Mercedes-Benz Unimog 416 1976, Instruction Manual

Page 1: ...Instruction Manual UNIMDI 416...

Page 2: ...IW ERCEDES DENZ 0 Instruction Manual UNIMDIi 416 Edition June 1976...

Page 3: ...strations of the present manual subject to change 4 Reprints and translations including extracts subject to our written permission Daimler Benz Aktiengesellschaft Stuttg art U ntertUrkhei m Plant Gagg...

Page 4: ...ter 21 Oil Overpressure 21 Retightening Cylinder Head Bolts 21 Replacing Cylinder Head Gasket 22 Adjusting Valve Clearances 22 Checking Compression Over pressures 23 Air Filter 23 Fuel 24 Filling up F...

Page 5: ...nting 54 Pto Shaft 54 BrakeFluid 56 Transmission Oil 56 Grease 56 Anti corrosive Oil 56 5 TroubleShooting 57 General 57 Towing 57 EngineGroup 57 EngineFailsto Start 57 Engine Difficult to Start 58 Eng...

Page 6: ...ging Current Warning Light Lights up while Driving 64 StarterMotor Doesnot Operate 65 Current Consumer Inoperative 65 lnefficient Headlights 66 Direction Indicator System 66 6 Technical Data 67 Typesa...

Page 7: ...and refer ences as to their possible cause as well as recommendations for their repair 8 For fast information all the significant dimensional data concerning the eng ne the chassis and the body are li...

Page 8: ...1 Chassis number 2 Type plate 3 Transmission number 4 Cab number 5 Engine number 6 Axle Number Fig 1 Arrangement of type plate and numbers URO OOO6 9...

Page 9: ...es for switching the switch box in the instrument panel The square drive bonnet key is in the left hand door box It is used for opening the bonnet Doors Seats and Tools The door locks of the folding t...

Page 10: ...switch lever 5 Spedometer 6 Cut out switch for blinker 7 Instrument cluster 9 2 8 7 5 6 Fig 6 Instrument cluster 1 Brake overpressure warning light red 2 Blinker control light UNIMOG green 3 Oil overp...

Page 11: ...I 00 R sv 3 2 Shifting I Shifting position lever 1 I Main shifting lever I 1 4 I 1s1 10 41h gear 2 Forward reverse shifting lever V Forward gears 0 Neulral position R Reverse gears 3 High low range s...

Page 12: ...light Blinker tail stop light Windshield wiper Instrument indicator 2 to 1 additional Parking Clearance light Instrument cluster light I I to 1 and 2 additional Headlight low beam I Headlight high be...

Page 13: ...diately after shutting off the warm engine or after a short running period of the previously cold engine Do not fill up beyond the maximum level mark Check contents of fuel tank Check tyre pressure C...

Page 14: ...tion At a coolant temperature of 90 to 95 C do 1 I I A 2 I J J II I II II II II UZ 30 0001 Fig 11 Hand throttle control 1 Full throttle position 2 Idle position 3 Stop position 4 Locking plate not sto...

Page 15: ...t all the wheels are turning at uniform speed or that the UNIMOG comes to a stop 16 The differential locks and the four wheel drive can also be disengaged while driving without declutching Briefly rel...

Page 16: ...etc Lubrication jobs Change engine oil Replace bypass oil filter element Change transmission oil Change oil in differential 2 Change oil in wheel hub drive 4 Check oil level in steering Check brake f...

Page 17: ...al instruments Body Check bolts of cab and body attach ment for tight seat retighten 1 14 15 12 8 2 5 18 work to be performed Lubrication jobs Pos No Oil Lub Grease daily Points Qly 1st TM 2nd TM x Ch...

Page 18: ...a Fill in engine oil b Fill in transmission oil c Check oil level d Drain oil e Lubricate with grease f Replace oil filter element CD Fill in and check brake fluid 14 11 8 13 4 10 7 16 12 19...

Page 19: ...k wiped off The oil level should be between the minimum and maximum mark When checking the oil level of the engine it must be considered that the 011cooler and various oil passages will drain after no...

Page 20: ...d when using engine oil of viscosity class SAE 30 at nominal speed the oil over pressure is at least 2 5 bar kp cm2 At idling speed it may drop to 0 6 bar kp cm2 without in any way endangering the ope...

Page 21: ...m bearing brackets Loosen cylinder head nuts with the engine cold in reverse to tightening sequence Unscrew stud bolts and remove cylinder head Clean contact surfaces of cylinder head gasket Posi tion...

Page 22: ...Filter A carefully cleaned air filter is absolutely necessary to protect the pistons and cy linder contact surfaces and in order to avoid damage Oil bath air filter Change oil according to UNIMOG con...

Page 23: ...rrel that is do not simply set suction pump into barrel Maintain minimum distance between bottom of barrel and end of intake pipe so that deposits such as dirt sludge and water will not be sucked in C...

Page 24: ...t tube ele ment in diesel fuel until drawn full of oil and blowout with compressed air or with an air pump through one of the holes from inside Repeat procedure until the blown out fuel remains clean...

Page 25: ...e in the fuel system never run the fuel tank completely empty Bleed entire fuel system prior to initial operation as well as after each major repair When the fuel system has not been run empty complet...

Page 26: ...y inside with wooden stick gasoline or diesel fuel Clean nozzle needle with clean rag hold nozzle needle by pin only to prevent any corrosion of the lapped surface r Remove carbon deposits on nozzle b...

Page 27: ...in any case attempt to plug up a leaking drain opening for a longer period of time since the ball bearings in the housing will be damaged by penetra tion of the coolant Thermostat The thermostat opera...

Page 28: ...out generator that it will give only approximately 10 mm under thumb pres sure from the straight line A too tight or loose V belt becomes worn out quickly Check new V belt several times during first...

Page 29: ...at bleeding until no more air bubbles escape When stepping on clutch pedal for the last time retain it in its lowest position until the bleeding plug has been screw ed down tight Remove bleeding hose...

Page 30: ...he lower oil filler oil level control plug thoroughly clean hub reduction housing at this point Removeoil filler plug 2 and oil level Controlplug 1 fill up with transmission oil With the unloaded UNIM...

Page 31: ...ll new filter Upon installation fill power steering oil reservoir with new hydraulic oil Clean plug with bleeding slot and screw Bleed power steering Bleeding Power Steering Crank engine serval times...

Page 32: ...y on roads mount tyres in such a manner that the arrow tread points forward on the ground on the front wheels and to the rear on the ground on the rear wheels as seen in driving direction Thus the UNI...

Page 33: ...e is no wheel or tyre damage remove wheels and tyres once a year and check them Clean rims from dirt and rust with a steel brush Have dented rims straightened and repaired Paint rims only with special...

Page 34: ...ic Brake System When no firm resistance is felt when fully stepping on the brake pedal the hydraulic brake system is either leaking the brake shoe clearance is too great or there is air in the hydraul...

Page 35: ...s after driving 50 km and thereafter according to maintenance schedule The brake linings must always be free from oil and water since the braking efficiency will otherwise be consider ably impaired Af...

Page 36: ...the wheels can just be turned without offering any resistance tighten parking brake lever to second notch Unscrewthrust rod with toothed wheel by meansof screwdriver until the brake shoesrest well ag...

Page 37: ...cylinder 2 Single chamber compressed air brake booster 3 Brake fluid reservoir 4 Clutch master cylinder 5 Shop light switch Fig 43 1 UZ 43 0030 0 5 6 7 8 4 Fig 44 Diagram of the compressed air brake a...

Page 38: ...n screw plug with tommy handle Screw tyre inflating hose onto thus ex posed hose connection Fig 47 After inflating tyre unscrew hose and tightly screw down screw plug Compressed Air Reservoir Release...

Page 39: ...ompressed air assistance the supply line is provided with an overflow valve Check function of differential locks according to maintenance schedule Once a year spray approximately 1 cc of engine anti c...

Page 40: ...l lock Disengage shifting lever engage oper ating valve on transmission cover by hand a second person has to check both wheels Both wheels should not turn because differential is cut off Shift shiftin...

Page 41: ...on the instrument panel lights up Be careful when using rapid charging equipment When charging the battery with a rapid charger remove battery terminals of UNIMOG When as an exception the rapid charg...

Page 42: ...inshield wiper instrument panel lighting Blinker light Taillight right speedometer light Taillight left instrument cluster light Socket interior light Fuses 8 8 8 8 8 8 16 8 8 8 8 8 43 Wiring I I Outp...

Page 43: ...arance lamp left 13 Fuse box fuse no 7 to 12 14 Fuse box fuse no 1 to 6 15 Shut off switch for blinker system 16 Starter switch 17 Line connector 18 Regulator 19 Alternator 20 Engine 44 21 Starter mot...

Page 44: ...2 ci li J 3 J i 11 17 16 23 I 21 22 I 111 10 I 19 18 17 33 34 32 Fig 51 Wiring Diagram 45...

Page 45: ...according to mainte nance schedule and make corrections if required Fig 52 Headlight alignment Lowbeamon The following test or adjustment accord ing to Fig 52 is a temporary expedient Have an exact ad...

Page 46: ...such contact will mar the highly polished surface Open headlights only when replacing a damaged bulb Fig 53 Headlight adjust 1 Fastening screw 2 Lateral adjustment 3 Height adiustment Fig 54 Changing...

Page 47: ...e steering in center position that the front wheels are pointing straight ahead Remove fitted screw on the steering gear side of the universal joint Pull off universal joint with steering column and s...

Page 48: ...versal joint of the steering with new self locking Cleveloc nuts Hint Press bottom of deflector housing for the hand brake cable upward until the leaf spring snaps into place after lower ing the cab...

Page 49: ...nsion lock on windscreen and remove canvas in upwards direction Push right and left hand canvas bow universal to the outside of its stop Fold canvas to the rear and at the same time on the second univ...

Page 50: ...asier to mount or remove the top bow Pay attention to the opening slot in the top bow this slot should always be point ing downwards When the bow is in stalled Towbar Tow bar mounting location is in t...

Page 51: ...ightened to the upper side panel which at the same time erve as a back rest for the men sitting on the benches with a rubber strip fastened to the bench lower side The mounting rod with the turn buckl...

Page 52: ...the UNIMOG for weeks must be ob served Place washed vehicle in an airy and dry room to do the preserving process 1 Laying up to 3 month Spray anti corrosive oil into inlet duct of engine The coolant...

Page 53: ...ge 14 Check all hoses and lines for leaks and cracks Check brakes 54 UR 0067 Fig 67 Rope winch mounting bracket 1 Rope winch holder riQhl 2 Rope winch holder left 3 Pia FrontWinch The front winch is m...

Page 54: ...hassis Consumption values Fuelconsumption on level highway Operative Materials I SAE 20 for winter SAE 30 for sommer Quintities Itr max 10 0 min 7 0 1 0 1 8 6 0 each 2 5 each 0 3 Transmission oil SAE...

Page 55: ...hassis Consumption values Fuel consumption on level highway Operative Materials SAE 20 for winter j SAE 30 for sommer Transmission oil SAE 90 Quintities Itr max 10 0 min 7 0 1 0 1 8 6 0 each 2 5 each...

Page 56: ...osity rules as the HD engine oils Due to their good anti corrosion charac teristics initial operation oils are also used for preserving the engines of UNI MOGs which are to be laid up Heavy DutyOil Us...

Page 57: ...the cause of the failure as well as expert repair in a UNIMOG repair shop Put main shift lever in 4th gear and low range high range lever into low range Shift forward reverse lever to neutral positio...

Page 58: ...uel prefilter fuel filter dirty Fuel system leaks Overflow valve in injection pump does not retain pressure Nozzle needle stuck Oil bath air filter or cyclone prefilter soiled r Remedies Fill in fuel...

Page 59: ...coolant V belt tension of coolant pump too low Thermostat not in order Remedies Declutch completely depress accelara tor pedel several times If the black smoke continue clean fuel filter Check injecti...

Page 60: ...e shaft hard to move or stuck Lining greasy Liningworn clutch damaged Remedies Have it exchanged Have cylinder head checked and replac ed if required Have it cleaned Check oil drain plug and oil level...

Page 61: ...essure too low Toe in adjusted wrongly Oil level too low air in oil circuit Control arm loose Steering knuckle hard to move Vehicle overloaded unequal axle load Ball heads on steering arm and tie rod...

Page 62: ...worn Brakes adjusted wrongly Air in the system System leaks Master brake cylinder damaged Remedies Release brake pedal briefly and depress twice in quick succession whereby the resistance must be fel...

Page 63: ...tor continuously blowing off Compressed air system leaks Remedies Clean compensating port with 0 5 mm thick wire Drain brake fluid flush system thorough ly with spirit of alcohol replace gaskets and h...

Page 64: ...tor damaged Battery discharged V belt of alternator loose Regulator damaged Line between charging current warning light and alternator is grounded Alternator or diodes damaged by loose contacts or wro...

Page 65: ...oose broken Starter defective Current Consumer Inoperative Fuse has poor contact Fuse damaged Line and plug connections or connect ing points have poor contact Grounded line Current consumer damaged R...

Page 66: ...ction indicator light system working Stop light not working 66 Possible causes Bulb damaged Fuses no contact damaged Electric cable broken Direction indicator control bulb failure Wrong direction indi...

Page 67: ...es designation OM 352 XIII at speed Idling speed Start of delivery STDC Injection order Ejection overpressure of injection nozzles new injection nozzles used Model 353 940 Valve clearance for intake c...

Page 68: ...ssure force Nm kpm Clutch plate designation Lining Clutch operation Clutch ply on slave cylinder Ply of piston rod clutch pedal master cylinder mm 68 Fichtei Sachs Single plate dry clutch GFX 310 KR 7...

Page 69: ...r Steering wheel turns from stop to stop 4 speed synchromesh transmission with rear axle drive front axle drive enga geable and disengageable while driving and transmission driven pto drive 1 2 3 4 14...

Page 70: ...e tread Tyres size Rim size Tyre Overpressures Highway up to max speed front rear Off lighway up to 20 km h front rear Press in depth 25 mm Track 1616 mm HUmin 1 min 1 min bar kp cm2 bar kp cm2 ZF Eat...

Page 71: ...ls Brake Assistance System Design Cutout pressure Compressed air brake assistance system bar kp cm2 7 35 Brake pressure warning light bar kp cm2 5 Electrical System Alternator Design Three phase alter...

Page 72: ...72 IL iIoo Weights 13 a Payload Perm GVW 2 200 kg 6 000 kg Perm front axle load 3 700 kg 3 700 kg Perm rear axle load Max trailer load 4 000 kg 3 300 kg Dead weight The dead weight includes the follo...

Page 73: ...20 G CD 121 I I 31 13 g 6 527 2800 Max height of cab unloaded to approx mm 2340 Max height of canvas frame to approx mm 2680 Ground clearance under axle housing approx mm 440 Vehicle overhang front 0...

Page 74: ...on nozzle in 350 to 400 35 to 40 nozzle holder 80 8 Axles Fastening of pitman Nozzle holder in arm to drag link 230 23 cylinder head 60 to 70 6 to 7 Thrust ball housing to transmission Chassis Protect...

Page 75: ...V belts Drive Crankshaft water pump alternator Crankshaft power steering pump Dimension Note 12 5 x 1450 12 5 x 900 Toothed 75...