Unimog U500 Mounting Manuallines Download Page 57

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Body and Implement Mounting Guidelines U500 North America

Vehicle Information

Page 60 of

294

August 2005

Note:
Dimensions marked with a * vary by

tires and/or vehicle (axle) loads.

Dimensions without brackets are in
[mm]. Dimensions in brackets are in [in].

Figure 3.2: Front view of U500 NA, short wheelbase

Summary of Contents for U500

Page 1: ...BODY IMPLEMENT MOUNTING GUIDELINES N O R T H A M E R I C A...

Page 2: ...nal Highway Traffic Safety Administration United States www nhtsa dot gov or Transport Canada www tc gc ca New standards and amendments issued by the National Highway Traffic Safety Administration wil...

Page 3: ......

Page 4: ...draulics closed circuit code H93 Chapter 7 Electrical system o Bulb warning system Installation of L E D lights o Unimog ground points isolated ground system o Current consumption auxiliary consumers...

Page 5: ......

Page 6: ...ing operations 24 1 11 6 Springs 25 1 11 7 Painting procedures 25 1 11 8 Pushing and towing 26 1 11 9 Electrical system 26 1 11 10 Mobile communication systems 27 1 11 11 Electromagnetic compatibility...

Page 7: ...77 4 9 1 Tires 77 4 9 2 Cooling 78 4 9 3 Engine air intake 78 4 9 4 Exhaust system 78 4 9 5 Springs 79 4 9 6 Brake system 79 4 9 7 Maintenance and repair 79 4 10 Secure mounting of implements counter...

Page 8: ...2 Technical data on auxiliary PTO s code N16 N19 182 5 10 3 Hydraulic pumps for N16 auxiliary power take off 185 5 10 4 Direct flange mounting on auxiliary PTO N16 188 5 11 Drive shafts for implement...

Page 9: ...Modification of the raised headlights code L47 239 7 11 Road speed signal and travel dependent signal 239 7 12 Electromagnetic compatibility 240 8 Pneumatic Consumers 242 8 1 General notes to pneumati...

Page 10: ...ng on the frame 278 10 9 2 Welding preparation 279 10 9 3 Regulations for seam preparation 280 10 9 4 Welding procedure 280 10 9 5 Seam finishing 280 10 10 Frame extensions 280 10 10 1 Design instruct...

Page 11: ...Body and Implement Mounting Guidelines U500 North America Table of Contents Page 14 of 294 August 2005...

Page 12: ...re Freightliner LLC reserves the right to discontinue models or change specifications or designs at any time without notice or incurring any obligation This Body and Implement Mounting Guideline cover...

Page 13: ...nly and serve to explain the texts and tables References to regulations standards directives etc are partially given in key words and serve only as information A CD ROM called Unimog Resource CD is av...

Page 14: ...noncompliance with any FMVSS or CMVSS as applicable as certified by Freightliner LLC FMVSS 101 CMVSS 101 This vehicle will conform to FMVSS CMVSS No 101 Control Location Identification and Illuminatio...

Page 15: ...in the windshield and windows of the cab FMVSS 206 CMVSS 206 This vehicle will conform to FMVSS CMVSS No 206 Door Locks and Door Retention Components if no alterations are made in the door assembly do...

Page 16: ...ification plate is located in the area below the left rear of the cylinder head cover above the compressor Vehicle identification plate The identification plates are intended primarily for identificat...

Page 17: ...rol consoles must be ex plained in the implement operating instructions In particular the opera tion procedures for emergency situations must be described 1 5 Warranty rights Warranty rights can only...

Page 18: ...vities 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 8 Accident prevention The body...

Page 19: ...colored plastic parts Design components in areas which are subject to accidents to be damage tolerant repairable and easily replaceable Only use plastics in places where they provide cost functional...

Page 20: ...n Fans for oil radiators etc must be enclosed in such a way that access to the rotating fan is impossible All kinds of sharp corners and edges are to be avoided The implement or body manufacturer must...

Page 21: ...g Only qualified personnel may carry out welding operations on the chassis Disconnect the positive and negative battery terminals and cover them for protection Short circuit the positive and negative...

Page 22: ...ds are only permitted in coordination with and with the written approval of the Unimog Implement Manager listed at the beginning of this guideline The surface and corrosion protection of the springs m...

Page 23: ...ly tow start the vehicle with the battery connected Only charge the battery with a rapid charger if it has been dis connected from the vehicle s electrical system The positive and negative terminals o...

Page 24: ...ment or body components which affect the electro magnetic compatibility of the vehicle components are fitted the imple ment or body manufacturer must ensure that the operating safety of the entire veh...

Page 25: ...Body and Implement Mounting Guidelines U500 North America General Information Page 28 of 294 August 2005...

Page 26: ...te code D12 Section 4 13 page 85 Drive Front PTO code N08 Hydraulic Section 5 9 page 176 Chapter 6 page 194 Electrical connection Code E37 Implement socket Code E45 Section 7 6 1 page 226 Section 7 6...

Page 27: ...Drive PTO code N05 driven by hydraulic pump or Power hydraulic code H63 closed circuit or Power hydraulic code H64 open circuit Section 5 8 page 172 Section 6 3 page 211 Section 6 3 page 211 Electric...

Page 28: ...is Section 4 14 2 page 96 Section 4 14 3 page 109 Section 4 14 5 page 133 Drive Hydraulic connector at the side H68 at the rear H58 H59 Chapter 6 page 194 Chapter 6 page 194 Electrical connection Code...

Page 29: ...e D12 Section 4 13 page 85 Drive Basic hydraulic Snow plow load release Section 6 2 page 199 Chapter 6 page 194 Electrical connection Code E45 Mounting of the control unit Section 7 6 2 page 227 Secti...

Page 30: ...tly on the chassis code D62 Front mounting plate code D12 Section 4 14 6 3 pg 152 Section 4 14 6 page 141 Section 4 13 page 85 Drive Basic hydraulic Section 6 2 page 199 Electrical connection Code E37...

Page 31: ...Drive Front PTO code N08 Hydraulic Section 5 9 page 176 Chapter 6 page 194 Electrical connection Code E45 Mounting of the control unit Section 7 6 2 page 227 Section 9 5 page 262 Notes Axle loads Whee...

Page 32: ...on 4 14 3 pg 109 Drive Power hydraulic code H63 closed circuit or Power hydraulic code H64 open circuit Section 6 3 page 211 Section 6 3 page 211 Electrical connection Implement socket Mounting of the...

Page 33: ...elated sections Mounting Front mounting plate code D12 Section 4 13 page 85 Drive Front PTO code N08 or Power hydraulic with front connection codes H63 H93 or H64 H94 or Basic hydraulic with front con...

Page 34: ...ting Front mounting plate code D12 Section 4 13 page 85 Drive Front PTO code N08 or Basic hydraulic Section 5 9 page 176 Chapter 6 page 194 Electrical connection Code E37 or Implement socket or Code E...

Page 35: ...ions Mounting Via sub frame directly on the chassis code D62 Section 4 14 6 page 141 Drive Gearbox PTO code N16 and Hydraulic pump Section 5 10 page 182 Section 5 10 3 page 185 Electrical connection C...

Page 36: ...ode D62 Mounting of cranes on Unimog s Section 4 14 6 page 141 Section 4 14 6 4 page 156 Drive Gearbox PTO N16 and Hydraulic pump Section 5 10 page 182 Section 5 10 3 page 185 Electrical connection Co...

Page 37: ...ounting Via sub frame directly on the chassis code D62 Section 4 14 6 page 141 Drive Gearbox PTO code N16 and Hydraulic pump Section 5 10 page 182 Section 5 10 3 page 185 Electrical connection Code E3...

Page 38: ...a heavy sub frame Mounted between the axles Section 4 13 3 pg 89 Section 4 14 8 1 pg 164 Section 4 14 6 2 pg 144 Section 4 14 8 1 pg 164 Section 4 14 8 pg 160 Drive Basic hydraulic Chapter 6 page 194...

Page 39: ...e code D12 or Integrated implement support Section 4 13 2 pg 85 Section 4 13 3 pg 89 Drive Front PTO code N08 or Power hydraulic or Basic hydraulic Section 5 9 page 176 Section 6 3 page 211 Chapter 6...

Page 40: ...on 4 13 page 85 Section 4 14 2 page 96 Section 4 14 3 page 109 Section 4 14 5 page 123 Drive Front PTO code N08 Center Engine PTO code N05 or gearbox PTO code N19 Section 5 9 page 176 Section 5 8 page...

Page 41: ...2 16 Water tanks Figure 2 18 Water tank Overview of related sections Mounting On platform P27 P40 like Spreader mounting Section 4 14 2 page 96 Section 4 14 2 1 pg 105 Drive Not necessary Electrical c...

Page 42: ...ons Mounting Front mounting plate code D12 or Integrated implement support Section 4 13 page 85 Section 4 13 3 pg 89 Drive Basic hydraulic Chapter 6 page 194 Electrical connection Not necessary Notes...

Page 43: ...rear axle 1t weight 2 5t Implement mounting bracket rear code D50 and Mounting points at rear stabilizer 2 5t weight 4t Code D62 Section 4 15 page 166 Section 4 14 8 1 pg 164 Section 4 14 8 pg 160 Sec...

Page 44: ...chassis Section 4 14 3 page 109 Section 4 14 5 page 123 Drive Gearbox PTO code N19 or Engine PTO code N05 Hydraulic connector at the side H68 at the rear H58 H59 Section 5 10 page 182 Section 5 8 page...

Page 45: ...g On ballpoints P60 or Directly on the chassis Section 4 14 3 page 109 Section 4 14 5 page 123 Drive Engine PTO code N05 Hydraulic connector at the side H68 at the rear H58 H59 Section 5 8 page 172 Ch...

Page 46: ...60 or Directly on the chassis Section 4 14 3 page 109 Section 4 14 5 page 123 Drive Engine PTO code N05 Hydraulic connector at the side H68 at the rear H58 H59 Section 5 8 page 172 Chapter 6 page 194...

Page 47: ...de D12 Section 4 13 page 85 Drive Front PTO code N08 Hydraulic Section 5 9 page 176 Chapter 6 page 194 Electrical connection Code E45 Mounting of the control unit Section 7 6 2 page 227 Section 9 5 pa...

Page 48: ...ints P60 or Directly on the chassis Section 4 14 3 page 109 Section 4 14 5 page 123 Drive Engine PTO code N05 Hydraulic connector at the side H68 at the rear H58 H59 Section 5 8 page 172 Chapter 6 pag...

Page 49: ...ounting Via sub frame directly on the chassis code D62 Section 4 14 6 page 141 Drive Gearbox PTO code N16 and Hydraulic pump Section 5 10 page 182 Section 5 10 3 page 185 Electrical connection Code E3...

Page 50: ...ounting On ballpoints P60 or Directly on the chassis Section 4 14 3 page 109 Section 4 14 5 page 123 Drive Hydraulic connector at the side H68 at the rear H58 H59 Chapter 6 page 194 Chapter 6 page 194...

Page 51: ...g bracket rear code D50 3 5 mt Via sub frame directly on the chassis code D62 Mounting of cranes on Unimog s Section 4 15 page 166 Section 4 14 6 page 141 Section 4 14 6 4 page 156 Drive Gearbox PTO N...

Page 52: ...Body and Implement Mounting Guidelines U500 North America Applications August 2005 Page 55 of 294...

Page 53: ...718 840 All synchromesh MB 8 speed EPS manual gearbox With integrated permanent front wheel drive all wheel drive Torque distribution front rear axle 50 50 1 6 gears can be driven in reverse G03 7 8 r...

Page 54: ...3 gal 2 x 28 5 l For detailed information about connecting possibilities to the com pressed air system see Section 8 Pneumatic Consumers page 242 Off road relevant data Tires 395 85R20 XZL Unimog Mode...

Page 55: ...hnical Data for mechanically implement drive For important detailed technical information about the mechanically drive of implements see Section 5 Mechanical drive of implements page 168 3 2 2 Hydraul...

Page 56: ...ugust 2005 Page 59 of 294 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 Di...

Page 57: ...th America Vehicle Information Page 60 of 294 August 2005 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 F...

Page 58: ...formation August 2005 Page 61 of 294 3 3 2 U500 NA wheelbase 153 54 in 3 900 mm Note Dimensions marked with a vary by tires and or vehicle axle loads Dimensions without brackets are in mm Dimensions i...

Page 59: ...th America Vehicle Information Page 62 of 294 August 2005 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 F...

Page 60: ...Body and Implement Mounting Guidelines U500 North America Vehicle Information August 2005 Page 63 of 294...

Page 61: ...es pan hard rods springs propeller shafts steering etc must also be guaranteed fol lowing the fitting of the implements or the bodies even at maximum axle articulation maximum and minimum axle loads a...

Page 62: ...voidable 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...

Page 63: ...nting guideline see Section 3 1 Gross Vehicle Weights and Axle Loads page 57 Permissible gross vehicle weight Permissible front axle load Permissible rear axle load must be observed To ensure sufficie...

Page 64: ...8 250lbs min 6 750lbs Axle load 15 000lbs 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 pleas...

Page 65: ...ines U500 North America Implement Body Installation Page 68 of 294 August 2005 Part numbers of the springs Front Axle Spring A405 321 05 04 Rear Axle Spring A405 324 03 04 Figure 4 5 Suspension graph...

Page 66: ...nes U500 North America Implement Body Installation August 2005 Page 69 of 294 Part numbers of the springs Front Axle Spring A405 321 05 04 Rear Axle Spring A405 324 03 04 Figure 4 6 Suspension graph w...

Page 67: ...G 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 po...

Page 68: ...wer 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 th...

Page 69: ...RAW Rear axle load FAWempty Front axle load by vehicle dead weight result of weigh ing or result of the Unimog weight calculator GVW Wmi Wre Wfr l lfr lre lmi FAW RAW lf lr RAWempty Rear axle load by...

Page 70: ...ht you also can determine the angle between the wheel centers to the horizontal Calculate the height of the center of gravity by using the Equation 4 4 to Equation 4 9 For confirming the height of the...

Page 71: ...tive equation for lifted front axle using the angle stat RAW s r l GVW RAW Q h tan 1 Equation 4 7 Equation for lifted rear axle stat f FAW f s r h l GVW FAW Q h l h 2 2 Equation 4 8 Alternative equati...

Page 72: ...0 98 Table 4 4 Necessary information in lbs lbs lbs lbs in lbs in lbs in lbs in lbs hs 98 0 100 1 410 4 750 1 600 17 5 29 100 1 5 70 410 4 6 27 750 1 65 34 600 17 in hs 31 39 To simplify the calculati...

Page 73: ...ht above the road surface with Equation 4 5 page 74 by yourself 4 8 4 Permissible height of center of gravity The design of the implement or body must ensure that the overall height of the center of g...

Page 74: ...ith standard anti roll bars on the guid ing on the front axle and rear axle This guarantees acceptable driv ing characteristics even in the case of implements and bodies with high centers of gravity 4...

Page 75: ...intake are not permissible Protect the air intake against flying sparks by fire fighting ve hicles wildfire rescue vehicles Use an auxiliary dust filter if the vehicle is operated in ex tremely dusty...

Page 76: ...com An alternative supplier for torsion frames is Order address Joe Zaloga Saddle River Road 7222 Monsey NY 10952 Phone 1 845 323 9231 Email Mbilunimog aol com The surface and anti corrosion protecti...

Page 77: ...tantly changing magnitude and frequency This means that all implements bodies must be secured against slipping and lifting This also applies to loads with the exception of bulk cargos Possible mountin...

Page 78: ...additionally counterweight can be the platform Mounting on the rear of the platform In case of a platform mounted counterweight the following require ments see also Figure 4 16 must be considered The...

Page 79: ...ith changing overall center of gravity 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 lic boom with a mower...

Page 80: ...ured values lbs 5 100 7 100 1 100 8 600 882 lbs or 10 of the FAW 882 lbs or 10 of the FAW 882 lbs or 10 of the RAW 882 lbs or 10 of the RAW Limit val ues defini tions LR LF GVW 4 1 1 220 lbs 1 220 lbs...

Page 81: ...ent mounting positions on the Unimog U500NA Front mounting F see chapter 4 13 Mounting between axles F see chapter 4 14 8 Rear mounting F see chapter 4 15 Center mounting Platform mounting F see chapt...

Page 82: ...500 mm depends on local regulations 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 o...

Page 83: ...ment Mounting Guidelines U500 North America Implement Body Installation Page 86 of 294 August 2005 Dimensions in mm and dimensions in brackets in in Figure 4 19 Front mounting plate code D12 part no A...

Page 84: ...he Unimog Caution Please use only suitable claws Grinding cutting or other fabrication on claws and on the front mounting plate is not permitted Listing of the Schmidt mounting kit for implement mount...

Page 85: ...dy and Implement Mounting Guidelines U500 North America Implement Body Installation Page 88 of 294 August 2005 Figure 4 21 Compatible claw for front mounting plate from SCHMIDT All dimensions are in m...

Page 86: ...unting plate 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 Standard to the Unimog is a...

Page 87: ...dy and Implement Mounting Guidelines U500 North America Implement Body Installation Page 90 of 294 August 2005 Dimensions in mm and dimensions in brackets in in Figure 4 24 Integrated implement suppor...

Page 88: ...tting the tubular cross member the following parts are necessary Part Number Description Quantity A 405 525 00 17 Screen 1 A 405 520 37 41 Right Bracket 1 A 405 520 42 41 Left Bracket 1 A 000 987 07 7...

Page 89: ...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...

Page 90: ...rts are diagramed on the follow ing two pages Figure 4 34 and Figure 4 35 4 14 1 Bodies implements with variable overall c o g Implements bodies with variable centers of gravity are for example boom m...

Page 91: ...nimog s using thrust plate nuts only The permissible thickness of wheel hub chassis supports fitted with the wheel hubs is shown in Figure 4 28 and Figure 4 29 The shown figures apply for the followin...

Page 92: ...Body and Implement Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 95 of 294 Figure 4 31 Drawing of the wheel hub chassis support...

Page 93: ...the platform The body implement on the platform must only have point shaped support at those points where the ballpoints of the platform sub frame are located In this way the weight of the implement...

Page 94: ...nd Implement Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 97 of 294 Figure 4 34 Overview of the platform and subframe mounting parts at the U500 with a short whe...

Page 95: ...nd Implement Mounting Guidelines U500 North America Implement Body Installation Page 98 of 294 August 2005 Figure 4 35 Overview of the platform and subframe mounting parts at the U500 with a long whee...

Page 96: ...ilable platforms Platform dimensions Outer dimensions Inner dimensions Code Dimension in mm in mm Length 109 05 2 770 105 79 2 687 Width 89 80 2 281 87 20 2 215 Height front 25 20 640 19 68 500 P27 He...

Page 97: ...ounting Guidelines U500 North America Implement Body Installation Page 100 of 294 August 2005 Holes for implement fastening Dimensions without brackets are in mm Dimensions in brackets are in in Figur...

Page 98: ...ounting Guidelines U500 North America Implement Body Installation August 2005 Page 101 of 294 Holes for implement fastening Dimensions without brackets are in mm Dimensions in brackets are in in Figur...

Page 99: ...ing cylinders Two different tipping cylinders are available for the Unimog U500NA 4 stages for short platform part no A 002 553 73 05 4 stages for long platform part no A 002 553 74 05 Tipping cylinde...

Page 100: ...without brackets are in mm Dimensions in brackets are in in 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 floo...

Page 101: ...ets are in mm Dimensions in brackets are in in Figure 4 46 Positions of the fastening holes in platform P40 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 47 Reinforci...

Page 102: ...ement from sliding to the front The implement must be secured against sliding to the front using two mechanical stops a and b One of them has to be adjustable in length The implement fastening must be...

Page 103: ...ness screw 7 8 length 4 KENFORGING Ohio Eye Nut Style B C1030 Stock No EN 9 HD Figure 4 53 Tie down eye option 1 ENKLER 4 x 5 8 min length 3 min Figure 4 54 Tie down eye option 2 Note The existing tie...

Page 104: ...h additional plate Additional fastening between the support points 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 usin...

Page 105: ...nce 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 diag...

Page 106: ...405 610 00 35 2 pieces required Ball half shell A 405 610 01 35 2 pieces required Plastic inlay A 405 615 00 75 4 pieces required Locating bolt A 405 619 00 74 1 piece required Locating bolt A 405 61...

Page 107: ...unting Guidelines U500 North America Implement Body Installation Page 110 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 60 Overview of the availabl...

Page 108: ...ation August 2005 Page 111 of 294 Platform sub frames dimensions Dimensions without brackets are in mm Dimensions in brackets are in in Low platform subframe Part No A405 610 04 03 High platform subfr...

Page 109: ...ent Body Installation Page 112 of 294 August 2005 Low platform subframe Part No A405 610 06 03 High platform subframe Part No A405 610 07 03 Dimensions without brackets are in mm Dimensions in bracket...

Page 110: ...Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 113 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 63 Ball half shell Part...

Page 111: ...Mounting Guidelines U500 North America Implement Body Installation Page 114 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 64 Ball half shell Part...

Page 112: ...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 t...

Page 113: ...mic 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 prevents bending of the platform i...

Page 114: ...unted on the ballpoints This can be done using the hole pattern of the chassis frame with a fastening part Figure 4 71 page 118 Therefore a holding plate must be cut off of the platform subframe and h...

Page 115: ...Guidelines U500 North America Implement Body Installation Page 118 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 71 Suggestion for reinforcing of t...

Page 116: ...of 294 High platform subframe and long wheelbase Dimensions without brackets are in mm Dimensions in brackets are in in High platform subframe and short wheelbase Low platform subframe and long wheel...

Page 117: ...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 73 on the implement frame must be mounted in the exact positi...

Page 118: ...nes U500 North America Implement Body Installation August 2005 Page 121 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 75 Position of the magnet for the tilt co...

Page 119: ...nes U500 North America Implement Body Installation Page 122 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 76 Position of the magnet for the tilt co...

Page 120: ...gitudinal members should be designed Two different solutions are possible Mounting frames with a maximum height of 6 3 in 160 mm Figure 4 77 Front end of a mounting frame with a max height of 6 3 in M...

Page 121: ...e 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...

Page 122: ...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 dime...

Page 123: ...Body and Implement Mounting Guidelines U500 North America Implement Body Installation Page 126 of 294 August 2005 Figure 4 84 Suggestion for a custom manufactured low mounting frame...

Page 124: ...Guidelines U500 North America Implement Body Installation August 2005 Page 127 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 85 Suggestion for a custom manufa...

Page 125: ...llation Page 128 of 294 August 2005 Vehicle frame Vehicle frame Mounting frame Mounting frame Mounting frame with a rectangular tube Mounting frame with a C profile Figure 4 86 Sketches with dimension...

Page 126: ...plement Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 129 of 294 Figure 4 87 Section modulus of the frame subframe combination for a mounting frame with C profile...

Page 127: ...ement Mounting Guidelines U500 North America Implement Body Installation Page 130 of 294 August 2005 Figure 4 88 Section modulus of the frame subframe combination for a mounting frame with C profiles...

Page 128: ...ent Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 131 of 294 Figure 4 89 Section modulus of the frame subframe combination for a mounting frame with rectangular t...

Page 129: ...nt Mounting Guidelines U500 North America Implement Body Installation Page 132 of 294 August 2005 Figure 4 90 Section modulus of the frame subframe combination for a mounting frame with rectangular tu...

Page 130: ...s Figure 4 91 Overview of fastening plates for directly mounting this figure shows a U500 with long wheelbase Console fastening with belleville spring washer package see pages 135 and 140 Console fast...

Page 131: ...lement Mounting Guidelines U500 North America Implement Body Installation Page 134 of 294 August 2005 Figure 4 92 Tightening torques for mounting bodies implements without outriggers directly to the c...

Page 132: ...2005 Page 135 of 294 L 1 35 in 34 2 mm 20 x A 000 993 05 26 2 x A 405 520 10 33 2 x A 387 619 00 97 1 x bolt M14x1 5x120 grade 10 9 MB No N 910105014022 1 x nut M14x1 5 MB No N 913023014003 Figure 4 9...

Page 133: ...12 9 4 Nut Diameter 9 16 UNF Nut M14x1 5 4 2 Fastening plates middle A405 611 01 11 Bolt Diameter 9 16 UNF Length Grade 8 Bolt M14x1 5 Grade 12 9 8 Nut Diameter 9 16 UNF Nut M14x1 5 8 2 Fastening plat...

Page 134: ...delines U500 North America Implement Body Installation August 2005 Page 137 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 95 Fastening plate only short wheelba...

Page 135: ...delines U500 North America Implement Body Installation Page 138 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 96 Fastening plate only long wheelbas...

Page 136: ...unting Guidelines U500 North America Implement Body Installation August 2005 Page 139 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 97 Fastening plate Part No...

Page 137: ...idelines U500 North America Implement Body Installation Page 140 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 98 Console Part No A405 520 10 33 Fo...

Page 138: ...plements 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 fi...

Page 139: ...ckhoes 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 123 et seqq 4 14 6 1 Code D70...

Page 140: ...merica Implement Body Installation August 2005 Page 143 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 101 Fastening plate code D70 included in D62 Part No A405...

Page 141: ...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 o...

Page 142: ...Part No A405 611 00 11 Code D70 Console Fastening plate Part No A405 611 00 11 Console Mounting frame Mounting frame Code D62 Code D62 U500 NA short wheelbase Dimensions without brackets are in mm Di...

Page 143: ...ounting Guidelines U500 North America Implement Body Installation Page 146 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 103 D60 D62 hole pattern i...

Page 144: ...delines U500 North America Implement Body Installation August 2005 Page 147 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 104 Heavy implement mounting support...

Page 145: ...t Body Installation Page 148 of 294 August 2005 Dimensions with a depends on the subframe height Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 105 Proposal for fasten...

Page 146: ...Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 149 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 106 Subframe tolerance w...

Page 147: ...ne tubular cross members and ballpoints to mount the plat form are required Optional a loose platform code P27 is available ex factory Dimensions without brackets are in mm Dimensions in brackets are...

Page 148: ...ordered by any authorized Freightliner Unimog dealer The ball points should be welded into a suitable tu bular cross member see Figure 4 109 Important Notes Attention should be paid to the correct pos...

Page 149: ...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 moun...

Page 150: ...tion August 2005 Page 153 of 294 Detail sketches of wing plow support suggestion Figure 4 114 Mounting frame side view Figure 4 115 Mounting frame top view Figure 4 116 Vertical frame member side view...

Page 151: ...ew Figure 4 120 Mounting frame with cross member and 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 mou...

Page 152: ...e 155 of 294 Figure 4 124 Side view of a Unimog with mounted wing plow support Figure 4 125 Top view of a Unimog with mounted wing plow support Figure 4 126 Side view of a Unimog with platform and mou...

Page 153: ...bolt Figure 4 129 Mounting via clamping devices The following key facts must be considered for mounting of cranes on Unimog s GVW and maximum axle loads Minimum axle loads Standing stability C o g he...

Page 154: ...aterials 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 Tab...

Page 155: ...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...

Page 156: ...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 15 20 147 15 196 2 Rectangular Profile 3 15 80 8 66 220 0 354 9 20 25...

Page 157: ...for other applications 4 14 8 Implement mounting between the axles The implement mounting brackets code D60 or D62 should be used for fastening implement supports by implements which must be fitted b...

Page 158: ...lines U500 North America Implement Body Installation August 2005 Page 161 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 141 Proposal for a implement mounting s...

Page 159: ...Body Installation Page 162 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 142 Counterpart of the implement mounting support on the rear stabilizer...

Page 160: ...an order address of SCHMIDT parts see page 87 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 5...

Page 161: ...Cranes Aerial devices man lifts Drillings All implements which can raise the vehicle Table 4 17 Examples for using codes D60 and D62 Bracket D62 is not mountable in combination with the plat form sub...

Page 162: ...Guidelines U500 North America Implement Body Installation August 2005 Page 165 of 294 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 4 147 Implement mounting support cod...

Page 163: ...with a di ameter of 0 98 in 25 mm Heavy implements must additionally fas tened with plates to the left and right of each mounting bracket The hydraulic supply for rear mounted implements can be provi...

Page 164: ...Body and Implement Mounting Guidelines U500 North America Implement Body Installation August 2005 Page 167 of 294...

Page 165: ...d is derived from the engine speed as follows i n n engine off take power This means For transmission ratios higher than one i 1 the PTO speed is lower than the engine speed step down Transmission rat...

Page 166: ...er clockwise 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 Retrofitting possibility of high speed...

Page 167: ...Implement Mounting Guidelines U500 North America Mechanical drive of implements Page 170 of 294 August 2005 5 5 Overview and positions of power take offs Figure 5 1 Overview of the available power ta...

Page 168: ...drive train efficiency approx 90 95 Multiplication of the reduced engine power output with this factor See also a calculation example in Section 5 9 2 Usable power output of the power take off shaft...

Page 169: ...N05 Gear ratio i 0 933 Speed at rated engine speed 2 200 rpm 2 356 rpm Direction of rotation viewed in direction of travel Counter clockwise Max delivered torque continuous 442 lb ft 600 Nm Max torque...

Page 170: ...Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements August 2005 Page 173 of 294 Figure 5 3 Drawing of the quick interchangeable driveline Part no A405 410 11 06...

Page 171: ...5 4 PTO N05 with vibration absorber and hydraulic pump Figure 5 5 Installation of a vibration absorber on N05 Figure 5 6 Use of the N05 with a vibration absorber Note for installation of the vibration...

Page 172: ...Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements August 2005 Page 175 of 294 Figure 5 7 Drawing of the vibration absorber part no A906 250 00 01...

Page 173: ...efficients duration of use ambient con ditions etc into consideration The implement manufacturer is responsible for carrying out practical tests with the implement to verify the operation of the drive...

Page 174: ...O 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 PT...

Page 175: ...shaft 1 spline shaft Note Shaft speed 500 1000 rpm can be set using cruise con trol Power take off shaft 1 spline shaft at output side of PTO transmission Spline according to SAE J499a 6 splines Shaft...

Page 176: ...e 179 of 294 5 9 5 Position of PTO shaft Note Dimensions marked with a vary by tires and or vehicle axle loads Dimensions without brackets are in mm Dimensions in brackets are in in Note Vehicle equip...

Page 177: ...pension part h Height of power take off shaft above the road surface rs tat Static tire radius measure at the loaded truck or see Table 4 3 page 74 e F A Spring height at the front axle dimension cent...

Page 178: ...Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements August 2005 Page 181 of 294 Figure 5 12 Effect of suspension travel on dimension h...

Page 179: ...ring driving it is necessary to stay in the previously selected gear Shifting gear while the auxiliary PTO is engaged is not possible as the drag torque of the driven im plement impedes synchronizatio...

Page 180: ...s U500 North America Mechanical drive of implements August 2005 Page 183 of 294 Drawings of the N16 and N19 flanges N 16 flange Dimensions without brackets are in mm Dimensions in brackets are in in F...

Page 181: ...Mounting Guidelines U500 North America Mechanical drive of implements Page 184 of 294 August 2005 N 19 flange Dimensions without brackets are in mm Dimensions in brackets are in in Figure 5 14 Drawing...

Page 182: ...ydraulic 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 pu...

Page 183: ...elines U500 North America Mechanical drive of implements Page 186 of 294 August 2005 950 1000 1050 1100 1150 1200 1250 1300 0 5 10 15 20 25 30 Flow gallons minute Engine speed rpm F1 41 F1 61 F1 81 Fi...

Page 184: ...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 c...

Page 185: ...MANY Phone 0049 651 68670 Fax 0049 651 64146 Email Werner t online de Figure 5 21 Directly mounted flange drive on auxiliary PTO N16 Length compensation is realized with a 1 57 in 40 mm travel slip jo...

Page 186: ...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 must also be not smaller than 1 Relevant vehicle safety components e...

Page 187: ...ent 1 2 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 deflectio...

Page 188: ...3 2 tan tan tan v Three dimensional angle of shaft 1 h Three dimensional angle of shaft 2 Offset angle The offset angle can be determined with the horizontal and vertical angles of deflection of the t...

Page 189: ...epending on the design of the drive shaft one of the two marks can be lo cated underneath the rubber sleeve Noises and vibrations Noises and vibrations may occur If the speed of an implement is too hi...

Page 190: ...Body and Implement Mounting Guidelines U500 North America Mechanical drive of implements August 2005 Page 193 of 294...

Page 191: ...bar Approx output of circuit 1 Efficiency not considered 10 7 hp Approx output of circuit 2 Efficiency not considered 21 4 hp Dual circuit system Code H06 H08 continued Application Implement actuation...

Page 192: ...For use with implements with max 3 actuating movements H14 4 valve hydraulic system For use with implements with max 4 actuating movements H43 Tipping cylinder for platform Multistage tipping cylinde...

Page 193: ...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 li...

Page 194: ...al circuit hydraulic system middle inc separate return line H73 Hydraulic connection front 2 lines on valve 3 H75 Hydraulic connection front 4 lines on valves 1 and 2 H78 Pressure line front for dual...

Page 195: ...be connected single acting i e re turn via the separate return line Lift connector hose on lift line circuit 1 port 3 or 7 Lower connector hose on lower port circuit 1 port 4 or 8 Only load the hydrau...

Page 196: ...er female ISO 16028 Size 12 5 1 2 2 4 Green Coupler female ISO 16028 Size 12 5 1 2 Circuit Cell Port Sym bol Symbol color 5 Yellow Coupler female ISO 16028 Size 12 5 1 2 3 6 Yellow Coupler female ISO...

Page 197: ...engine Circuit 2 Casappa gear pump 16 6 cm3 turn 1 013 cu in turn driven via belt by the engine Table 6 5 Hydraulic pumps of circuit 1 and 2 6 2 1 2 Hydraulic control unit Electrically controlled 4 3...

Page 198: ...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...

Page 199: ...mp hydrostatic fan drive 1a Oil filter 5 Hydraulic oil cooler Z1 Cell 1 in circuit I connector 1 and 2 2 Valve block SR Separate return line Z2 Cell 2 in circuit I connector 3 and 4 2a Snow plow load...

Page 200: ...The following hydraulic connections of the basic hydraulic cir cuit 1 and 2 are on the front of the Unimog above the bumper see Figure 6 4 and Figure 6 5 Figure 6 4 Front hydraulic connections drive d...

Page 201: ...Body and Implement Mounting Guidelines U500 North America Hydraulic system Page 204 of 294 August 2005 Figure 6 6 Overview of hydraulic connections at the vehicle front...

Page 202: ...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...

Page 203: ...ions 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 o...

Page 204: ...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 6 2 3 Volume flows of the basic hydraulic systems The fig...

Page 205: ...August 2005 Circuit I II w ith combinations 0 00 5 00 10 00 15 00 20 00 25 00 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 Engine speed rpm Volume flow gal min circuit I circuit II circuit I...

Page 206: ...ircuit I II w ith combinations 0 00 10 00 20 00 30 00 40 00 50 00 60 00 70 00 80 00 90 00 100 00 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 Engine spe e d rpm Volume flow l min circuit I cir...

Page 207: ...6 IF5020 75PUUNF UNF Inside thread 20 with pressure elimination IF5020PUUNF NPT Inside thread 14 with pressure elimination IF5020PUNPT UNF Inside thread 16 with pressure elimination IF5020 75PUUNF Tab...

Page 208: ...cessary for the operation of a continuous consumer This is why the Unimog has electrically controlled variable displacement pumps for the power hydrau lic systems circuit 3 and circuit 4 Before operat...

Page 209: ...005 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...

Page 210: ...tem August 2005 Page 213 of 294 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 p...

Page 211: ...nnections of the power hydraulics circuit 4 6 3 4 Center power hydraulic connections The connections for the power hydraulic circuits 3 and 4 are integrated in the platform subframe They are located o...

Page 212: ...space under the cab above the longitudinal frame member is used and cannot used for other applications see also Section 4 14 7 page 160 Important Note The pressure free leakage oil connec tion of the...

Page 213: ...stem Page 216 of 294 August 2005 Circuit III IV 0 00 5 00 10 00 15 00 20 00 25 00 30 00 35 00 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 Engine speed rpm Volume flow gal min circuit III circ...

Page 214: ...stem August 2005 Page 217 of 294 C ircuit III IV 0 00 20 00 40 00 60 00 80 00 100 00 120 00 140 00 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 Engine speed rpm Volume flow l min circuit III c...

Page 215: ...NF16 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 3 7 Dealer for power hydra...

Page 216: ...rated pressure in order to estimate the required output The standard output is thus 29 1714 max Rated E p Q P with htotal 1 Examples Power hydraulics closed circuit 33 02 gal min 4350 PSI P 83 8 hp Po...

Page 217: ...Body and Implement Mounting Guidelines U500 North America Hydraulic system Page 220 of 294 August 2005...

Page 218: ...on codes Descriptions E44 12 V jump start terminals E53 Preparation for CB mobile telephone 12 V incl antenna E54 Preparation for two way radio 12 V incl antenna E55 Antenna and two loudspeakers Table...

Page 219: ...Warning Indicator To disconnect the Bulb Warning system two wires 1999A and 1999B must be disconnected at the Basic Module First remove the covers of the Basic Module behind the passenger seat Re mov...

Page 220: ...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 chaf...

Page 221: ...sulation displacement connectors Provide consumers with sufficient protection via addi tional fuses The implement body manufacturer may install additional electrical consumers ONLY if the following in...

Page 222: ...mn 2 Read to right and find wire length in feet equal to or greater than circuit being installed 3 Read up to find Minimum Wire Gage needed for circuit 4 Both the positive and ground cable MUST be the...

Page 223: ...rfaces 7 6 1 Power outlet in the cab E37 Socket outlet 3 pin Data 12 V 25 A Location Behind the driver seat Suitable plug Part No A 022 545 90 28 Ports 12 V Terminal 30 steady plus 0 V Ground Road spe...

Page 224: ...t bumper Figure 7 8 Socket E45 A suitable plug part no A 004 545 21 28 can be ordered at any authorized Freightliner Unimog dealers The cables are fas tened in the plug with screw connectors Figure 7...

Page 225: ...ternator speed signal 10 WB Warning beacon 11 BUL Back up light 12 C3 Road speed signal 13 C4 Distance signal 14 Not con nected 15 UI Universal input to EPS control unit 16 UI ground EPS Ground for un...

Page 226: ...mbers for plug with crimp connectors Description AMP Part No MB Part No Housing plug HB K 16 STS GR 1 21 51 42 42 16 07 A 043 545 15 28 Cartridge HE 16 Sti C 43 12 16 41 A 043 545 19 28 Terminal crimp...

Page 227: ...towing vehicle 31 2 black Clearance side marker and identifica 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 l...

Page 228: ...control functions Engine Start Stop o Operation code W01 W02 or W05 refer to page 237 must be activated o Carried out via UI pins 15 and 16 o Engine stop via connection between pin 15 and pin 16 sign...

Page 229: ...an be carried out except engaging neutral Engine speed remote control Operation codes W04 or W05 must be activated With an open circuit between pin 15 and pin 16 the engine runs at idling speed If the...

Page 230: ...4 7 7 2 Examples for designing an external manual control Figure 7 15 Suggestion for an engine speed remote control circuit Note Potentiometer R1 may be replaced with a fixed value re sistor if only o...

Page 231: ...gestion for a fixed speed of 1 200 rpm Figure 7 19 Suggestion for an fixed engine speed of 1 200 rpm Operating states Basic state S1 open S2 closed Increased idle speed approx 750 rpm S1 and S2 closed...

Page 232: ...trol unit EPS Code W30 and code W35 can therefore not be combined The following factory settings are possible for the implement socket at the battery unit Code Description W01 Engine stop function via...

Page 233: ...ransmission PTO option code N16 N19 is acti vated Engagement of transmission PTO will automatically limit the engine speed to 900 rpm In case of over speeding on a down hill run the warning buzzer wil...

Page 234: ...n transmission PTO option code N16 N19 is acti vated 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 buzze...

Page 235: ...n headlamp switch and an electrical interface which is located in the switch box in the area behind the power outlet behind driver seat in the cab To connect your roof mounted headlamp support you wil...

Page 236: ...road speed signal and travel dependent signal comply with ISO 16844 2 The road speed signal C3 can be taken from the power supply socket in the cab behind the driver s seat and also from the implement...

Page 237: ...d 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 impl...

Page 238: ...Body and Implement Mounting Guidelines U500 North America Electrical system August 2005 Page 241 of 294...

Page 239: ...onsidered 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...

Page 240: ...e 8 2 Vehicle without CTIS back view 8 3 2 Air extraction on vehicles with CTIS On vehicles with CTIS dried air can be extracted behind a pro tection valve part no A005 429 55 44 at the in interface s...

Page 241: ...nnected to secondary supply reservoir Figure 8 4 Serial mounting parts on vehicles w o CTIS Serial and additional mounting parts for pneumatic consumers on vehicles without CTIS Connected to secondary...

Page 242: ...idelines U500 North America Pneumatic Consumers August 2005 Page 245 of 294 Serial mounting parts on vehicles with CTIS Connected to secon dary supply reservoir CTIS interface Figure 8 6 Serial mounti...

Page 243: ...4 August 2005 Serial and additional mounting parts for pneumatic consumers on vehicles with CTIS Connected to secon dary supply reservoir CTIS Interface Interface for additional pneumatic consumers Fi...

Page 244: ...traction with air extraction Part MB Part No PARKER Hannifin Part No 0 1 1 2 A405 997 00 67 PH 2225P 8 0 1 1 1 A405 997 07 71 PH VS68NTA 10 8 0 1 1 1 A405 990 08 70 PH 209P 8 6 0 1 1 1 A405 997 06 71...

Page 245: ...Body and Implement Mounting Guidelines U500 North America Pneumatic Consumers Page 248 of 294 August 2005...

Page 246: ...oad 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 als...

Page 247: ...vement 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 the...

Page 248: ...seat near the power outlet see Figure 9 4 Since the Unimog cab can be tilted plug connections must be provided for the cables so the lines are not damaged when the cab is tilted 9 3 2 Cable passage th...

Page 249: ...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 pl...

Page 250: ...Body and Implement Mounting Guidelines U500 North America Cab August 2005 Page 253 of 294 Figure 9 8 Drawing of the pass through plug...

Page 251: ...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 soon as the cable has...

Page 252: ...er 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 I...

Page 253: ...hould 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 15...

Page 254: ...ust be enclosed equipped with strain relieves and fixed to the vehicle with cable ties 9 4 Mountings on the cab 9 4 1 Roof loads roof bars Roof loads or the installation of roof bars are limited Impor...

Page 255: ...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 attach...

Page 256: ...ed 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 be ordered via the following part no A381 811...

Page 257: ...sions by use of the suggested proposals 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 lig...

Page 258: ...outlet 12 V 25 A in the cab behind the driver seat combined with an external switch and a suitable fuse must be used See also section 7 6 1 page 226 The cable should be routed through the cable passag...

Page 259: ...is fitted in the factory National laws and regulations must be taken into considera tion Special caution is required when passing railroad cross ings If the aerial comes into contact with the overhea...

Page 260: ...1 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 263 and the following pages Figure 9 30 Fasten...

Page 261: ...264 of 294 August 2005 Figure 9 32 Accessibility of fastening points on the gearshift console These 3 holes are always acces sible for mounting an implement control panel These 4 holes are only acces...

Page 262: ...nes U500 North America Cab August 2005 Page 265 of 294 Figure 9 33 Position of the fastening points on the center console All dimensions in millimeters All thread insert M8 Usable thread length 16mm F...

Page 263: ...nter mounting use with VarioPilot Figure 9 35 3D view of the frame for center mounting use with VarioPilot see drawing no RK 999 000 P 207 Figure 9 36 Position of the frame for left mounting Figure 9...

Page 264: ...Body and Implement Mounting Guidelines U500 North America Cab August 2005 Page 267 of 294 Figure 9 38 3D view of the frame for left mounting All dimensions in millimeters...

Page 265: ...Body and Implement Mounting Guidelines U500 North America Cab Page 268 of 294 August 2005 Figure 9 39 3D view of the frame for left mount All dimensions in millimeters...

Page 266: ...Body and Implement Mounting Guidelines U500 North America Cab August 2005 Page 269 of 294 Figure 9 40 3D view of the frame for left mount All dimensions in millimeters...

Page 267: ...Body and Implement Mounting Guidelines U500 North America Cab Page 270 of 294 August 2005 Figure 9 41 3D view of the frame for left mount All dimensions in millimeters...

Page 268: ...Body and Implement Mounting Guidelines U500 North America Cab August 2005 Page 271 of 294...

Page 269: ...5 mm 5th frame cross member Welded closed profile 6th frame cross member U cross member Section modulus of the frame over the front axle 16 48 in3 270 cm3 Section modulus of the frame over the rear ax...

Page 270: ...North America Chassis frame modifications August 2005 Page 273 of 294 10 2 2 Chassis frame of the U500 short wheelbase Dimensions without brackets are in mm Dimensions in brackets are in in Figure 10...

Page 271: ...North America Chassis frame modifications Page 274 of 294 August 2005 10 2 3 Chassis frame of the U500 long wheelbase Dimensions without brackets are in mm Dimensions in brackets are in in Figure 10...

Page 272: ...authorized Freightliner Unimog Dealers Dimensions without brackets are in mm Dimensions in brackets are in in Figure 10 4 Frame material A405 311 10 01 10 4 Rear cross member The chassis frame of the...

Page 273: ...ling the holes must be deburr and reamed Drilling must not be carried out on the following locations of the chassis frame On the upper and lower flange of the chassis frame see Figure 10 6 In the area...

Page 274: ...ead and flange nuts or flange lock nuts for bolt connections on the Unimog see Figure 10 9 Use existing drillings and drill new holes only if it is es sential Adapt the number of bolts to the load if...

Page 275: ...cuits 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 Remove the spri...

Page 276: ...m The distance between seams and the outer edge should be at least 0 59 in 15 mm Figure 10 10 Grinding of the weld seam 10 9 2 Welding preparation It is recommended that a double V seam see Figure 10...

Page 277: ...direction of torsion i e parallel to the longitudinal axis see also Figure 10 10 The surface roughness of the grinding should not exceed sur face roughness of Rz6 3 After welding sufficient anti corro...

Page 278: ...nsion with reinforcement plates Drillings in the chassis frame must not be cut To reinforce the weld section and relieve the weld seam a reinforcement plate must be welded to the frame see Figure 10 1...

Page 279: ...Implement Mounting Guidelines U500 North America Chassis frame modifications Page 282 of 294 August 2005 Dimensions without brackets are in mm Dimensions in brackets are in in Figure 10 15 Reinforceme...

Page 280: ...ase of direct welding Figure 10 16 Frame extension without reinforcement plates 10 11 Shortening of the frame On shortening the end of the frame the end transverse member must be moved to the remainin...

Page 281: ...Body and Implement Mounting Guidelines U500 North America Chassis frame modifications Page 284 of 294 August 2005...

Page 282: ...03 Name To convert from To Multiply by Pressure lbf in2 Pa 6894 757 Pressure lbf ft2 Pa 47 88026 Pressure bar Pa 100 000 Pressure lbf in2 bar 0 0689475 Pressure Pa lbf in2 1 4504E 04 Pressure Pa lbf f...

Page 283: ...igure 2 1 Front mounted mower 29 Figure 2 2 Front mounted mower in transport position 29 Figure 2 3 Rear mounted mower 30 Figure 2 4 Rear mounted mower in transport position 30 Figure 2 5 Spreader mou...

Page 284: ...4 Front mounted counterweights 80 Figure 4 15 Rear mounted counterweights 81 Figure 4 16 Fastening of platform mounted counterweights 81 Figure 4 17 Implement mounting positions on the Unimog U500NA 8...

Page 285: ...ames for short wheelbases 111 Figure 4 62 Platform sub frames for long wheelbases 112 Figure 4 63 Ball half shell Part No A405 610 00 35 113 Figure 4 64 Ball half shell Part No A405 610 01 35 114 Figu...

Page 286: ...rackets 141 Figure 4 100 Limited accessibility to holes on plate D70 142 Figure 4 101 Fastening plate code D70 included in D62 Part No A405 550 01 39 left A405 550 02 39 right 143 Figure 4 102 Overvie...

Page 287: ...ement 162 Figure 4 144 Implement mounting support manufactured by SCHMIDT for an order address of SCHMIDT parts see page 87 163 Figure 4 145 Example for use of code D60 164 Figure 4 146 Example for us...

Page 288: ...aulics circuit 3 214 Figure 6 16 Front connections of the power hydraulics circuit 4 214 Figure 6 17 Center power hydraulic connections circuit 3 214 Figure 6 18 Center power hydraulic connections cir...

Page 289: ...bility on the roof of the cab 257 Figure 9 18 Front support for roof mounted devices 258 Figure 9 19 Proposal for a front support 258 Figure 9 20 Dismounting of the interior light 259 Figure 9 21 Fast...

Page 290: ...1 4 Table of Tables Table 1 1 Unimog VIN Coding 19 Table 1 2 Minimum bending radii of plastic lines 24 Table 3 1 Vehicle and model designations 56 Table 3 2 Technical Data for mechanically implement d...

Page 291: ...ons 211 Table 6 10 Power hydraulics circuit III code H63 212 Table 6 11 Power hydraulics circuit IV code H64 213 Table 6 12 Parts list for high working pressure power hydraulic system 218 Table 6 13 D...

Page 292: ...ations 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...

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