Unimog U3000 2006 - User Manual

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DaimlerChrysler AG

UNIMOG Division

D-76742 Woerth

Body and Implement Mounting Directives

U3000/U4000/U5000

Edition 2006

Main Page

Table of Contents3
General19
General Notes19
Vehicle Type and Model Designations21
Technical Advice21
Registration/Licensing22
General22
Acceptance/Approval in EU22
Technical Data, Differences between U3000/U4000/U500023
Engine (EURO 3)23
Transmission23
Axles23
Warranty Rights24
Mercedes Star and MB Badge24
Maintenance Instructions25
Anti-Corrosion Measures25
Accident Prevention26
Recycling and Reuse of Components26
Quality Management System Recommendation27
Field of Application for the U3000/U4000/U500028
Legal References, Product Liability and CE Mark29
Legal References29
Product Liability29
Product Liability in EC Countries30
CE Mark31
Accident Prevention and Safety Directives32
General Notes32
Delivery of Chassis32
Prevention of Accidents on the Vehicle32
Plastic Compressed-Air Lines, Fuel Lines and Brake Lines33
Welding Operations34
Springs35
Painting Operations35
Towing and Tow-Starting36
Electrical System36
Mobile Communication Systems37
Requirements on Mobile Communication Equipment37
Electromagnetic Compatibility (EMC)37
Implement Drives38
Mounted Implements and Bodies39
General Notes39
Clearance for Free Movement of Chassis Components, Implements/Bodies at the Chassis40
Modifications to the Chassis41
Dimensions and Weight Specifications42
Springs and Suspension Diagrams, General Notes43
U3000/U4000 Suspension Graph (Old)44
U5000 Suspension Graph46
Unladen Weight U3000/U4000/U500047
Unladen Weight of Actual, Typical Chassis47
Permissible Axle Loads (Kg) and Gross Vehicle Weights (Kg) (Not Applicable for Special Bodies)48
Weight Distribution (L/R Wheels on the same Axle)49
Coordinate Systems49
Centre of Gravity (Cog)51
General Notes on the Centre of Gravity51
Determination of the Centre of Gravity51
Cog Coordinates in X Direction (Axle Load Distribution FA/RA)51
Calculation Procedure for Determination of the Height of the Overall Centre of Gravity (Cog)56
Determining the Height of the Centre of Gravity by Means of a Tilt Test57
Chassis Centre of Gravity (Cog)58
Maximum Permissible Cog Height58
Anti-Roll Bars60
Calculating the Tilt Speed When Cornering61
General Notes on Vehicle Components62
Chassis Overhang62
Trailer Coupling62
Tyres64
Cooling64
Engine Air Intake64
Soundproofing65
Important Note65
Exhaust System66
Springs67
Brake System67
Side Marker Lights67
Maintenance and Repair69
Permissible Loads/Weights69
Secure Mounting of the Implement/Ballast on the Vehicle70
Variable Overall Cog Position Due to Implement Operation71
Static Test71
Test Conditions71
Dynamic Test71
Mounting Implements to the Front of the Vehicle72
General Notes72
Front Mounting Plate (FMP)73
Overview, Implement Mounting Brackets at the Front of the Chassis Frame77
Front Mounting Support (Code D10)78
Winch Mounting Brackets80
Permissible Load (Weight, Force or Torque) Application to the Front Mounting Plate (FMP)82
Front End Dimensions83
Notes on Mounting Snow Ploughs84
Mounting Bodies or Implements to the Chassis Frame85
Torsion/Relative Movement/Clearances to Vehicle Components85
Rear Axle Articulation/Clearance between Rear Wheels and Body87
3-Point Mounting/4-Point Mounting, Capable of Chassis Torsion (2 X 3-Point Mounting)88
Mounting Bodies or Implements on the Platform of a Dropside Body91
Mounting of Subframes for Heavy Implements (E.g.: Cranes, Excavators), Code D6092
Implement Mounting Points (Code D60) at Centre of the Chassis Frame96
Lashing Eye Fitted to Implement Mtg. Point D6098
Body Mounting Components for "Non-MB Bodies" (Code D65)99
Code D65 Body Mounting Parts for U3000/U4000 Without X21100
Code D65 Body Mounting Parts on U5000 and U4000 with X21101
Body Mounting, Crossmember U3000/U4000102
Body Mounting, Crossmember U5000102
Body Mounting, Front Crossmember U3000/U4000 W. N16 or N19103
Body Mounting, Front Crossmember U5000 W. N16 or N19104
Installation of Body Mtg. Crossmember in Conjunction with Power Take-Off, Code N16/N19105
Pivot Bearings and Fixed Bearings (Code D65), Installation Details106
Subframe Assemblies P61/P69 for Special Bodies (Particularly Suitable for Box Bodies, Etc.)109
Subframe Assemblies (Code P61) for the U3000/U4000110
Subframe Assemblies (Code P61) for the U5000111
Subframe Assemblies (Code P69) for the U5000L112
Body/Implement Dimensions, Length and Width113
Notes on Rear and Side Underrun Protections119
Tractors for Semitrailers119
Rear Mounting Points120
Implement Drives122
Mechanical Drive122
Notes on the Transmission Ratio122
General Notes on the Mechanical Drive123
Important Notes123
Safety Instructions Regarding the Mechanical Implement Drive124
Power Take-Offs124
General Notes on N16/N19 Power Take-Offs124
Direction of Rotation, Engine Speed and Available Output of N16/N19 Power Take-Offs125
Remote Conrol for Clutch, General Information126
Hydraulic Pumps for N16 Power Take-Off128
Bending Moment at the Mounting Flange130
Mounting Flange of Power Take-Off N16131
Drive Flange Design of N19 Power Take-Off132
Flange Drive at N16 Power Take-Off133
Position Diagram of N16/N19 Power Take-Offs134
N16/N19 Power Take-Offs134
Information on Engine Features Relevant to the Implement Drive135
Speed Control135
Intermediate Engine Speed Limiter135
Drive Shafts for Implements136
General Notes on Drive Shafts136
Delivery Condition136
Transport and Mounting136
Installation and Assembly137
Design138
Joint Angles138
Single Plane Shaft Layout139
Three-Dimensional Shaft Layout139
Forces in the Drive Shaft System140
Assembly of the Drive Shaft140
Bearings141
Imbalance141
Maintenance141
Hydraulic System142
General Notes on the Hydraulic System142
Typical Applications for the Hydraulic System H10143
Snow Plough/Grit Spreader Combination144
General Notes on Using the Vehicle Hydraulic System145
Hydraulic System Interfaces/Connections146
Data on the Connections146
Hydraulic Couplings at the Front146
Hydraulic Couplings at the Rear, Option Code H50147
Pressure Connection147
Vehicle Hydraulic System H10, Circuit Diagram148
Data of the Hydraulic System, Code H10149
Important Note about the H10 Hydraulic System149
Hydraulic Power Output151
Fluid Temperature Tests to be Carried out by the Implement Manufacturer152
Types of Fluid152
Hydraulic Couplings at the Implement154
Electrical System156
General Notes on the Electrical System156
Vehicle Electrical System Data156
Lighting157
Adjusting the Headlights157
Electrical Wiring157
Current Draw of Auxiliary Consumers158
Electrical Interfaces159
Sockets in the Cab159
Trailer Sockets at the Rear of the Vehicle160
Implement Socket at the Front of the Vehicle, E45162
Implement Socket Option Code E47 (Option Available until 2006)163
Implement Socket E87, Pin Assignment (E87 Without PSM, Option Code E16)165
Programmable (Parameterizable) Special Module - PSM167
Typical PSM Functions167
Implement Socket E87, Pin Assignment (E87 with PSM, Option Code E16)168
Engine Remote Control169
Plugs for Sockets173
W-Codes174
Road Speed Signal (C3) and Distance Travelled Signal (C4)178
Voltage Transformer179
Electromagnetic Compatibility179
Pneumatic Auxiliary Equipment180
General Notes on the Pneumatic System180
Pneumatic Auxiliary Consumers180
Four-Circuit Protection Valve181
Connection for Pneumatic Auxiliary Consumers, Code Y31182
Table of Connection Parts to be Used for the Auxiliary Consumer Distributor185
Technical Data185
Modifications to the Chassis Frame186
Frame Data186
Overview Chassis Frame Variants187
U3000/U4000, Wheelbase 3250 MM, Model 437.420188
U3000/U4000, Wheelbase 3850 MM, Model 437.425189
U5000, Wheelbase 3250 MM, Model 437.430190
U5000 Wheelbase 3850 MM, Model 437.435191
Chassis Frame Materials192
Drilling Holes into the Frame192
Bolted Connections193
Frame Modifications194
Frame Extensions194
Welding at the Chassis Frame195
Further Precautionary Measures195
The Joint Must be Checked at Regular Intervals Following Welding195
Design Instructions for Extending the Frame196
Seam Preparation197
Directives for Seam Preparation197
Welding Sequence197
Subsequent Treatment of Welding Seams198
Reinforcement of the Welded Joint198
Reducing the Frame Overhang200
Wheelbase Modifications200
Mounting of Implements and Auxiliary Components201
Mounting at the Chassis Frame201
Wheel Chocks202
Mudguards and Wheel Houses202
Spare Wheel202
Rear Underride Protection203
Side Underride Protections in Accordance with 89/297/EEC204
Rear Crossmember204
Cab205
Tilting the Cab205
Before Tilting the Cab205
Cable Passage into the Cab207
Cable Passage through a Panel at the Rear Side of the Cab (Left Side in the Direction of Travel)207
Cable Passage through the Front Wall of the Cab208
Proposal for a Cable Passage through the Rear Window209
Attachments on the Cab Roof211
Roof Brackets211
Fitting an Aerial to the B-Pillar212
Mounting an Implement Control Panel in the Cab213
Connectors (Electrical)213
Relative Movement between Cab and Body in Case of Chassis Frame Torsion214

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Unimog U3000 2006 Specifications

General

Brand	Unimog
Model	U3000 2006
Category	Utility Vehicle
Language	English

Unimog U3000 2006 - User Manual

Table of Contents

Unimog U3000 2006 Specifications