 10.9.5 Seam finishing
In case of root seams, it must be ensured that even root pene- The final run and root layer must be ground flat with the plate,
tration is achieved. The root seam must be of a high quality and the grinding grooves must run in the direction of torsion,
and must not reveal any fusion defects. Subsequently, the i.e. parallel to the longitudinal axis, see also Figure 10.9. The
seam must be grinded internally, if necessary. Depending on surface roughness of the grinding should not exceed surface
the form of the seam, the seam must be filled in with filling ma- roughness of Rz6.3. After welding, sufficient anti-corrosion
terial. protection must be applied.
10.9.4 Welding procedure 10.10 Frame extensions

The upper and lower flange should first be welded externally
In order to ensure that the bending and twisting strength of
and then flanged internally such that work should begin on the
the rear frame overhang is sufficient, the distance between
opposite end of the flange to the last part to be welded (see
the last transverse member and the rear cross member must
Figure 10.11).
be kept as small as possible. The permissible trailer load
must be reduced in accordance with the extension. Use the
same materials and profile form for a frame extension (see
Section 10.3 Chassis frame material, page 266).
Cutting the frame is not permissible in the following areas:
• Load induction points
• Suspension and axle supports
• 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.
Figure 10.11: Welding procedure Note: Axle loads and gross vehicle weight decreases in
case of frame extensions.

10.10.1 Design instructions for extending the frame The following shows examples of web plates and frame rein-
forcement plates. The end section of web reinforcement
In principle, there are two possible methods of welding. Weld-
plates must always be designed as Figure 10.14 shows. En-
ing can be carried out
sure that the welding seams project over the ends of the web
• With reinforcement plates (web plates) and upper or plate edges, in order to reduce the stress concentration in the
lower flange reinforcement or transitional area between the longitudinal member and the
web plate.
• Directly without reinforcement plates.
The reinforcement plate should be welded in the following or-
Cutting the longitudinal member with a flame cutter is not per-
der: First the upper and then the lower flange. The seam
missible. This must be carried out with a cutting tool.
should be welded in the entire length in one pass.
Frame extension with reinforcement plates

The longitudinal member may be cut as shown in Figure
10.12.
Drillings in the chassis
frame must not be cut.
To reinforce the weld
section and relieve the
weld seam a reinforce-
ment plate must be
welded to the frame (see
Figure 10.13 and Figure
10.14).
Figure 10.12: Frame extension with Figure 10.13: Reinforcement plates on inside/outside of the
reinforcement plates frame


Figure 10.14: Reinforcement plates

Frame extension without reinforcement plates
In the case of direct welding, the cut must be diagonal. The cut 10.11 Shortening of the frame
must correspond to figure x whereby the cutting angle must be
between 30° and 45° measured to the vertical. Drillings on the On shortening the end of the frame, the end transverse member
frame must not be cut. Vertical cuts are not permitted in case of must be moved to the remaining end of the frame. The connection of
direct welding! the end transverse member must be carried out as the original.
10.12 Wheelbase extensions
Wheelbase extensions are permitted in special cases only.

In case of wheelbase extensions contact the Unimog Implement
Manager listed at the beginning of this guideline.
Note: Permissible axle loads and permissible gross vehicle
weight do not increase in case of wheelbase extensions.
Figure 10.15: Frame extension without

reinforcement plates


Body and Implement Mounting Guidelines U500 North America Appendix
11 Appendix
To convert
Name To Multiply by
from
11.1 Conversion Table Pressure lbf/in2 Pa 6894.757
2
Pressure lbf/ft Pa 47.88026
B = A*C
Pressure bar Pa 100,000
Pressure lbf/in2 bar 0.0689475
2
Pressure Pa lbf/in 1.4504E-04
A B C Pressure Pa lbf/ft2 0.0208854
Name To convert Pressure Pa bar 1E-05
To Multiply by
from Pressure bar lbf/in2 14.50377
Acceleration ft/sec2 m/s2 0.3047987 Temperature Temp.[°C] = (Temp.[°F]-32)*5/9
Acceleration m/s2 ft/sec2 3.2808539 Temperature Temp. [°F] = Temp. [°C] * 9/5 + 32
Area ft2 m2 0.09290304 Torque ft*lbf Nm 1.35582
Area in2 m2 0.00064516 Torque in*lbf Nm 0.1129848
Area m2 ft2 10.76391 Torque Nm ft*lbf 0.737561
Area m2 in2 1550.1473 Torque Nm in*lbf 8.8507481
Force lbf N 4.4482225 Velocity ft/s m/s 0.3048
Force N lbf 0.2248089 Velocity miles/hour m/s 0.44704
Length ft m 0.3048 Velocity km/hour m/s 0.2778
Length in m 0.0254 Velocity miles/hour km/hour 1.609344
Length mile m 1,609.344 Velocity m/s ft/s 3.28084
Length in mm 25.4 Velocity m/s miles/hour 2.2369363
Length m ft 3.2808399 Velocity m/s km/hour 3.6
Length m in 39.370079 Velocity km/hour miles/hour 0.6213712
Length m mile 6.2137E-04 Volume ft3 m3 0.02831685
Length mm in 0.03936996 Volume in 3
m3 1.638706E-05
Mass lb kg 0.4535929 Volume Liters m 3
0.001
Mass kg lb 2.20462 Volume U.S. gallons m3 0.003785412
Moment of inertia ft*lb*s2 kg*m2 1.3557 Volume U.S. gallons Liters 3.785412
Moment of inertia in*lb*s2 kg*m2 0.1130 Volume m 3
ft 3
35.314725
Moment of inertia kg*m2 ft*lb*s2 0.7376 Volume m3 in3 61,023.759
Moment of inertia kg*m2 in*lb*s2 8.4956 Volume m3 Liters 1,000
Power hp W 745.71 Volume m3 U.S. gallons 264.17287
Power W hp 1.341E-03 Volume Liters U.S. gallons 0.264172
Table 11.1: Conversion Table

11.2 List of Abbreviations

11.3 Table of Figures
Defined abbreviations often used in drawings in this guideline:
FE Front edge Figure 1.1: Unimog U500 North America.............................................11
RE Rear edge Figure 2.1: Front mounted mower........................................................25
LE Lower edge
Figure 2.2: Front mounted mower in transport position .......................25
UE Upper edge
IE Inner edge Figure 2.3: Rear mounted mower ........................................................26
FA Front axle Figure 2.4: Rear mounted mower in transport position........................26
RA Rear axle
FAW Front axle weight Figure 2.5: Spreader mounted on ballpoints........................................27
RAW Rear axle weight Figure 2.6: Snow plow .........................................................................28
GVW Gross vehicle weight
Left / right information Regarded in the direction of travel Figure 2.7: Wing plow ..........................................................................29
Table 11.2: Abbreviation table Figure 2.8: Snow blower ......................................................................30
Figure 2.9: Suction sweeper ................................................................31
Figure 2.10: Front mounted sweeper...................................................32
Figure 2.11: Front mounted winch .......................................................33
Figure 2.12: Aerial device ....................................................................34
Figure 2.13: Crane with V-outriggers ...................................................35
Figure 2.14: Drill device .......................................................................36
Figure 2.15: Front end loader ..............................................................37
Figure 2.16: Example of a front mounted device .................................38
Figure 2.17: Sewer cleaning device.....................................................39
Figure 2.18: Water tank .......................................................................40
Figure 2.19: Front mounted 3-point hitch.............................................41
Figure 2.20: Rear mounted 3-point hitch .............................................42
Figure 2.21: Fire body..........................................................................43
Figure 2.22: Refuse collection vehicle .................................................44

Figure 2.23: Box body..........................................................................45 Figure 4.15: Rear mounted counterweights ........................................ 77
Figure 2.24: Wood chipper ..................................................................46 Figure 4.16: Fastening of platform-mounted counterweights .............. 77
Figure 2.25: Concrete mixer ................................................................47 Figure 4.17: Implement mounting positions on the Unimog U500NA . 80
Figure 2.26: Backhoe...........................................................................48 Figure 4.18: Front mounting plate on the Unimog U500NA ................ 81
Figure 2.27: Skip loader.......................................................................49 Figure 4.19: Front mounting plate (code D12, part-no.
A 405 550 12 38).......................................................................... 82
Figure 2.28: Rear mounted crane < 3.5 mt..........................................50
Figure 4.20: Schmidt claw size 5......................................................... 83
Figure 2.29: Sketch of a rear mounted crane < 3.5 mt ........................50
Figure 4.21: Compatible claw for front mounting plate from
Figure 3.1: Side view of U500 NA, short wheelbase ...........................55
SCHMIDT® ................................................................................... 84
Figure 3.2: Front view of U500 NA, short wheelbase ..........................56
Figure 4.22: Angle between front mounting plate and the vehicle
Figure 3.3: Side view of U500 NA, long wheelbase.............................57 frame (serial mounting position of the front mounting plate) ........ 85
Figure 3.4: Front view of U500 NA, long wheelbase ...........................58 Figure 4.23: Angle between front mounting plate and the vehicle
Figure 4.1: Chassis frame torsion........................................................60 frame (optional mounting position of the front mounting plate) .... 85
Figure 4.2: Minimum rear axle loads ...................................................62 Figure 4.24: Integrated implement support ......................................... 86
Figure 4.3: Weight distribution (example) ............................................63 Figure 4.25: Integrated implement support with cross member (MB
part-no. A405 520 00 48) ............................................................. 87
Figure 4.4: Sketch of the upper edge frame level over the wheel center
......................................................................................................63 Figure 4.26: Permitted implement weights .......................................... 88
Figure 4.5: Suspension graph with measurements in metric units ......64 Figure 4.27: Sketch to front end dimensions....................................... 88
Figure 4.6: Suspension graph with measurements in U.S. units .........65 Figure 4.28: Fastening of wheels and wheel hub chassis supports .... 90
Figure 4.7: Unimog frame with the zero point of the coordinate system Figure 4.29: Standard fastening of wheels on the Unimog ................. 90
......................................................................................................66 Figure 4.30: Fastening of the MULAG wheel hub chassis support ..... 90
Figure 4.8: Detail drawing of zero point ...............................................66 Figure 4.31: Drawing of the wheel hub chassis support...................... 91
Figure 4.9: Sketch for center of gravity and axle load calculations......68 Figure 4.32: Ball half shell assembly................................................... 92
Figure 4.10: Determining the height of the center of gravity................69 Figure 4.33: Securing platform against tipping.................................... 92
Figure 4.11: Tilting test ........................................................................71 Figure 4.34: Overview of the platform and subframe mounting parts
Figure 4.12: Minimum bending radius .................................................75 at the U500 with a short wheelbase ............................................. 93
Figure 4.13: Incorrect pipes .................................................................75 Figure 4.35: Overview of the platform and subframe mounting parts
at the U500 with a long wheelbase .............................................. 94
Figure 4.14: Front mounted counterweights ........................................76
Figure 4.36: Overview of available platforms ...................................... 95

Figure 4.37: Platform P27 ................................................................... 96 Figure 4.64: Ball half shell, Part-No.: A405 610 01 35.......................110
Figure 4.38: Platform P40 ................................................................... 97 Figure 4.65: Ball point, Part-No.: A405 991 00 20 .............................111
Figure 4.39: Platform gate stop ........................................................... 98 Figure 4.66: Diagonally mounting of the ball half shells.....................111
Figure 4.40: Fastening points.............................................................. 98 Figure 4.67: Correct mounting of the plastic plates ...........................112
Figure 4.41: Tie-down eye................................................................... 99 Figure 4.68: Contact points of the plastic plates on the subframe .....112
Figure 4.42: Tie-down eye label .......................................................... 99 Figure 4.69: Skip loader.....................................................................113
Figure 4.43: Positions of the towing eyes on platform P27 ................. 99 Figure 4.70: Implement / body fastening with additionally U-bolts.....113
Figure 4.44: Positions of the tie down eyes on platform P40 .............. 99 Figure 4.71: Strengthened mounting of the platform subframe .........114
Figure 4.45: Positions of the fastening holes in platform P27 ........... 100 Figure 4.72: Magnet of the tilt-warning lamp......................................115
Figure 4.46: Positions of the fastening holes in platform P40 ........... 100 Figure 4.73: Position of the magnet and the tilt control sensor..........115
Figure 4.47: Reinforcing plate ........................................................... 100 Figure 4.74: Position of the magnet for the tilt control sensor on the
short wheelbase .........................................................................116
Figure 4.48: Implement fastening with ring eyes............................... 100
Figure 4.75: Position of the magnet for the tilt control sensor on the
Figure 4.49: Prohibited mounting ...................................................... 101
long wheelbase...........................................................................117
Figure 4.50: Rear mechanical locking ............................................... 101
Figure 4.76: Suggestion for reinforcing of the front fastening
Figure 4.51: Front mechanical locking .............................................. 101 interface......................................................................................118
Figure 4.52: Front end mounting with chains or belts ....................... 102 Figure 4.77: Front end of a mounting frame with a max. height of
Figure 4.53: Tie-down eye (option 1) ................................................ 102 6.3 in...........................................................................................119
Figure 4.54: Tie-down eye (option 2) ................................................ 102 Figure 4.78: Front end of a mounting frame higher than 6.3 in..........119
Figure 4.55: Rear end mounting........................................................ 102 Figure 4.79: Possible profiles for mounting frames............................120
Figure 4.56: Rear end mounting with additional plate ....................... 103 Figure 4.80: Possible transition from closed to open profiles ............120
Figure 4.57: Center mounting of heavy implements.......................... 103 Figure 4.81: Possible transition from closed to open profiles ............120
Figure 4.58: Correct and incorrect gritter design............................... 104 Figure 4.82: Suggestion for design of cross members ......................121
Figure 4.59: Mounting diagram on the platform subframe ................ 105 Figure 4.83: Suggestion for design of cross members ......................121
Figure 4.60: Overview of the available platform sub frames ............. 106 Figure 4.84: Suggestion for a custom-manufactured low mounting
frame ..........................................................................................122
Figure 4.61: Platform sub frames for short wheelbases.................... 107
Figure 4.85: Suggestion for a custom-manufactured high mounting
Figure 4.62: Platform sub frames for long wheelbases ..................... 108 frame ..........................................................................................123
Figure 4.63: Ball half shell, Part-No.: A405 610 00 35 ...................... 109

Figure 4.86: Sketches with dimensions of the subframe-frame- Figure 4.104: Heavy implement mounting support, code D62 (Part-
combination for the following section modulus diagrams ...........124 No.: A405 552 04 18) ................................................................. 143
Figure 4.87: Section modulus of the frame-subframe-combination for a Figure 4.105: Proposal for fastening of a mounting frame by use of
mounting frame with C-profiles (U.S. units)................................125 heavy mounting brackets (code D62) ........................................ 144
Figure 4.88: Section modulus of the frame-subframe-combination for a Figure 4.106: Subframe tolerance when using code D62 ................. 145
mounting frame with C-profiles (metric units) .............................126
Figure 4.107: Code D62 mounted on the frame................................ 146
Figure 4.89: Section modulus of the frame-subframe-combination for a
Figure 4.108: subframe body on implement mounting ball points..... 146
mounting frame with rectangular tubes (U.S. units) ...................127
Figure 4.109: Welding of the ball points into to cross members........ 147
Figure 4.90: Section modulus of the frame-subframe-combination for a
mounting frame with rectangular tubes (metric units).................128 Figure 4.110: Ball point, Part-No.: A405 991 01 20........................... 147
Figure 4.91: Overview of fastening plates for directly mounting (this Figure 4.111: Suggestion for self-supporting frame with a wing plow-
figure shows a U500 with long wheelbase) ................................129 support ....................................................................................... 148
Figure 4.92: Tightening torques for mounting bodies/implements Figure 4.112: Example 1 for a wing plow on a Unimog..................... 148
without outriggers directly to the chassis frame..........................130 Figure 4.113: Example 2 for a wing plow on a Unimog..................... 148
Figure 4.93: Console with belleville spring washers ..........................131 Figure 4.114: Mounting frame (side view) ......................................... 149
Figure 4.94: Arrangement of belleville spring washers......................131 Figure 4.115: Mounting frame (top view)........................................... 149
Figure 4.95: Fastening plate (only short wheelbase; Part-No.: A405 611 Figure 4.116: Vertical frame member (side view).............................. 149
01 11) .........................................................................................133
Figure 4.117: Vertical frame member (top view) ............................... 149
Figure 4.96: Fastening plate (only long wheelbase; Part-No.: A405 611
03 11) .........................................................................................134 Figure 4.118: Cross member (side view) .......................................... 149
Figure 4.97: Fastening plate (Part-No.: A405 611 00 11)..................135 Figure 4.119: Cross member (top view) ............................................ 150
Figure 4.98: Console (Part-No.: A405 520 10 33) .............................136 Figure 4.120: Mounting frame with cross member and vertical frame
member (side view).................................................................... 150
Figure 4.99: Sub frame with outriggers mounted on D62 brackets ...137
Figure 4.121: Mounting frame with cross member and vertical frame
Figure 4.100: Limited accessibility to holes on plate D70..................138 member (top view) ..................................................................... 150
Figure 4.101: Fastening plate code D70 (included in D62), Part-No.: Figure 4.122: Wing plow-support mounted via code D62 and D70 on
A405 550 01 39 (left), A405 550 02 39 (right) ............................139 the chassis frame (side view)..................................................... 150
Figure 4.102: Overview of the different mounting points and fastening Figure 4.123: Wing plow-support mounted via code D62 and D70 on
plates ..........................................................................................141 the chassis frame (side view)..................................................... 150
Figure 4.103: D60/D62 hole pattern in the vehicle frame ..................142 Figure 4.124: Side view of a Unimog with mounted wing plow-
support ....................................................................................... 151

Figure 4.125: Top view of a Unimog with mounted wing plow-support Figure 4.147: Implement mounting support, code D60 (Part-No:
................................................................................................... 151 A427 551 03 21) .........................................................................161
Figure 4.126: Side view of a Unimog with platform and mounted wing Figure 4.148: Drawing of the rear mounting bracket (code D50).......162
plow-support............................................................................... 151
Figure 5.1: Overview of the available power take-offs .......................166
Figure 4.127: Top view of a Unimog with platform and mounted wing
Figure 5.2: Drawing of the N05 flange ...............................................168
plow-support............................................................................... 151
Figure 5.3: PTO N05 with vibration absorber and hydraulic pump ....169
Figure 4.128: Attachment of mounting frames with a U-bolt ............. 152
Figure 5.4: Installation of a vibration absorber on N05 ......................169
Figure 4.129: Mounting via clamping devices ................................... 152
Figure 5.5: Use of the N05 with a vibration absorber.........................169
Figure 4.130: Front mounted crane................................................... 153
Figure 5.6: Drawing of the vibration absorber (part-no.
Figure 4.131: Center mounted cranes............................................... 153
A906 250 00 01) .........................................................................170
Figure 4.132: Rear mounted cranes.................................................. 153
Figure 5.7: Drive shaft angle β...........................................................172
Figure 4.133: Dual outriggers............................................................ 154
Figure 5.8: PTO shaft profile..............................................................173
Figure 4.134: 4-point outriggers ........................................................ 154
Figure 5.9: Position of the PTO shaft in relation to the front mounting
Figure 4.135: Single V-outriggers, front ............................................ 154 plate............................................................................................174
Figure 4.136: Single V-outriggers, rear ............................................. 154 Figure 5.10: Position of the N08 shaft in relation to the front........175
Figure 4.137: Double V- outriggers ................................................... 154 Figure 5.11: Effect of suspension travel on dimension “h”.................176
Figure 4.138: Leveling jack on the front mounting plate.................... 154 Figure 5.12: Drawing of the N16 flange .............................................178
Figure 4.139: Serial bearing cover of the rear stabilizer arm ............ 156 Figure 5.13: Drawing of the N19 flange .............................................179
Figure 4.140: Proposal for a mounting support ................................. 156 Figure 5.14: Hydraulic pump model F1..............................................180
Figure 4.141: Proposal for a implement mounting support on the rear Figure 5.15: Adapter for Parker hydraulic pumps ..............................180
stabilizer arm.............................................................................. 157
Figure 5.16: Pump F1 with adapter for N16.......................................180
Figure 4.142: Counterpart of the implement mounting support on the
Figure 5.17: PARKER® part numbers ................................................180
rear stabilizer arm ...................................................................... 158
Figure 5.18: PARKER® hydraulic pumps ...........................................181
Figure 4.143: Proposal for fastening of an inter-axle implement....... 158
Figure 5.19: Permissible mass torque at N16 flange .........................182
Figure 4.144: Implement mounting support manufactured by
SCHMIDT® (for an order address of SCHMIDT® - parts see page Figure 5.20: Directly mounted flange drive on auxiliary PTO N16 .....183
84) .............................................................................................. 159
Figure 5.21: Sketch of the connecting flange.....................................183
Figure 4.145: Example for use of code D60...................................... 160
Fig. 5.22: Drive shaft, length compensation.......................................184
Figure 4.146: Example for use of code D62...................................... 160

Figure 5.23: Z-deflection of a drive shaft ...........................................185 Figure 7.2: Left front bumper............................................................. 219
Figure 5.24: W-deflection of a drive shaft ..........................................185 Figure 7.3: Socket E45...................................................................... 219
Figure 5.25: Three-dimensional deflection ........................................186 Figure 7.4: Suitable plug for socket E45 ........................................... 219
Figure 6.1: Braked lowering function with a metered orifice ..............196 Figure 7.5: Implement socket ............................................................ 220
Figure 6.2: Braked lowering with a flow restrictor ..............................196 Figure 7.6: Suitable plug ................................................................... 220
Figure 6.3: Basic hydraulics circuit I and II – 4 cells ..........................197 Figure 7.7: Pins of the plug ............................................................... 220
Figure 6.4: Front hydraulic connections (drive direction: left) ............198 Figure 7.8: Rear trailer socket ........................................................... 222
Figure 6.5: Front hydraulic connections (drive direction: right)..........198 Figure 7.9: Pin and color assignment................................................ 222
Figure 6.6: Overview of hydraulic connections at the vehicle front....199 Figure 7.10: Suggestion for an engine speed remote control circuit . 225
Figure 6.7: Position of the H68 hydraulic connections.......................200 Figure 7.11: Suggestion for a variable engine speed limiting circuit . 225
Figure 6.8: H68 hydraulic connections ..............................................200 Figure 7.12: Suggestion for an engine speed remote control unit..... 226
Figure 6.9: Hydraulic connections on left hand side ..........................201 Figure 7.13: Resistor R1 .................................................................... 226
Figure 6.10: Hydraulic connections on right hand side......................201 Figure 7.14: Suggestion for an fixed engine speed of 1,200 rpm...... 226
Figure 6.11: Shut-off valve.................................................................202 Figure 7.15: Important note for remote controls ................................ 227
Figure 6.12: Flow rates of hydraulic circuits I + II with combinations in Figure 7.16: Example for a roof-mounted headlights ........................ 230
[gal/min] ......................................................................................203
Figure 7.17: Example for raised headlights....................................... 231
Figure 6.13: Flow rates of hydraulic circuits I + II with combinations in
Figure 7.18: Speed signal C3............................................................ 231
[l/min] ..........................................................................................204
Figure 7.19: Travel distance signal C4.............................................. 231
Figure 6.14: Flow rate over engine speed .........................................206
Figure 8.1: Location of the compressed air system........................... 234
Figure 6.15: Front connections of the power hydraulics circuit 4.......209
Figure 8.2: Vehicle without CTIS (back view).................................... 235
Figure 6.16: Center power hydraulic connections circuit 3 ................209
Figure 8.3: Air extraction interface on vehicle with CTIS................... 235
Figure 6.17: Center power hydraulic connections circuit 4 ................209
Figure 8.4: Serial mounting parts on vehicles w/o CTIS ................... 236
Figure 6.18: Hose laying of the H94 lines above the battery box ......210
Figure 8.5: Serial mounting parts on vehicles with CTIS................... 236
Figure 6.19: Flow rates of hydraulic circuits III + IV without
combinations in [gal/min] ............................................................211 Figure 8.6: Serial and additional mounting parts for pneumatic
consumers on vehicles with CTIS .............................................. 237
Figure 6.20: Flow rates of hydraulic circuits III + IV without
combinations in [l/min] ................................................................212 Figure 8.7: Serial and additional mounting parts for pneumatic
consumers on vehicles with CTIS .............................................. 238
Figure 7.1: Power outlet and grommet behind the driver seat...........218

Figure 9.1: Tilting of the cab.............................................................. 241 Figure 9.28: Left mounted gearshift console......................................254
Figure 9.2: Cab tilting curve .............................................................. 242 Figure 9.29: Center mounted gearshift console.................................254
Figure 9.3: Free movement of the body and the cab ........................ 242 Figure 9.30: Fastening points for mounting control consoles ............255
Figure 9.4: Cable passage through the rear wall of the cab.............. 243 Figure 9.31: Clearance between steering and gearshift console.......255
Figure 9.5: Cable passage through the front wall of the cab............. 243 Figure 9.32: Accessibility of fastening points on the gearshift console256
Figure 9.6: Pass-through plug for four different cable diameters ...... 244 Figure 9.33: Position of the fastening points on the center console ..257
Figure 9.7: Caps for pass-through plug............................................. 244 Figure 9.34: position of the frame for center mounting (use with
VarioPilot) ...................................................................................258
Figure 9.8: Drawing of the pass-through plug ................................... 245
Figure 9.35: 3D view of the frame for center mounting (use with
Figure 9.9: Cutting of the plugs ......................................................... 246
VarioPilot) RK 999 000 P 207.....................................................258
Figure 9.10: Removing of the plug ports ........................................... 246
Figure 9.36: position of the frame for left mounting ...........................258
Figure 9.11: Pass-through plug with removed port ........................... 246
Figure 9.37: 3D view of the frame for left mounting ...........................258
Figure 9.12: Cut-in of the plug........................................................... 247
Figure 9.38: 3D view of the frame for left mounting ...........................259
Figure 9.13: Cable mounting ............................................................. 247
Figure 9.39: 3D view of the frame for left mount................................260
Figure 9.14: Fastening of the cable with a cable tie .......................... 247
Figure 9.15: Use of the plug ports ..................................................... 248
Figure 9.16: Use of seal cap (part no. A409 583 00 83) ................... 248
Figure 10.1: Chassis frame cross-section..........................................263
Figure 9.17: Mounting possibility on the roof of the cab.................... 249
Figure 10.2: Chassis frame of the U500, short wheelbase ................264
Figure 9.18: Front support for roof-mounted devices ........................ 250
Figure 10.3: Chassis frame of the U500, long wheelbase .................265
Figure 9.19: Proposal for a front support........................................... 250
Figure 10.4: Drilling dimension on the chassis frame ........................267
Figure 9.20: Dismounting of the interior light..................................... 251
Figure 10.5: Drilling on the frame flange is prohibited .......................267
Figure 9.21: Fastening of the roof-mounted front support................. 251
Figure 10.6: Use of clamping sleeves................................................268
Figure 9.22: Mounting of the front support on the cab ...................... 251
Figure 10.7: Use of anti-fatigue sleeves ............................................269
Figure 9.23: Reinforcement plate for the inside of the cab................ 251
Figure 10.8: Use flange head bolts and flange nuts ..........................269
Figure 9.24: Reinforcement plate for the inside of the cab................ 252
Figure 10.9: Grinding of the weld seam .............................................270
Figure 9.25: Sleeve for beacon light stand (Part-No.: A405 821 0028)................. 252
Figure 10.10: Welding preparation.....................................................270
Figure 9.26: Cable passage through the rear wall of the cab ............................. 253
Figure 10.11: Welding procedure.......................................................271
Figure 9.27:Routing of the cable behind the chimney of the air intake ................. 253

Figure 10.12: Frame extension with ..................................................272
Figure 10.13: Reinforcement plates on inside/outside of the frame ..272 11.4 Table of tables
Figure 10.14: Reinforcement plates...................................................273
Table 1.1: Unimog VIN Coding............................................................ 15
Figure 10.15: Frame extension without .............................................274
Table 1.2: Minimum bending radii of plastic lines................................ 20
Table 3.1: Vehicle and model designations......................................... 52
Table 3.2: Technical Data for mechanically implement drive .............. 54
Table 3.3: Technical Data for hydraulically implement drive ............... 54
Table 4.1: Symbol definitions .............................................................. 68
Table 4.2: Symbol definitions .............................................................. 69
Table 4.3:Statically (loaded) tire radius ............................................... 70
Table 4.4: Necessary information........................................................ 71
Table 4.5: Chassis center of gravity .................................................... 72
Table 4.6: Permissible c.o.g. height .................................................... 72
Table 4.7: Example for a static check ................................................. 79
Table 4.8: SCHMIDT® mounting kit for Unimog front mounting plate.. 83
Table 4.9: Parts list for removing the front mounting plate.................. 87
Table 4.10: Front end dimensions....................................................... 88
Table 4.11: Platform dimension........................................................... 95
Table 4.12: Tipping cylinders for U500NA........................................... 98
Table 4.13: Necessary mounting parts for ballpoint mounting .......... 105
Table 4.14: Necessary mounting parts.............................................. 132
Table 4.15: Material data................................................................... 153
Table 4.16: Suggestions for mounting frame dimensions ................. 155
Table 4.17: Examples for using codes D60 and D62 ........................ 160
Table 4.18: Part numbers of the rear mounting brackets (code D50) 162
Table 5.1: Technical Data of mechanically implement drive ............. 165

Table 5.2: Examples of PTO applications ......................................... 167 Table 7.8: Part numbers for plug with screw connectors ...................221
Table 5.3: Position of PTO´s N05 thru N19....................................... 167 Table 7.9: Pin assignment of the rear trailer socket...........................222
Table 5.4: Technical data of N05 auxiliary PTO................................ 168 Table 7.10: W-code description .........................................................229
Table 5.5: PTO shaft power output ................................................... 172 Table 7.11: Pin assignment of code L49 connector...........................230
Table 5.6: PTO shaft dimensions ...................................................... 173 Table 8.1: Technical data of the compressed air system...................234
Table 5.7: Technical data of auxiliary PTO’s..................................... 177 Table 8.2: Necessary parts for air extraction .....................................239
Table 6.1: Technical data of available hydraulic circuits ................... 189 Table 10.1: Chassis frame data .........................................................263
Table 6.2: Available hydraulic options for the Unimog ...................... 191 Table 11.1: Conversion Table............................................................276
Table 6.3: Available hydraulic packages ........................................... 192 Table 11.2: Abbreviation table ...........................................................277
Table 6.4 UNIMOG basic hydraulic connections............................... 194
Table 6.5: Hydraulic pumps of circuit 1 and 2 ................................... 195
Table 6.6: Dealer for hydraulic couplings .......................................... 205
Table 6.7: Tema parts list for Unimog hydraulic sockets circuit 1 ..... 205
Table 6.8: Tema parts list for Unimog hydraulic circuit 2 .................. 205
Table 6.9 UNIMOG power hydraulic connections ............................. 206
Table 6.10: Power hydraulics circuit III, code H63 ............................ 207
Table 6.11: Power hydraulics circuit IV, code H64............................ 208
Table 6.12: Parts list for high working pressure power hydraulic system
................................................................................................... 213
Table 6.13: Dealer for power hydraulic couplings ............................. 213
Table 7.1: Technical data of the electrical system ............................ 216
Table 7.2: Electrical interfaces .......................................................... 216
Table 7.3: Optional electrical equipment ........................................... 216
Table 7.4: Power outlet in the cab..................................................... 218
Table 7.5: Pin assignment of front implement socket E45 ................ 219
Table 7.6: Pin assignment of implement socket 16-pin..................... 220
Table 7.7: Part numbers for plug with crimp connectors ................... 221


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.

Unimog Body and Implement Mounting Guidelines

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Unimog Body and Implement Mounting Guidelines

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BODY & IMPLEMENT

Table of Contents 2 Applications ................................................................. 25

1.5 Warranty rights ..............................................................16 2.7 Suction sweepers .......................................................... 31

1.6 Maintenance instructions ...............................................16 2.8 Front mounted sweepers ............................................... 32

1.7 Corrosion protection measures......................................17 2.9 Winches......................................................................... 33

1.9 Recycling – Re-use of components ...............................18 2.11 Big cranes...................................................................... 35

1.10 Product liability...............................................................18 2.12 Drill devices ................................................................... 36

1.11.1 General notes ................................................................19 2.14 Front mounted devices .................................................. 38

1.11.2 Delivery of chassis.........................................................19 2.15 Sewer cleaning devices ................................................. 39

1.11.6 Springs...........................................................................21 2.19 Fire bodies..................................................................... 43

1.11.7 Painting procedures .......................................................21 2.20 Refuse collection vehicles ............................................. 44

1.11.8 Pushing and towing .......................................................21 2.21 Box bodies ..................................................................... 45

1.11.10 Mobile communication systems .................................22 2.23 Concrete mixers ............................................................ 47

1.11.11 Electromagnetic compatibility (EMC) .........................22 2.24 Digger ............................................................................ 48

1.11.12 Implement drives ........................................................23 2.25 Skip loader..................................................................... 49

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January 2005 Page 7 of 286

5.9.1 General ........................................................................171 6.2 Basic hydraulics........................................................... 194

Page 8 of 286 January 2005

January 2005 Page 9 of 286

Page 10 of 286 January 2005

1.1 Introduction This Body and Implement Mounting Guideline

Unimog U500 NA, wheelbase: 131.89 in / 3,350 mm

Regulations such as those issued by the Federal Highway Ad-

January 2005 Page 11 of 286

Page 12 of 286 January 2005

1.2 Emission, Noise and Safety FMVSS 102 / CMVSS 102

January 2005 Page 13 of 286

Page 14 of 286 January 2005

January 2005 Page 15 of 286

1.5 Warranty rights

Page 16 of 286 January 2005

January 2005 Page 17 of 286

1.9 Recycling – Re-use of components

Page 18 of 286 January 2005

• Lack of knowledge and training of the vehicle owner / customer /

January 2005 Page 19 of 286

Page 20 of 286 January 2005

• Brake discs • For information about the installation of additional electrical

January 2005 Page 21 of 286

1.11.10 Mobile communication systems

Page 22 of 286 January 2005

January 2005 Page 23 of 286

Page 24 of 286 January 2005

Overview of related sections:

Front mounting plate

Front PTO (code N08) → Section 5.9, page 171

Code E37 → Section 7.4.1, page 218

Axle loads → Section 4.4, page 62

Figure 2.2: Front mounted mower in transport position

January 2005 Page 25 of 286

2.2 Rear mounted mowers Overview of the related sections:

On platform P27 / P40 or → Section 4.14.2, page 92

PTO (code N05) → Section 5.8, page 168

Figure 2.3: Rear mounted mower

Cable passage into the cab → Section 9.3, page 243

Figure 2.4: Rear mounted mower in transport position

Page 26 of 286 January 2005

On platform P27 / P40 → Section 4.14.2, page 92

Code E37 → Section 7.4.1, page 218

January 2005 Page 27 of 286

2.4 Snow plows

Front mounting plate

Basic hydraulic → Section 6.2, page 194