Mercedes-Benz 404 Service Manual

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9-1

CHAPTER 9

CLEANING INSTRUCTIONS – UNIMOG

9.1This 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.

9.2This 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 air 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

9.3The cleaning instructions for the Unimog’s external areas, as illustrated in Figure 9-1, include the points detailed in Table 9-1.

1	2	3

4

	6
	5
	Figure 9-1: Unimog’s External Areas
	Table 9–1: Cleaning Instructions for the Unimog’s External Areas
Serial	Comments or Tasks		Technical
			Time (hours)
1	Clean all rubber seals around the windows and doors.
2	Remove the cabin seats to facilitate cleaning.		1.5
	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

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9-3

Underside

9.4The 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	Technical
			Time (hours)
	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	1.5
		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.

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9-4

Cabin

9.5The 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	Technical
			Time (hours)
	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	1.0
		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.

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9-6

Cabin Holes

9.6The 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	Technical
			Time (hours)
	1	The holes under the cab are to be flushed through to remove all debris.

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9-7

Front Areas

9.7The 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

9.8The 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						2.0
	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						0.5
	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.

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9-9

Tray Checker Panel

9.9The 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	Technical
			Time (hours)
	1	Where evidence of QRM has been found the checker plate is to be	1.0
		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.

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9-10

Chassis

9.10The 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	Technical
			Time (hours)
	1	The chassis rail on the vehicle has open areas which collect debris.
		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.

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9-11

Chassis Support Tubes

9.11The 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	Technical
			Time (hours)
	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.

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9-12

Cross Members

9.12The 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	Technical
			Time (hours)
	1	The mounting brackets for the cross members collect debris that
		requires flushing using a flexible nozzle.

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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	Technical
			Time (hours)
	1	The chassis cross member collects debris that requires flushing using
		a flexible nozzle.

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9-14

Chassis Cavities

9.14The 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	Technical
			Time (hours)
	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

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9-15

Sump

9.15The 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	Technical
			Time (hours)
	1	Grease and oil from the front of the sump and on the back of the
		flywheel housing is to be removed.

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9-16

Torque Tube Wiring Looms and Air Lines

9.16The 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	Technical
			Time (hours)
	1	Loosen hose clamps and mounting channels and clean in between all
		air lines on the torque tube.

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9-17

Chassis Air Lines and Wiring Looms

9.17The 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	Technical
			Time (hours)
	1	Clean in between all cables, paying attention to where the cable ties
		are located and between the cable and vehicle.

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9-18

Suspension

9.18The 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		Technical
			Time (hours)
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.

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9-19

Engine and Transmission

9.19The 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 Compartment

	Serial	Comments or Tasks	Technical
			Time (hours)
	1	Clean the engine compartment and engine to ensure they are free of
		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

9.20The 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		Technical
			Time (hours)
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.

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9-21

Winches, Wire Ropes and Slings

9.21The 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

9.22The 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				Technical
							Time (hours)
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

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