Unimog U500 Instruction Manual

BODY & IMPLEMENT
MOUNTING GUIDELINES
NORTH AMERICA

Body and Implement Mounting Guidelines U500 North America Table of Contents
This is the 2005 Body and Implement Mounting Guideline for the Unimog
U500 North America.
Request additional copies through your local dealer or via email:
[email protected]
The specifications and descriptions contained in this guide are believed to
be accurate at the time of publication. In a continuing effort toward product
improvement, changes affecting this data may be made without notice.
Important Information
This document is provided as an aid to intermediate and final stage manu-
facturers in determining conformity to applicable U.S. and California Emis-
sion Control standards, and U.S./Canadian Motor Vehicle Safety Standards
and other applicable standards. This document is not a substitute for
knowledge of the requirements of these standards. Final stage manufactur-
ers should maintain familiarity with all current Emissions Control and
U.S./Canadian Motor Vehicle Safety Standards and be aware of their spe-
cific responsibility in regard to each standard.
The U.S. and Canadian Governments have established Motor Vehicle
Safety Standards for various categories of motor vehicles and motor vehicle
equipment under the provisions of the National Traffic and Motor Vehicle
Safety Act (United States) and the Canadian Motor Vehicle Safety Act
(Canada). The Acts impose important legal responsibilities on manufactur-
ers, dealers, body builders, and others engaged in the manufacturing and
marketing of motor vehicles and motor vehicle equipment.
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
particularly so because the standards and other requirements or interpreta-
tions are subject to change by government agencies in charge, the National
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 will appear in the Federal Registry from time to time.
You may obtain the Federal Register through the Superintendent of Docu-
ments, U.S. Government Printing Office, Washington, D.C. 20502
(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 final stage manufacturer is solely responsible for the final certification
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.
Freightliner LLC neither approves nor disapproves and does not warrant
vehicle component or chassis modifications or equipment installations ar-
ranged by dealers or customers and performed by entities other than
Freightliner LLC, since Freightliner LLC has no control over the work being
performed by the various vehicle body equipment builders.
If dealers or customers have any vehicle modifications or equipment instal-
lations performed, to the extent these modifications or equipment installa-
tions adversely affect other vehicle components or vehicle performance,
Freightliner LLC's shall not accept any product liability or claims under
terms of the vehicle warranty. These claims become the sole responsibility
of the person performing the modifications or equipment installations.
If additional technical information or explanation concerning the contents of
this vocational reference guide is required, contact the Unimog Implement
Manager:
Unimog North America, Phone: [phone]
[email protected]
(c) 2005 Freightliner LLC
All rights reserved. Reproduction or translation in whole or in part is not
permitted without written authorization from the publisher.
Fifth edition: August, 2005

Body and Implement Mounting Guidelines U500 North America Table of Contents
For your orientation:
This is the fifth edition of the Unimog Body & Implement Mounting
Guidelines and contains the following new subjects:
•Chapter 6 Hydraulic system:
oFront hydraulic connectors of power hydraulics,
closed circuit (code H93)
•Chapter 7 Electrical system:
oBulb warning system & Installation of L.E.D. lights
oUnimog ground points (isolated ground system)
oCurrent consumption – auxiliary consumers
The following chapters have been updated:
•Chapter 1.11.5 Welding operations
•Chapter 3 Vehicle Information
•Chapter 5.8 Engine dependent power take-off (code N05)
•Chapter 5.10.4 Direct flange mounting on auxiliary PTO N16
•Chapter 8 Pneumatic Consumers
•Chapter 10.1 Chassis frame data

Body and Implement Mounting Guidelines U500 North America Table of Contents
August 2005 Page 9 of 294
Table of Contents
1General Information.....................................................15
1.1 Introduction ....................................................................15
1.2 Emission, Noise and Safety...........................................17
1.3 Identification...................................................................19
1.4 Requirements for implement mounting and operating ......
instructions.....................................................................20
1.5 Warranty rights ..............................................................20
1.6 Maintenance instructions ...............................................20
1.7 Corrosion protection measures......................................21
1.8 Accident prevention .......................................................21
1.9 Recycling – Re-use of components ...............................22
1.10 Product liability...............................................................22
1.11 Damage prevention and safety regulations ...................23
1.11.1 General notes ................................................................23
1.11.2 Delivery of chassis.........................................................23
1.11.3 Prevention of accidents on the vehicle ..........................23
1.11.4 Plastic compressed-air, fuel and brake lines .................23
1.11.5 Welding 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 (EMC) .........................27
1.11.12 Implement drives ........................................................27
2Applications .................................................................29
2.1 Front mounted mowers..................................................29
2.2 Rear mounted mowers .................................................. 30
2.3 Spreaders ......................................................................31
2.4 Snow plows ...................................................................32
2.5 Wing plow ......................................................................33
2.6 Snow cutters / blowers ..................................................34
2.7 Suction sweepers ..........................................................35
2.8 Front mounted sweepers...............................................36
2.9 Winches.........................................................................37
2.10 Aerial devices (man lifts) ...............................................38
2.11 Cranes ...........................................................................39
2.12 Drill devices ...................................................................40
2.13 Front end loaders ..........................................................41
2.14 Front mounted devices ..................................................42
2.15 Sewer cleaning devices.................................................43
2.16 Water tanks ................................................................... 44
2.17 Front mounted 3-point hitches.......................................45
2.18 Rear mounted 3-point hitches .......................................46
2.19 Fire bodies.....................................................................47
2.20 Refuse collection vehicles .............................................48
2.21 Box bodies.....................................................................49
2.22 Wood chipper (front mounted).......................................50
2.23 Concrete mixers ............................................................ 51
2.24 Diggers / excavators......................................................52
2.25 Skip loader.....................................................................53

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2.26 Rear mounted small cranes...........................................54
3Vehicle Information .....................................................56
3.1 General Technical Data .................................................56
3.2 Technical Data of implement drives...............................58
3.2.1 Mechanical drives ..........................................................58
3.2.2 Hydraulic drives .............................................................58
3.3 Vehicle drawings............................................................59
3.3.1 U500 NA, wheelbase: 131.89 in / 3,350 mm .................59
3.3.2 U500 NA, wheelbase: 153.54 in / 3,900 mm .................61
4Implement / Body Installation.....................................64
4.1 General Notes................................................................64
4.2 Free movement of implements/bodies on the chassis...64
4.3 Vehicle modifications .....................................................65
4.4 Dimensions and weight specifications ...........................66
4.5 Weight distribution .........................................................67
4.6 Suspension graph..........................................................67
4.7 Coordinate systems .......................................................70
4.8 Center of gravity ............................................................71
4.8.1 General information .......................................................71
4.8.2 Determination of the center of gravity............................71
4.8.3 Chassis center of gravity ...............................................76
4.8.4 Permissible height of center of gravity...........................76
4.8.5 Anti-roll bars...................................................................77
4.9 General notes on vehicle components ..........................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 / counterweights......... 80
4.11 Bodies with changing overall center of gravity...............82
4.11.1 Static check ...................................................................82
4.11.2 Dynamic check ..............................................................83
4.12 Mounting of implements ................................................84
4.13 Front mounting of implements .......................................85
4.13.1 General notes to front mounting ....................................85
4.13.2 Front mounting plate...................................................... 85
4.13.3 Integrated implement support........................................89
4.13.4 Permitted implement weights; permitted forces and .........
torques on the front mounting plate...............................92
4.13.5 Front end dimensions ....................................................92
4.14 Center mounting of implements and bodies ..................93
4.14.1 Bodies/implements with variable overall c.o.g...............93
4.14.2 Bodies/implements on the platform ...............................96
4.14.3 Bodies/implements on the ball points ..........................109
4.14.4 Dimensioning of implement mounting frames..............123
4.14.5 Bodies/implements directly mounted at the chassis .........
frame without outriggers (e.g. shelters, fire bodies,.. ).133
4.14.6 Bodies/implements with outriggers..............................141
4.14.7 Mounting space under the cab ....................................160
4.14.8 Implement mounting between the axles ......................160

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4.15 Rear mounting of implements and bodies ...................166
5Mechanical drive of implements...............................168
5.1 Notes on the transmission ratio ...................................168
5.2 General notes on mechanical implement drives..........168
5.3 Overview of available mechanical PTO’s for Unimog: .169
5.4 Safety instructions for mechanical implement drives...169
5.5 Overview and positions of power take-offs ..................170
5.6 Maximum available power output of the PTO’s ...........171
5.7 Engine controls and speed settings.............................171
5.8 Engine dependent power take-off (code N05) .............172
5.8.1 Technical data for N05 auxiliary power take-off...........172
5.8.2 Vibration absorber .......................................................174
5.9 Power take-off shaft drive (code N08) .........................176
5.9.1 General notes ..............................................................176
5.9.2 Usable power output of the power take-off shaft .........177
5.9.3 Technical data of power take-off shaft drive N08.........178
5.9.4 Power take-off shaft profile (according to SAE J499a) 178
5.9.5 Position of PTO shaft...................................................179
5.9.6 Calculation of the PTO shaft height above ground ......180
5.10 Auxiliary power take-off drives (code N16/N19) ..........182
5.10.1 General notes on auxiliary PTO’s (code N16/N19)......182
5.10.2 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 implements .........................................189
5.11.1 General information on drive shafts.............................189
5.11.2 Angle of deflection/joint angle “β” of drive shafts.........190
5.11.3 Forces in the drive shaft system..................................191
5.11.4 Assembly of the drive shaft .........................................192
5.11.5 Bearing ........................................................................192
5.11.6 Unbalance ...................................................................192
5.11.7 Maintenance ................................................................192
6Hydraulic system....................................................... 194
6.1 Overview of codes and hydraulic circuits on the Unimog194
6.1.1 Hydraulic drives ...........................................................194
6.1.2 Overview of available hydraulic equipment .................195
6.1.3 General instructions for the use of the Unimog ................
hydraulic system..........................................................198
6.1.4 Oil heating ................................................................... 198
6.2 Basic hydraulics...........................................................199
6.2.1 Information to the basic hydraulic system ...................200
6.2.2 Shut-off valve...............................................................207
6.2.3 Volume flows of the basic hydraulic systems .............. 207
6.2.4 Dealers for hydraulic couplings in the USA .................210
6.2.5 Tema parts list for Unimog hydraulic connectors ........210
6.3 Information to the power hydraulic systems ................ 211
6.3.1 Power hydraulic flow rates........................................... 211
6.3.2 Drawings of the power hydraulics................................ 212
6.3.3 Front connectors of the power hydraulic system ..............
(code H93 & H94)........................................................214
6.3.4 Center power hydraulic connections ...........................214
6.3.5 Volume flows of the power hydraulic systems.............215
6.3.6 Parts list for power hydraulic system ...........................218

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6.3.7 Dealer for power hydraulic couplings in the USA.........218
6.4 Further information on Unimog hydraulic systems.......219
6.4.1 Hydraulic output / standard values ..............................219
7Electrical system .......................................................221
7.1 General notes on the electrical system........................221
7.1.1 Technical data of the electrical system........................221
7.2 Lighting ........................................................................221
7.3 Electric cables..............................................................223
7.4 Current consumption - auxiliary consumers.................224
7.5 Unimog ground points..................................................226
7.6 Electrical interfaces......................................................226
7.6.1 Power outlet in the cab (E37) ......................................226
7.6.2 Implement socket at the front of the vehicle ................227
7.6.3 Implement socket on the battery box...........................228
7.6.4 Rear trailer socket........................................................230
7.7 Engine remote control..................................................231
7.7.1 Remote control functions .............................................231
7.7.2 Examples for designing an external manual control ....233
7.7.3 Important note for engine remote controls...................235
7.8 W code descriptions ....................................................235
7.9 Preparation for the installation of roof-mounted ................
auxiliary headlights ......................................................238
7.10 Modification of the raised headlights code L47............239
7.11 Road speed signal and travel dependent signal..........239
7.12 Electromagnetic compatibility ......................................240
8Pneumatic Consumers ..............................................242
8.1 General notes to pneumatic consumers ......................242
8.2 Technical data of the compressed air system .............242
8.3 Air extraction................................................................243
8.3.1 Air extraction on vehicles without CTIS .......................243
8.3.2 Air extraction on vehicles with CTIS ............................243
9Cab..............................................................................249
9.1 General notes ..............................................................249
9.2 Tilting the cab .............................................................. 249
9.3 Cable passage into the cab .........................................251
9.3.1 Cable passage through the rear wall of the cab ..........251
9.3.2 Cable passage through the front wall of the cab .........251
9.3.3 Pass-through plug ....................................................... 252
9.3.4 Important notes on cable passages into the cab .........257
9.4 Mountings on the cab ..................................................257
9.4.1 Roof loads / roof bars ..................................................257
9.4.2 Aerial mounting............................................................262
9.5 Attaching of an implement control console in the cab .262
10 Chassis frame modifications....................................272
10.1 Chassis frame data......................................................272
10.2 Chassis frame dimensions ..........................................272
10.2.1 Cross-section of the chassis frame..............................272
10.2.2 Chassis frame of the U500, short wheelbase..............273
10.2.3 Chassis frame of the U500, long wheelbase ............... 274
10.3 Chassis frame material................................................275
10.4 Rear cross member ..................................................... 275
10.5 Wheel chocks ..............................................................275
10.6 Mounting of implements ..............................................275

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10.7 Drilling on the frame.....................................................276
10.8 Bolted connections ......................................................277
10.9 Welding on the frame...................................................278
10.9.1 General notes for welding on the frame.......................278
10.9.2 Welding preparation.....................................................279
10.9.3 Regulations for seam preparation................................280
10.9.4 Welding procedure.......................................................280
10.9.5 Seam finishing .............................................................280
10.10 Frame extensions ........................................................280
10.10.1 Design instructions for extending the frame.............281
10.11 Shortening of the frame ...............................................283
10.12 Wheelbase extensions.................................................283
11 Appendix ....................................................................285
11.1 Conversion Table.........................................................285
11.2 List of Abbreviations ....................................................286
11.3 Table of Figures...........................................................286
11.4 Table of Tables ............................................................293

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Body and Implement Mounting Guidelines U500 North America General Information
August 2005 Page 15 of 294
1 General Information
1.1 Introduction
Figure 1.1: Unimog U500 North America
This manual is a source of basic information for body, implement and
equipment manufacturers, and dealers who install their products on the
Unimog. Information on possible mounting, electrical connections and
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.
The information in this manual is believed to be accurate to the best of
our knowledge at the time this manual was approved for publication.
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
particular vehicle, or as authorization by Freightliner LLC for the as-
sembly, modification, or alteration of any particular vehicle, whether
delivered by Freightliner LLC in complete or incomplete state of manu-
facture. 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
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-
lication or technical information is required, please call the Unimog
Implement Manager listed at the beginning of this guideline.
If you choose to contact us by mail our address is:
Unimog North America
6650 N Basin Ave, Ste. A
Portland, OR 97217
As a vehicle manufacturer, Freightliner LLC neither approves nor
disapproves truck chassis modifications or equipment installations
because Freightliner LLC cannot and does not control the manu-
facturing and installation techniques of the various
body/implement/equipment builders.

Body and Implement Mounting Guidelines U500 North America General Information
Page 16 of 294 August 2005
Implement manufacturers and companies who mount bodies, imple-
ments and equipment to Unimog U500 should have the following
documents:
•The current Unimog option list containing description of the Uni-
mog models and all optional equipment available
•The Unimog technical data book with all technical data and im-
portant additional information
•Body and Implement Mounting Guidelines including all informa-
tion on mounting implements and the Freightliner LLC require-
ments for implement mounting.
These documents form the basis for the development, modification
and review of bodies, implements and equipment of all types,
which are temporarily or permanently mounted on and operated with
the Unimog. The development and review of implements or bodies
for the Unimog does not, in principle, entitle claims for costs or dam-
ages to be made against Freightliner LLC. This also applies with re-
gard to compliance with road traffic law and accident prevention as
specified in the national and international regulations on road traffic
and technical equipment.
Particular reference is made to the responsibility of the implement
manufacturer for his scope of delivery and to the rules of safety to
be complied with in respect of the vehicle/implement interface.
The instructions given must be observed exactly to maintain the op-
erating and road traffic safety of the chassis and to maintain war-
ranty rights.
Illustrations and drawings are examples only 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 available with the fol-
lowing documents:
•Body and Implement Mounting Guidelines
•Unimog Chassis Drawings (two-dimensional data in .dwg
and .dxf format)
•Technical Data Book
•Unimog Option List
•Unimog Weight Calculator and Axle Load Calculations
•Center of Gravity Calculation
The Unimog Resource CD can be requested from the Unimog Im-
plement Manager.
Instructions regarding vehicle safety
We recommend the following:
Only use genuine Mercedes-Benz service parts and conversion
parts and accessories, which have been explicitly approved by
Freightliner for use with your vehicle model. Such parts have been
specially tested for safety, reliability and suitability.
Freightliner can give no guarantee with regard to reliability, safety
and suitability in the following cases:
•If original parts or approved conversion parts or accesso-
ries have been exchanged for other parts or other changes
have been made to the vehicle.
•If bodies are not manufactured or mounted according to
the valid Body and Implement Mounting Guidelines or if, in
the event of deviations, the approval of Freightliner is not
sought.
Official acceptance by public testing bodies or official approval
does not rule out safety hazards.
Please contact the Unimog Implement Manager listed at the be-
ginning of this guideline for further general technical data of the
Unimog, which is not contained in this Body and Implement
Mounting Guideline.
Confidential. All rights reserved. Reproduction or translation
in whole or in part is not permitted without written authoriza-
tion from the publisher.

Body and Implement Mounting Guidelines U500 North America General Information
August 2005 Page 17 of 294
1.2 Emission, Noise and Safety
The purpose of this information and the following summarized text is to
assist you in interpreting the Federal Motor Vehicle Safety Standards
(FMVSS) and Canadian Motor Vehicle Safety Standards (CMVSS) for
vehicles and how to apply to the sale of the Unimog U500 NA in the
U.S. and Canada.
Unimog U500 NA manufactured by Freightliner LLC is certified for com-
pliance with the U.S. Federal Motor Vehicle Safety Standards and the
Canadian Motor Vehicle Safety Standards.
The vehicle certification is a requirement of the National Traffic and Mo-
tor Vehicle Safety Act (United States) and Canadian Motor Vehicle
Safety Act (Canada). The FMVSS and CMVSS regulations control the
manufacturer and sale of motor vehicles and their usage. Other laws
apply to the application and use of vehicles. Owners or operators using
vehicles are responsible for those vehicles meeting certain legal re-
quirements. The MVSS laws, by contrast, put the burden of obeying the
law on the manufacturer, dealer, or body manufacturer who sells the
completed vehicle to the end user. For this reason, it is important that all
concerned parties review information carefully to ensure compliance
with the MVSS laws and related safety standards. It is recommended
that dealers and others concerned review this information with their legal
counsel.
No modification or addition to the vehicle can be made which cause
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 Illumination, if no alterations are made to the vehicle
controls including their location, means of identification and method of
illumination.
FMVSS 102 / CMVSS 102
This vehicle will conform to FMVSS / CMVSS No. 102, Transmis-
sion Shift Lever Sequence, Starter Interlock and Transmission
Braking Effect, if no alterations are made to the shift pattern dis-
play(s).
FMVSS 103 / CMVSS 103
This vehicle will conform to FMVSS / CMVSS No. 103, Windshield
Defrosting and Defogging Systems, if no alterations are made in
the windshield defrosting and defogging systems, controls, wiring,
plumbing and air flow to the windshield.
FMVSS 104 / CMVSS 104
This vehicle will conform to FMVSS / CMVSS No. 104, Windshield
Wiping and Washing Systems, if no alterations are made in the
windshield wiper arms, blades, washer, controls, wiring, or plumb-
ing.
FMVSS 106 / CMVSS 106
This vehicle will conform to FMVSS / CMVSS No. 106, Brake
Hoses, if no alterations are made to the air or hydraulic brake
hoses, brake hose assemblies, and brake hose fittings including
the labeling on these components.
FMVSS 108 / CMVSS 108
This vehicle will conform to FMVSS / CMVSS No. 108, Lamps,
Reflective Devices, and Associated Equipment, if no alterations
are made to any associated items supplied on the vehicle and no
obstructions are installed which limit visibility of any item.
FMVSS 111 / CMVSS 111
This vehicle will conform to FMVSS / CMVSS No. 111, Rearview
Mirrors, if no alterations are made to mirrors, mounts, locations, or
cab structure and no obstructions are installed which limit usage.

Body and Implement Mounting Guidelines U500 North America General Information
Page 18 of 294 August 2005
FMVSS 113 / CMVSS 113
This vehicle will conform to FMVSS / CMVSS No. 113, Hood Latch Sys-
tem, if no alterations are made in the Hood Latch System, including the
attachments for the hood latches.
FMVSS 119 / CMVSS 119
This vehicle will conform to FMVSS / CMVSS No. 119, New Pneumatic
Tires, if no alterations are made to the pneumatic tires.
FMVSS 120 / CMVSS 120
This vehicle will conform to FMVSS / CMVSS No. 120, Tire Selection
and Rims for Motor Vehicles Other Than Passenger Cars, if no changes
are made to the tires, rims, or labeling.
FMVSS 121 / CMVSS 121
This vehicle will conform to FMVSS / CMVSS No. 121, Air Brake Sys-
tem, if it does not exceed any of the gross axle or gross vehicle weight
ratings, and if no alterations or changes are made in, or affect the air
system components, or circuitry, electric wire circuit or components as-
sociated with the above, tire size and wheelbase.
FMVSS 124 / CMVSS 124
This vehicle will conform to FMVSS / CMVSS No. 124, Accelerator Con-
trol Systems, if no alterations are made to any components of the throt-
tle control or fuel metering system.
FMVSS 125 / CMVSS 125
This vehicle will conform to FMVSS / CMVSS No. 125, Warning De-
vices, if no alterations are made to any components or items of the
warning devices and no obstructions are installed which limit visibility or
usage of any item.
FMVSS 205 / CMVSS 205
This vehicle will conform to FMVSS / CMVSS No. 205, Glazing Materi-
als, if no alterations are made in the glazing material installed 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, door latches, door striker assemblies, door
hinges, door locks, door latch posts, door hinge posts, and sup-
porting cab structure.
FMVSS 207 / CMVSS 207
This vehicle will conform to FMVSS / CMVSS No. 207, Seating
Systems, if no alterations are made to the seats, seat adjusters,
restraining devices, release and adjustment controls, seat risers,
and supports, and the cab floor and supporting structure.
FMVSS 208 / CMVSS 208
This vehicle will conform to FMVSS / CMVSS No. 208, Occupant
Crash Protection, if no change is made in the number of desig-
nated occupants seating positions provided, and if no alterations
are made in the cab and supporting structure, cab underbody,
seat belt assemblies, seat belt anchorages and attachments, and
the cab structure to which the anchorages are attached.
FMVSS 209 / CMVSS 209
This vehicle will conform to FMVSS / CMVSS No. 209, Seat Belt
Assemblies, if no alterations are made in the seat belt assemblies,
seat belt anchorages and attachments, and the cab structure to
which the anchorages are attached.
FMVSS 210 / CMVSS 210
This vehicle will conform to FMVSS / CMVSS No. 210, Seat Belt
Assembly Anchorages, if no additional occupant seats or seat belt
assembly anchorages are added and if no alterations are made
which affect the function, physical, or mechanical properties, envi-
ronmental or vital clearance of the components, assemblies or
systems of any components of the seat belt assembly anchor-
ages.
FMVSS 302 / CMVSS 302
This vehicle will conform to FMVSS / CMVSS No. 302, Flammabil-
ity of Interior Materials, if no alterations are made to the materials,

Body and Implement Mounting Guidelines U500 North America General Information
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including the surface of material and padding or cushioning used in the
interior of the vehicle’s occupant compartment including but not limited
to the following components: seat cushions, seat backs, seat belts, arm
rests, all trim panels including door, front, rear, and side panels, com-
partment shelves, floor covering, headlining, sun visors and other inte-
rior materials.
If the body, implement or equipment manufacturer installs any of the
aforementioned items, those items must also meet the requirements of
this standard.
Summary
The body, implement or equipment manufacturer must install the body,
implement or equipment to the vehicle in such a manner that it conforms
to all standards in effect on the date of manufacture by Freightliner LLC.
1.3 Identification
The Unimog has the following identification characteristics for clear iden-
tification:
•Engine identification plate:
All parts used in the respective engine series can be identified via the
engine identification plate. This number supplements the Vehicle Identi-
fication Number (VIN) as an identification characteristic.
The imprinted engine identification 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 identification and
therefore contain only certain information. The identification plates on
the cab are located on the B-pillar of the driver’s side. They can be seen
only when the left-hand side door is open.
•Vehicle Identification Number:
•The Vehicle Identification Number (VIN) contains coded informa-
tion about the Unimog. It is composed of sub codes.
•The VIN is located on the left longitudinal member of the
frame in the wheelhouse, below the driver’s location in the
cab.
Unimog VIN Coding:
Example
of VIN WD6 D E1 CS ? 4 4 000001
Position 1 2 3 4 5 6 7 8
Position Name Content
1 World manufacturer
identifier (WMI) WD6, WD7, WD8
2 Type of chassis D = 4x4 truck
3 Model (see also follow-
ing table)
E1 = 405.210 class 6
E2 = 405.210 class 7
E3 = 405.230 class 6
E4 = 405.230 class 7
4 Engine CS = Mercedes-Benz OM
906
5 Check digit
6 Model year 4 = 2004,…, 9 = 2009
A = 2010,…, F = 2015
7 Manufactured in 4 = Woerth, Germany
8 Sequentially assigned
vehicle serial number 000 001 – 999 999
Model Chassis Class Wheelbase Gross vehicle
weight rating
E1 405.210 6 131.89 inch
3,350 mm 26,000 lbs
E2 405.210 7 131.89 inch
3,350 mm 33,000 lbs
E3 405.230 6 153.54 inch
3,900 mm 26,000 lbs
E4 405.230 7 153.54 inch
3,900 mm 33,000 lbs
Table 1.1: Unimog VIN Coding

Body and Implement Mounting Guidelines U500 North America General Information
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1.4 Requirements for implement mounting and operating
instructions
Implement mounting instructions:
When composing mounting and operating instructions, Unimog-specific
details must be included. The implement mounting instructions shall de-
scribe the mounting of the implement on the Unimog. It should consider
Unimog-specific details explained by pictures or exploded drawings. The
instructions should be easy to understand so it is possible to mount the
implement without safety hazards.
Examples of Unimog-specific details:
•When mounting on the front mounting plate detail the mounting
location on the front of the vehicle.
•In case of heavy front mounted implement a counterweight is
necessary otherwise the front axle will be over loaded and the
rear axle will be under loaded. Required components, ballast lo-
cation and amount must be shown in a mounting drawing.
•Connection of the hydraulic hoses with a note to the float posi-
tion during connecting to the Unimog.
•Pictures showing cable and hose routing and assembly and fix-
ing of the implement control console.
•Information about cable passage into the cab and use of the seal
cap (part number: A405 583 00 83).
Implement operating instructions:
Operation of the vehicle components (power take-off (PTO) switch, hy-
draulic control panel, etc.) and implement control 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 be asserted within the framework of the
purchase agreement between the purchaser and the vendor. The
relevant vendor of the object supplied is then obliged to the pur-
chaser as regards the warranty.
Warranty obligations are not assumed by Freightliner LLC if
•the body and mounting guidelines have been ignored
•the chassis used does not correspond to the country-
specific equipment and the equipment required for the ap-
plication.
The implement or body must not affect operating and driving
safety. In the case of cabs, free movement for tilting must be
guaranteed. In the case of implements and bodies, asymmetrical
load on the chassis must be avoided wherever possible.
If asymmetrical load is unavoidable (e.g. in the case of a side-
mounted loading crane, generator, mower, etc.) and the difference
in wheel loads exceeds 10 % of the relevant axle loads (see Sec-
tion 4.8 Center of gravity, page 71), then the approval of the
Freightliner Unimog Implement Department is necessary. In this
case please contact the Unimog Implement Manager listed at the
beginning of this guideline. Driving trials may be necessary.
1.6 Maintenance instructions
The body manufacturer must note the following prior to delivery of
the vehicle:
•Servicing due must be carried out at a Freightliner / Mer-
cedes-Benz Service Center.
•Headlamp adjustment must be checked and, if necessary,
corrected following the mounting or attachment of an im-
plement.

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

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

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•Lack of knowledge and training of the vehicle owner / customer /
driver
Only basic notes regarding product liability can be provided within
the framework of these Body and Implement Mounting Guideline.
1.11 Damage prevention and safety regulations
1.11.1 General notes
In all operations of the vehicle or the vehicle/implement combination, the
accident prevention directives, especially the directives and recommen-
dations listed in the operating instructions of the vehicle and the
body/implement etc. must be complied with.
1.11.2 Delivery of chassis
Minimum rear axle load needs to be at least 41 % of the total vehicle
weight to meet the empty failed front reservoir stopping distance.
If the vehicle has to be delivered under its own power, the rear axle
must be properly ballasted to the minimum rear axle load. U500 chassis
from the factory only achieve the minimum rear axle load with platforms
mounted. Highway travel without platforms (only with platform subframe
or without platform subframe) is not allowed.
1.11.3 Prevention of accidents on the vehicle
The implement or body manufacturer is responsible for compliance with
laws and regulations. This also applies to interfaces between the vehicle
and the implement and to safety when mounting or removing exchange-
able implements. Drive shafts must also be equipped with protection
against accidental contact, so that shearing and crushing points are
avoided. Connectable systems must be protected against improper use
and unintentional actuation. 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 ensure that servicing and maintenance operations
can be carried out safely.
1.11.4 Plastic compressed-air, fuel and brake lines
Before welding, drilling, grinding and working with cutting discs:
•Cover plastic lines and brake hoses
•Remove if necessary
The system must be checked for leaks after the lines have been
fitted.
If lines (e.g. hydraulic lines from implement or body units) have to
be retrofitted in the vehicle, these must not be attached to chassis
lines (e.g. brake lines, electric cables, etc.). The relative move-
ments, which occur between body and chassis in the event of
chassis diagonal torsion, and the related elongation or compres-
sion of the lines, must be taken into consideration when lines are
routed.
We recommend that when routing lines, implement manufacturers
manufacture and fit brackets appropriate for the line or pipe rout-
ing on the chassis. The brackets must be attached to existing
holes in the chassis.
They must not be attached to existing, highly-stressed threaded
connections, such as longitudinal member frame connections, en-
gine mounting systems, anti-roll bar mountings, spring mountings,
etc.
For additionally required holes, e.g. in the frame, see section 10.6,
page 275 and section 10.7 Drilling on the frame, page 276.
Existing brackets on the chassis may be used provided that the
bracket can bear the additional load.
Subsequently installed lines must not rub on brake lines, electric
cables, etc.; use spacers if necessary.
Changes to the brake system (e.g. wheelbase or frame exten-
sions) may only be carried out using the pipe connection parts and
plastic lines, which we have approved.