Mercedes-Benz Unimog 435 User manual

Mercedes- Benz
Unimog
Workshop Manual
Unimog 435
Volume 1
Service

© Buch&Bild, Helma Wessel
Buch&Bild hat 1994 vom Produktbereich Unimog der damaligen Daimler-Benz AG
das Exklusivrecht fUr den Nachdruck dertechnischen Unimog- und MBtrac-Oldtimer-Literatur erhalten.
Silmtliche Rechte der Verbreitung -in jeglicher Form und Technik
einschlieBlich der Einspeicherung in elektronische Medien -sind vorbehalten.
Technical details ofthe vehicle
in relation to data and illustrations contained in this manual
are subject to change. All rights, including reprint, reproduction
or translation (also of extracts), reserved.
Nachdruck 2008
Printed in Germany
Buch&Bild
Helma Wessel
Finkenweg 13
D 76571 Gaggenau
TeL [phone]
Fax
+49 (0) 7225/4779
[email protected]
www.buchundbild.de
Stand 5.1989
UKD 30 402 21 42 03

The present Workshop Manual contains the descrip-
tions of all important assembly, adjusting, testing and
repair work.
The entirecontents of the Workshop Manual are subdi-
vided according to the well-known group system. The
group index serves to facilitate finding the individual
groups, the list of contents of each group serves to find
the individual jobs to be carried out.
The relevant data, settings, dimensions and toleran-
ces as well as the special tools are compiled on the first
pages of the respective groups.
Introduction
The contents are listed according to unit versions and further
subdivided into chapters and sections.
The contents are subdivided to provide smaller, integrated
sections. Each section begins with a new page 1 an~ is
identified as follows (example):
Removat and Installation ofSteeringSystem 46.1
Title of chapter
~ MS mechanical recirculating ball steering system L 3,5 K
I
Unit designation
Group
Unit version
Page reference:
Page
Section
Chapter I
4.1/1
All references to this page at any point throughout the Workshop Manual are expressed as follows:
See page 46.1-4.1/1.
UKD 30 402 21 42·03 © www.buchundbild.de 1

Introduction
The unit versions are consecutively numbered starting
with 1; i.e. each version has a special code number. In
addition, the unitdesignation
is shown at the head ofeach
page. A separating sheet and a detailed list of contents
head each unit.
The sections valid for all unit versions are covered in
version
O. The respective data (settings, tightening tor-
ques, machining dimensions etc.) and special tools are
listed together at the start of each unit version.
The numerical values
in SI units resulting from the intro-
duction of the international unit system are converted and
rounded-off values (in accordance with DIN 1335).
The pressure values specified in bar are positive.
Pressure In
bar
Previous Unil kp/cm2
(Kiloponds per square centimeter)
1 bar = 1.019716 kp/cm2 -1.02 kp/cm2
1 kp/cm2 = 0.980665 bar -0.981 bar
2
Power in kW (kilowatt)
Previous unit HP (horsepower)
1 kW= 1.360 HP
1 HP = 0.735 kW
Torque in Nm (Newtonmeters)
Previous unit kpm (kilopond meters)
1 Nm = 0.101972 kpm -0.102 kpm
1 kpm= 9.80665 Nm - 9.81 Nm
The specified part numbers and the figure numbers in the
exploded views are designed solely for identHication pur-
poses and improve differentiation between the individual
versions. When ordering spare parts, always use the part
numbers given in the valid microfiches.
The job descriptions provided in this Workshop Manual
make allowance for special versions (see 00 -1.6/1).
Special vehicles:
Type
Condor
Messrs Thyssen Henschel
0-3500 Kassel
Type TN 170
Messrs Thyssen Maschinenbau GmbH
0-5810 Wilten 6
We shall endeavour to keep this Workshop Manual up-to-
date by supplying the relevant"Supplementswhen neces-
sary.

Contents
Chapter
1 General
Installation survey
General view
Vehicle dimensions 435.115
Vehicle dimensions 435.111
Vehicle dimensions 435.115 (special vehicle with box-type body)
Maximum speeds 435.115/117
Maximum speeds 435.110/111
Weights and trailer loads
Service products, capacities
Special versions considered U 1300 L
UKD 30 40021 42 -04
General 00
Page
1.1/1
1.1/5
1.211
1.212
1.213
1.3/1
1.3/2
1.4/1
1.5/1
1.6/1

General 00
General view
UROO~01:tR
435.113
435.113
UKD 30 402 21 42 • 04
1.1/7

00 General
General view
435.115 Front- with box-type body
435.115 Rear- with box-type body
1.1/8

General 00
Installation Survey
Vehicle Model 435.110 I 435.111 435.113 ",
435.115 I 435.115" 435.117
Sales designation U 1700 U 1700 L U 1700
U38 U 1300 L U 1300
U37
Engine Model 353.961 353.961
353.959 oder 353.961 Or
353.959" 353.959"
Sales designation 352. Xl2 . 352. Xl2
352 A. VI2 Or 352.
Xl1
Or
352 A. L1111 '"
352 A.V12 352. A.V12
352.A.L1li1 " 352
A.L1111"
Installation
Series
Series with Series
Series Or SA 16457126 Or
SA
36019"
SA 35 975"
SA 36 019"
Single Model . -
clutch Sales designation F &S GFM 330 K replaced by F &S GMF 330
Installation
Series
Double Model - - - - -
clutch Sales designation DT 3301310 G -DT 3301310 G -DT 3301310 G
----
Installation SA 35 741
-SA
35 7!11
-
SA 35 741
Converter Model -- - - -
clutch Sales designation WSK 310 -WSK 310 -
Installation SA 35 948 - SA 35 948 -
Main Model 717.901 or 717.900 7t7.901
transmission Sales designation UG 3140 -13,01 GPA"
UG 3140 -13,01 GPA
Installation Series or
SA Series
ft,ith SA 35 977"1
Series
Auxiliary Model Working or crawler gear -
transmission Sales designation
NG 3140 - 215, 76 '" -
Installation SA 35 736 -
Power Version PTO shaft with pump connection
iake'off Ratio i = 1
Maximum speed 1/min
2800
' ..
Instalation SA 35 925
Version
PTO shaft
Ratio i =
0,71
. Maximum speed 1/min
4000
Installation SA 35 925
Hydrostatic Manufacturer Unde units -
system Sales designation Gr. 70/75 -
.-----
Installation SA 36 036 -
PTO shaft Version
Engine and transmission shaft 4)
--,..----.
Transmission Engine and
transmission
shaft 1] 31
transmission
shaft
.. _---
Ratio i = 4,32
SI/or 4,32 6)/2,46 7)
i = 4,32 ' I·
4,32
61
2,46 "
---,-"
Maximum speed 1/min 540lmin/or 540/1000/min 540 540:1000Imin.
._-_.
Installation SA 35 737 SA 35 73714
SA 35737
-
Version Fast engine and transmission PTO shaft -
'"
Ratio i = 0,745 -
i" 0,745
Maximum speed 1/min 3700
-
3700
Installation
SA 35 926 - SA 35 926
UKD 30 402
21 42-03 1.1/1

00 General
Installation Survey
Vehicle Model 435.110 435.111 I 435.113'" 435.115 I 435.115" 435.117
Sales designation U 1700 U 1700 L U 1700 U38 U 1300 L U 1300 U37
Front axle Model 737.200") or 737.201 737.111
Sales designation AU 311 S - 5,3 AU 2114 S - 4,0
Installation Series or SA
Series
with SA 35 973" Series
Rear axle Model 747.204 or 747.205 or 747.206 747.111 747.117
Sales designation
HU 311 S - 5,3 or HU 311 S - 6,8
HU 2114 S - 4,0
HU 2114 S-4,0
Installation Series or SA
Series withSA35974" Series
Steering Model 765.601 or 765.305 765.601
system Sales designation
-LS3BorLS7F
LS 3 B
Installation Series or with SA 35 776
Series withSA35976" Series
Steering Model --
pump Sales designation ZF 7672 or ZF 7673" ZF 7672 ZF 7673
. Installation Series or SA 35
776"
Series Series
Drivers gap Model 425.8211825
425.80018201821
425.820 425.8211825
Sales designation -- - -
Installation SA
Series or SA with SA SA
1) Basic unit with SA fording ability
2) Only valid for fire service vehicles
3) Connection only for front PTO shaft
4) Connection for front or front and area
5) Fast engine or transmission PTO shaft
6) From chassis end.No. 072513 i = 4,08
7) From chassis end No. 072 513 i = 2,32
8) Only
.in connection with steering system LS 7 F
9) Or UG 3140-819,35 GPA
10) Or NG
3140-3155,87
11) From engine end No. 691 150
12) From chassis end No. 084389 model 737.202
13) From chassis end
No. 084389
1.1/2

General 00
Installation Survey
Vehicle . Model 435.160 435.170
Sales Attachment Attachment
designation TM 170 Condor
Engine Model 353.959 353.977
Sales designation 352 A.LIII1 352 A.V!2
Installation Series.
Single Model -
clutch Sales designation GFM 330 K replaced by GFM 330
Installation
Series
.
Double Model -
clutch Sales designation -
Installation -
Converter Model -.
clutch Sales designation -
Installation -
Main Model 717.931 717.930
!ransmission Sales designation
UG 63/40-8/13,01 GPA
Installation Series
Auxiliary Model -
transmission Sales designation -
Installation -
Power Version
Transmission PTO shaft with pump connection
take·off Ratio i = 1
Maximum speed 1/min 2800 .
Installation
Series
Version
-
Ratio
-
Maximum speed llmin
-
Installation -
Hydrostatic Manufacturer
-
unit Sales designation -
Installation -
PTO shaft Version
-
transmission
-
Ratio -
Maximum speed llmin
-
Installation -..
Ratio -
Version
-
Maximum speed limin
-
Installation -
UKD 30 402 21 42 - 03
1.1/3

00 General
Installation Survey
Vehicle Model 435.160 435.170
Sales designation Attachment Attachment
TM 170 Condor
Front axle Model 737.232 737.231
Sales designalion AU 3/1 S·6,8
Installation
Series
Rear axle Model 747.231 747.230
Sales designation
HU 3/1 S-6,8
Inslallalion
Series
Sleering Model 765.305
system
sales designation
LS 7 F
Installation mil SA 35 776
Sleering Model -
pump
Sales designation ZF 7673
Inslallalion SA 35 776
Driver's cab
Model -
Sales designalion -
Installation -
1.1/4

General 00
General View
435.115
URO-0129
435.115
UKD 30 402 21 42'()3 1.1/5

00 General
General View
URO-0128
435.111
URO-0120
435.111
1.1/6

General 00
Vehicle dimensions 435115
12,5 -20
9,00 -20 14,5 -20
Tire sizes 12,5 R 20
11
9,00 R 20 14,5 R 20
Wheelbase
mm 3250 3250 3250
Track front
mm 1 860 1 860 1 860
Track rear mm 1 860
1860
1860
Track circle diameter mm
12890 12890
12890
Turning circle diameter mm
13800 13800
13800
Length without winch mm
5540 5540 5540
Length with winch mm
5870 5870 5870
Overall width (without rear·view mirror) mm
2300 2300 2300
Overall height (unladen)
2830 2880
,
2900
approx. mm
Height above
cab, unladen approx. mm 27502)
2630
2650
Ground clearance on a convex surface approx. mm 470 465 495
Overhang
front, without winch 0 46 46 46
Overhang
front, with winch 0 40
40 40
Overhang rear 0
51 51
51
approx.
Ground clearance,
front axle (laden) approx. mm
440 435 465
Ground clearance, rear axle (laden) approx. mm 440
435 465
Wading depth approx. mm 1 220 - -
Permissible height of center of gravity above platform
mm
800
--
floor for 2000 kg payload, with stabilier at front
Height of trailer coupling (unladen) mm 945 950 970
loading space
Length inside mm
3150 3150 3150
Width inside mm
2200 2200 2200
Height of side boards mm 500 500 500
Height beneath canopy top, min. mm 1 370 1 370
1370
Height beneath canopy top, max. mm
1480 1 480
1480
Loading height above ground -(unladen)' mm 1 290 1 285 1 315
1) special vehicle
2) with camoftage net support
UKO 30 402 21 42-02
1.2/1

00 General
Vehicle dimensions 435.110/.111/.113
Tire sizes mm
14}5/80 R 201)2)
12.5R22.5
14.5 -20 12.00 R 20
14.5 R 20 16/17-24 13 R 22.5
14.75/80 R 20
1)
Wheelbase mm
3850 3250 3250 3250
Track front mm 1840
1840 1 840 1 890
Track rear mm 1840 1 840 1840 1 890
Track circle diameter mm - 12880 12880 12930
Turning circle diameter mm 15800
14200
14200
14200
Length without winch mm 5580 5345 5345 5345
Length with winch approx. mm 6500
---
Overall width (without rear·view morror) mm 2350
2350 2350 2350
Overall width (with rear·view morror) mm 2465 2465 2465
2465
Overall height, unladen approx. mm
3050
3030 3010 3050
Ground clearance on a convex surface,
unladen approx. mm 680 660 640 680
Overhang
front
0 48 50
50
50
approx.
Overhang rear 0 47
approx. ---
Ground clearance, front axle (laden) approx. mm 520 500 480 520
Ground clearance; rear axle (laden) approx. mm 520 500 480 520
Wading depth approx. mm 1 200 1 200
1200 1 200
Height of trailer coupling (unladen) mm 1050 1050 1050
1 070
Loading space
Length inside mm 4050
3 1503) 3 1503)
3150
3)
Width inside mm
2350 2200 2200
2200
Height of side boards mm 500 500 500 500
L.oading height above ground (unladen) mm 1 500 1 480
1460
1 500
1; 13.>:'0 -20 Pilate XL
2) 435.113
3) at L~35.110 opti'onal2050, 2550, 3000
'1.2/2

c
"
o
'"
o
"
:;l
'Y
I:>
~
......
~
------.-==--~~-~
0'
"-
....
JC[] ffi\
• I • 3250 • I
I- -5560 • I
A Unladen
B At maximum load
C Unladen
o Upper edge of frame
E Upper edge of floor
F Laden
iil
f
I
I
I
II I I I I I
G Unladen
H Transit loading dimension
J Inside length
= , -
;;:
o
o
,
o
o
N
:::>
\I;
I~
, \ I
-<
(JJ ..
"O::r
<1> _,
Q.2.
!!C ..
<e:
~3
_ ...
!2"
<1> en
:; 0'
;::;'::l
::Ten
0' ....
0""
Xu.
~~
"0 ~
mu.
8:
:::.
G)
CD
::J
CD
@
o
o

Maximum speeds 435.115/.117
Total
axle
ratio
6.53
1 2 3
c:
.~
6.0
8.7
13.2
~
.~
t::!
6.3
9.1 13.7
c:
'"
b "
Cl
.S
c:
6.3 9.1
13.8
'"
.;;
:;; :;;
6.6
9.5
14.4
6.1
8.7
13.2
6.1
8.9
13.4
1) Locked with SA 35 985
2} standard
Total
axle
ratio
5.31
1 2 3
7.4 10.7 16.2
c:
.~
7.7
11.1 16.9
'E
c:
~
:;;
b "
7.8
11.2 17.0
Cl
.S
.S
'"
'"
:;;
:;;
8.1 11.7 17.7
7.4 10.7 16.2
7.6 10.9 16.5
1) Locked with
SA 35 985
2) standard
UKD 30 402 21 42--D2
Forwards
4 5 6
17.9 26.4 38.1
la6 27.5 .39.7
18.8
27.8 40.0
19.6
28.9
41.7
18.0
26.5
38.2
18.2
26.9
38.8
Forwards
4 5 6
22.0 32.5 46.8
22.9
33.8
48.8
23.2
34.1
49.2
24.1 35.6 51.3
22.1 32.6
47.0
22.4 33.1 47.7
7
57.7
60.1
60.6
63.2
57.9
58.7
7
71.0
73.9
74.6
77.7
71.2
72.2
General 00
Maximum speeds km/h
at engine rated speed 2800/min
Reverse
Tires
8 1 2 3 4
51 f 61) 71
) 81)
18·20
78.5 6.2 9.0
13.6 18.5 27.2 39.2 59.4 80.9
12.5 - 20
2)
81.7 6.5 9.3
14.1 19.3
28.4 40.8 61.9
84.2 12.5 R
20
82.5 6.5 9.4
14.3 19.4 28.6 41.2
62.5 85.0 14.5 - 20
85.9 6.8
9.8 14.9 20.3 29.8 43.0 65 .. 1 88.6 14.5 R
20
78.8
6.2
9.0 13.6
18.6 27.3 39.4 59.6 81.2 9.00·20
79.9 6.3 9.1 13.8 18.8 27.7
39.9 60.5 82.4 9.00 R 20
Maximum speeds km/h
at engine rated speed 2800/min
Reverse Tires
8 1 2 3 4
51 ) 61) 71) 81
,'
96.5. 7.6 11.0 16.7 22.8 33.5
48.2
73.1 99.5 18 -20
12.5 -20
21
100.5 8.1 11.5 17.4 23.7 34.9 50.2 76.1 103.6
12.5R20
101.4 8.0 11.6 17.5
23.9
35.2
50.7 76.8
104.5 14.5 - 20
105.7 8.4 12.1 18.3
24.9
36.7
52.8 80.0 109.0 14.5 R 20
96.8
7.7 11.1 16.8 22.8 33.6 48.4
73.3
99.8
9.00 - 20
98.2 7.8 11.2 17.0
23.2
34.1 49.1 74.4 101.3
9.00 R 20
1.3/1

00 General
Maximum speeds 435.110/.111/.113
Total
axle Maximum speeds km/h
ratio at engine rated speed 2800/min
6.38
Forwards
Reverse
1 2 3 4 5 6 7 8 1 2 3 4
5'} 6'} 7' }
8'}
6.5
904
14.2 19.3 2804 41.0
62.1
84.4 6.7 9.7 14.6 19.9 29.3 42.2 63.9
87.0
6.8 9.8
14.8 20..1 29.6 42.7
64.7
88.0 7.0 10..1 15.2 20.7 30..5 44.0. 66.6
90..7
c:
0
7.4 10..6 16.1 21.9 32.3 46.6 70..6 96.0. 7.6 11.0. 16.6 22.6
33.3 48.0 72.7
99.0
oB;
"§
~
7.1 10.3 15.6 21.2
31.2 45.0. 68.2
92.7 704 10..6 16.0 21.9 32.2 46.3 70..2 95.6
c:
~
..
"
'"
c:
c:
.n; .n;
6.6 9.6 14.5 19.7 29.1 41.9 63.5
86.4
6.9 9.9 14.9
20.04 30.0
43.2 65.4
89.0
:2 :2
7.0 10..1
15.2 20..7 30..6 44.1 66.8
90..8 7.2
lOA 15.7 21.4
31.5
4504 68.8
93.7
6.0. 9.9
15.0.
20.04 30..1 43.3
65.6
89.3 7.1 10.2 1504
21.1
31.0 44.6 67.6
92.0
I} Locked with SA :is 985
2) standard
Total
axle
ratio
5.40
1 2 3
7.66 11.0.5
16.72
7.98 11.52 17.44
c:
0
.~
8.71 12.56 19.0.2
.~
~
c:
:;;
8041 12.14 18.38
~
"
~
Cl
.!:
c:
'"
.n;
7;84 11;31 17.11
:2
:2
8.25 11.90.
18.0.1
8.11 16.69 17.70.
1} Locked with SA 35 985
2} standard
1.3/2
Forwards
4 5 6 7
22.75
33.55 48.39 73.31
23.73
34.99 50047 76.47
25.87 38.15 55.0.3
83.37
25.00
36.87 53.18 80.57
23.79 34.33
49.53 75.0.3
24.51 36.13
52.12
78.96
24.08 5.51
31.22 77.59
Maximum speeds km/h
at engine rated speed 2800/m in
Reverse
8 1 2 3 I 4
5' }
6'} 7'}
I 8'}
99.64 7.91 11040. 17.24 23.50 34.50. 49.82 75047 102.69
17.98/24.51 I
10.3.94 8.25 11.89 36.06
5}.97 78.721107.11
113.32
8.99 12.96
19.61 26.72 39.35
56.6~ 85.821,,6.78
I f
109.51 8.69 12.53 18.95125.82 38.0.3 54.76 82.941
11
2.85
10.1.99 8.0.9 11.67 17.65124.05 35042 50.99
77.24
105.10
107.33 8.52
12.28 18.57 25.31 37.27153.6 81.29 110.61
105.47 8.37 12.07 18.25 24.87 36.63 52.73 79.88 108.69
Tires
14.5·20
16170.·24
12 R 22.5
2}
14.5 R2o.
14.5 R 24
14.5·24
11.0.0.·20.
11.DDR2D
12.00R2D
13R22.5
16170.·24
14.75/80 R 20
12.00.·20.
Tires
14.5·20
16/70.·24
12.5 R 22.52}
14.5 R 20
14.5 R 24
14.5·24
11.00·20
11.0.0. R 20
12.00R20
13 R 22.5
16170.· 24
14.75/80 R 20
12.00.·20.