Mercedes-Benz 404 Service Manual

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9-1

CHAPTER 9

CLEANING INSTRUCTIONS – UNIMOG

9.1 This chapter provides basic and specific cleaning requirements for selected vehicles.

Where there is a specific requirement or need to highlight particular problem areas detailed
cleaning guides are provided as tables and figures in this chapter.

9.2 This Section deals with the cleaning of the basic Unimog vehicle. The section is structured
as follows:

a. external areas;
b. underside;
c. cabin;
d. cabin holes
e. front areas;
f. under tray;
g. tray checker panel;
h. chassis;
i. chassis support tubes;
j. cross members;
k. chassis cross members;
l. chassis cavities;
m. sump;
n. torque tube wiring looms and air lines
o. chassis ai r lines and wiring looms;
p. suspension;
q. engine and transmission;
r. battery box;
s. winch, wire ropes and slings;
t. tarpaulins;
u. camouflage nets; and
v. tyres (new, old and spares).

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9-2

External Areas

9.3 The cleaning instructions for the Unimog’s external areas, as illustrated in Figure 9-1,

include the points detailed in Table 9-1.

6

5

Figure 9-1: Unimog’s External Areas

Table 9–1: Cleaning Instructions for the Unimog’s External Areas

Serial Comments or Tasks

1

2

3

4

Technical

Time (hours)

1 Clean all rubber seals around the windows and doors.
2 Remove the cabin seats to facilitate cleaning.

Remove the rubber floor matting to clean the cabin floor.
3 Remove the snorkel to facilitate cleaning. 0.5
4 Remove the bonnet to facilitate cleaning.
5 Remove the mudflaps and pay attention to cleaning around the

attachment points.
6 Remove Cupola crash pad and any lining to facilitate cleaning and

inspection.
7 Loosen fuel and air tank retaining straps
8 Remove light covers and flush housing
9 Clean and inspect channel tubing at cargo tie down points on cargo

tray

1.5

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9-3

Underside

9.4 The cleaning instructions for the Unimog’s external areas, as illustrated in Figure 9-2,

include the points detailed in Table 9-2.

Figure 9-2: Unimog’s Underside Areas

Table 9–2: Cleaning Instructions for the Unimog’s Underside Areas

Serial Comments or Tasks

1 All tools are to be fully removed and extended to facilitate cleaning.
2 All externally fitted items of equipment to be removed and both the

items and the mounting brackets to be cleaned of all QRM
3 Jerry cans are to be removed to facilitate cleaning. 0.5
4 All toolboxes are to be emptied to facilitate cleaning.

If required, remove the toolboxes and Jerry can holders to facilitate

cleaning of soil, plant and insect debris between the items and the

chassis.
5 Spare tyre to be fully removed and to be cleaned as per “tyres”

para.10.9 below.
6 Tyre cover (if fitted) to be fully removed and to be washed and

scrubbed to remove all QRM (refer paragraph 9-23 below).
7 Frame areas are to be washed with high-pressure water utilising a

flexible nozzle.

Technical

Time (hours)

1.5

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9-4

Cabin

9.5 The cleaning instructions for the Unimog’s cabin, as illustrated in Figures 9–3 and 9–4,

include the point detailed in Table 9–3.

Figure 9–3: Unimog’s Cabin

Figure 9–4: Unimog’s Doors

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9-5

Table 9–3: Cleaning Instructions for the Unimog’s Doors

Serial Comments or Tasks

1 Remove the cabin seats to facilitate cleaning. 1.5
2 Remove the rubber floor matting to clean the cabin floor.
3 Inspect mirror sills and mirrors.
4 Door trims are to be removed and cleaned
5 The window and door rubber seals are to be cleaned of all soil, plant

and insect matter. Seals on the bonnet area are to be cleaned in a

similar fashion.
6 The seats and the floor mats are to be removed and the cabin floor

cleaned.
7 The cabin area is to be vacuumed and air-blown clean.
8 Ventilation ducts are to be unscrewed and air-blown clean.
9 Remove the front cover from the ventilation fan housing and clean the

fan housing. All soil, plant and insect matter are to be removed.

10 Critically inspect the gun mount and manhole (if fitted) to ensure they

are free from dirt, dust, plant and insect material.

Technical

Time (hours)

1.0

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9-6

Cabin Holes

9.6 The cleaning instructions for the Unimog’s cabin holes, as illustrated in Figure 9-5, include

the point detailed in Table 9–4.

1

Figure 9-5: Unimog’s Cabin Holes

Table 9–4: Cleaning Instructions for the Unimog’s Cabin Holes

Serial Comments or Tasks

1 The holes under the cab are to be flushed through to remove all debris.

Technical

Time (hours)

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9-7

Front Areas

9.7 The cleaning instructions for the Unimog’s front areas as illustrated in Figure 9-6 include

the points detailed in Table 9–5.

3

4

2

1

Figure 9-6: Unimog’s Front Areas

Table 9–5: Cleaning Instructions for the Unimog’s Front Areas

Serial Comments or Tasks

Technical

Time (hours)

1 Headlights are to be removed to facilitate cleaning behind them. 1.0
2 The brush guard is to be removed. 0.25
3 The air cleaner element is to be removed and disposed of in

accordance with AQIS directions.

Clean the ventilation nozzles on the centre top of the dash using low

pressure compressed air.

Remove the ventilation blower assembly filter element, from the front

left-hand side of the cabin, and dispose of in accordance with AQIS

directions. Clean out the ventilation blower assembly housing and

ensure no dirt, seed or plant material remains.

Raise the heating/ventilation flap, on the selected gear indicator panel,

and vacuum clean the discharge cavity to remove dust and other

foreign material.
4 The bonnet is to be removed.
5 Remove the radiator to facilitate cleaning.

The radiator is to be high-pressure air-cleaned to remove seed and

then washed down by a low-pressure water high-volume wash;

Bent radiator grills may require heat treatment to burn any embedded

seed material (using heat shrink guns).

It may be necessary to use brushes or pick insect and seed matter out

from between the veins on the radiators.

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9-8

Under Tray

9.8 The cleaning instructions for under the Unimog’s tray, as illustrated in Figure 9-7, include

the points detailed in Table 9–6.

1

2

3 4 5 6

Figure 9-7: Under the Unimog’s Tray

Table 9–6: Cleaning Instructions for Under the Unimog’s Tray

Serial Comments or Tasks

Technical

Time (hours)

1 High-pressure water clean around the fittings using a flexible nozzle as

is necessary to get into all areas.
2 Remove the tank straps to facilitate cleaning. 1.0
3 Clean all the supporting members for the floor area.

The wooden floor is to be lifted to allow inspection and to facilitate

cleaning of the chassis cross members and underside of the floor. If

the wooden floor plates are cracked, gouged or damaged, they are to

be disposed of in accordance with AQIS directions.
4 The underside hollow cross members are to be subject to

high-pressure water using a flexible nozzle to remove all soil, plant and

insect matter.
5 Remove the driver’s step to facilitate cleaning where the step attaches

to the vehicle. Additionally, the hollow tube is to be subject to a high-

pressure water clean and, if necessary, drill a hole near the step point

to provide an exit point for water and debris.

2.0

0.5

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9-9

Tray Checker Panel

9.9 The cleaning instructions for the Unimog’s tray checker panel, as illustrated in Figure 9-8,

include the points detailed in Table 9–7.

1

2

Figure 9-8: Unimog’s Tray Checker Panel

Table 9–7: Cleaning Instructions for the Unimog’s Tray Checker Panel

Serial Comments or Tasks

1 Where evidence of QRM has been found the checker plate is to be

seperated from the Wooden floor to facilitate cleaning. Remove the

checker plate to facilitate cleaning and an AQIS inspection underneath.

Timber floor panels passed by AQIS inspectors will require fumigation

action upon entry to Australia and will not be refitted to vehicle.
2 Use a high-pressure water clean on the attachment points on the cargo

tray.

Technical

Time (hours)

1.0

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9-10

Chassis

9.10 The cleaning instructions for the Unimog’s chassis, as illustrated in Figure 9-9, include the

points detailed in Table 9–8.

1

Figure 9-9: Unimog Chassis

Table 9–8: Cleaning Instructions for the Unimog’s Chassis

Serial Comments or Tasks

1 The chassis rail on the vehicle has open areas which collect deb ris.

The area is to be flushed behind the plate using a flexible nozzle and

moving around to ensure all areas behind the plate are cleaned until

the water is observed to be clear on exit.
2 Loosen and clean air line restraining straps. Foam covering may

require to be disposed of if heavenly contaminated.

Technical

Time (hours)

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9-11

Chassis Support Tubes

9.11 The cleaning instructions for the Unimog’s chassis support tubes, as illustrated in

Figure 9-10, include the point detailed in Table 9–9.

1

1

Figure 9-10: Unimog’s Chassis Support Tubes

Table 9–9: Cleaning Instructions for the Unimog’s Chassis Support Tubes

Serial Comments or Tasks

1 The rear view of the chassis support tubes are to be flushed out. The

right-hand tube has a closed end and may require extensive flushing.

Some vehicles have been modified and have drilled holes at the cabin

end of the tube to allow water to drain out.

Technical

Time (hours)

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9-12

Cross Members

9.12 The cleaning instructions for the Unimog’s cross members, as illustrated in Figure 9-11,

include the point detailed in Table 9–10.

1

Figure 9-11: Unimog’s Cross Members

Table 9–10: Cleaning Instructions for the Unimog’s Cross Members

Serial Comments or Tasks

1 The mounting brackets for the cross members collect debris that

requires flushing using a flexible nozzle.

Technical

Time (hours)

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9-13

Chassis Cross Member

9.13 The cleaning instructions for the Unimog chassis cross member, as illustrated in

Figure 9-12, include the point detailed in Table 9–11.

1

Figure 9-12: Unimog Chassis Cross Member

Table 9–11: Cleaning Instructions for the Unimog’s Chassis Cross Member

Serial Comments or Tasks

1 The chassis cross member collects debris that requires flushing usi ng

a flexible nozzle.

Technical

Time (hours)

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9-14

Chassis Cavities

9.14 The cleaning instructions for the Unimog chassis cavities, as illustrated in Figure 9-13,

include the point detailed in Table 9–12.

1

Figure 9-13: Unimog’s Chassis Cavities

Table 9–12: Cleaning Instructions for the Unimog’s Chassis Cavities

Serial Comments or Tasks

1 All soil and debris is to be removed from the chassis cavities.
2 Remove plastic ties to expose grouped cables and air lines for

inspection

Technical

Time (hours)

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9-15

Sump

9.15 The cleaning instructions for the Unimog sump, as illustrated in Figure 9-14, include the

point detailed in Table 9–13.

1

Figure 9-14: Unimog Sump

Table 9–13: Cleaning Instructions for the Unimog’s Sump

Serial Comments or Tasks

1 Grease and oil from the front of the sump and on the back of the

flywheel housing is to be removed.

Technical

Time (hours)

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9-16

Torque Tube Wiring Looms and Air Lines

9.16 The cleaning instructions for the Unimog’s wiring looms and air lines, as illustrated in

Figure 9-15, include the point detailed in Table 9–14.

1

Figure 9-15: Unimog’s Wiring Looms and Air Lines

Table 9–14: Cleaning Instructions for the Unimog’s Wiring Looms and Air lines

Serial Comments or Tasks

1 Loosen hose clamps and mounting channels and clean in between all

air lines on the torque tube.

Technical

Time (hours)

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9-17

Chassis Air Lines and Wiring Looms

9.17 The cleaning instructions for the Unimog’s cables, as illustrated in Figure 9-16, include the

point detailed in Table 9–15.

1

Figure 9-16: Unimog’s Cables

Table 9–15: Cleaning Instructions for the Unimog’s Cables

Serial Comments or Tasks

1 Clean in between all cables, paying attention to where the cable ties

are located and between the cable and vehicle.

Technical

Time (hours)

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9-18

Suspension

9.18 The specific cleaning instructions for Unimog’s suspension include those points detailed in

Figure 9-17 and Table 9–16.

Figure 9-17: Unimog’s Suspension

Table 9–16: Cleaning Instructions for the Unimog’s Suspension

Serial Comments or Tasks

1 Ensure suspension rocker beam mounts on chassis are clean and free

of soil, plant and insect material.
2 Mud and other debris collect in the spring seat, where the spring is

mounted to the axle assembly, and are difficult to remove from the

base of the springs.

Ensure that this area is cleaned well.
3 Mud and other debris collect in the inside area on the inner side of the

wheel.

Ensure that this area is cleaned well.
4 Ensure axles and mounts on chassis are clean and free of soil, plant

and insect material.

Technical

Time (hours)

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9-19

Engine and Transmission

9.19 The specific cleaning instructions for Unimog’s engine and transmission include those

points detailed in Figure 9-18 and Table 9–17.

Figure 9-18: Unimog’s Engine and Transmission

Table 9–17: Cleaning Instructions for the Unimog’s Engine and Transmission Compar tment

Serial Comments or Tasks

1 Clean the engine compartment and engine to ensure they are free of

Technical

Time (hours)

dust, built-up dirt and grease, insect and plant material..
2 Ensure any engine openings/breathers are taped or plugged to stop

ingress of water.
3 Ensure the starter motor and alternator are covered and taped to stop

ingress of water.
4 Do not direct high-pressure water jets at any of the engine

openings/breathers, or at any of the electrical/electronic components

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9-20

Battery Box

9.20 The cleaning instructions for the Unimog’s battery box, as illustrated in Figure 9-19, include

the point detailed in Table 9–18.

1

Figure 9-19: Unimog’s Battery Box

Table 9–18: Cleaning Instructions for the Unimog’s Battery Box

Serial Comments or Tasks

1 The battery box support member is to be flushed through using a

flexible nozzle until clear water is seen to exit.
2 Flush support bases and tubing underneath battery box.

Technical

Time (hours)

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9-21

Winches, Wire Ropes and Slings

9.21 The cleaning instructions for Winches, Wire Ropes and Slings, as illustrated in Figures 9-

20 and 9-21, include the point detailed in Table 9–19.

Figure 9-20: Unimog’s Winch Assembly

Figure 9-21: Unimog’s Winch Assembly Underside

Table 9–19: Cleaning Instructions for Winches, Wire Ropes and Slings

Serial Comments or Tasks

Technical

Time (hours)

1 All items are to be extended to full length and subject to a high-pressure

water clean using degreaser, if required, to remove all soil, plant and
insect matter

2 The winch drum is also to be degreased and subject to a high-pressure

water clean

3 All winch ropes, wire ropes and slings are to be re-oiled after inspection.

An application of a protective covering (plastic bag) may be required to
protect the refurbished ropes and cables

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9-22

Tarpaulins

9.22 The cleaning instructions for the tarpaulins include the points detailed in Table 9-20.

Table 9–20: Cleaning Instructions for the Tarpaulin Areas

Serial Comments or Tasks

1 All tarpaulins are to be given a brush down, brush scrubbing and hose

cleaning, paying particular attention to the seam areas and then
hung so as not to contact the ground for drying

2 All ropes and universal dispatch straps are to be extended to

their full length and wiped or washed clean of all soil, plant and insect
matter

Attention to attachment points and fixtures and tension devices is
required

Personnel are to inspect and remove all twigs, foliage, and so on that
has become embedded in the rope fibres

3 Velcro panels and seams (where fitted) are to be brushed and

washed to ensure all seed, plant and soil material is removed

4 Canvas bags are to be turned inside out and checked for burrs, seeds

and insects;

5 Where fitted, poles, knuckles and pegs are to be subject to a

high-pressure water clean to remove all soil, plant and insect matter
(ants, spiders and mud wasps are of particular concern)

6 If tarpaulins have not been used during the entire deployment,

then the requirement is for all tarpaulins to be unrolled, brushed and
swept clean to ensure no vermin or insect infestation and then
subject to an AQIS inspection

Technical

Time (hours)

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