Maintenance Procedures

3 Maintenance Procedures

3.1 Daily (before driving)

1. Engine. Check the engine oil level and top up as necessary.
2. Radiator. Check the coolant level and top up as necessary.
3. Windscreen Washer. Check the water level and top up as necessary.
4. Fuel. Check the fuel level and refuel if necessary.
5. Security. Check that the spare wheel is securely mounted and that external lockers are locked. Check that all stores and loads are securely fastened to the truck.
6. Truck Serviceability. Inspect the truck for any damage, and loose or missing parts.
7. Tyres. Check the tyre pressures and inspect the treads and side walls for signs of damage. Refer to EMEI Vehicle A 291-5 for the correct tyre pressures.
8. Leakage. Check under the truck for any signs of coolant, oil or fuel leaks.
9. Air-pressure Check. Start the engine. Check that the air pressure warning lamp extinguishes and the warning alarm mutes.
10. Accessories. Check the following accessories for the correct operation:
    1. headlights,
    2. horn,
    3. indicator lights,
    4. hazard warning lights,
    5. (if fitted) crane spotlight, and
    6. windscreen washers.
11. Brakes. Allow the truck to move forwards slowly and check that the foot brake works. Stop the truck and check that the parking brake operates correctly.
12. Steering. Whilst moving slowly, check that the steering is free and responsive without any undue slackness or sponginess.
13. General. Check all lashings, tie downs and canopy security. Report all defects or damage.

3.2 After 4 hours of Operation

1. Engine. Check the engine oil level and top up as necessary. Do not remove the coolant expansion tank filler cap while the engine is hot.
2. Radiator. Check the coolant level and top up as necessary.
3. Fuel. Check the fuel level and refuel if necessary.
4. Tyres. Check the tyre pressures and inspect the treads and sidewalls for signs of damage.

3.3 At End of Trip

1. Fuel. Fill the fuel tank.
2. Engine. Check the oil level and top up as necessary.
3. Radiator. Check the coolant level and top up as necessary. Do not remove the coolant expansion tank filler cap while the engine is hot.
4. Parking. Ensure the truck is correctly parked with the parking brake engaged, the transmission in neutral and the Fwd/Rev selector in the Fwd position.
5. Crane. Ensure the crane controls are at neutral and that the crane and stabilisers are correctly stowed.
6. General. Ensure the truck is left in a clean condition. Report any service due. Report any malfunctions or damage. Ensure the truck is locked.

3.4 Regular Servicing

I have moved this information to a separate servicing page as it became too large for here.

3.4.1 Check Engine Oil

Provided that you are at least 6 foot six, then this is an easy job :-). All jokes aside, it is an easy job, but it is also high up. I use a stool. Others climb up the front step and stand on the front bar work. The dipstick is at the front central part of the engine bay, covered in a red rubber cap. The dipstick shows full through to 1 litre down. As the Army Mogs were intended to use oil, the oil is likely to need topping up every few hundred k's.

3.4.2 Greasing

The Unimog is an old school vehicle, and it requires greasing of many points - something that most modern vehicle owners probably don't do. A few users on Facebook report that greasing the Mog is not as simple as it sounds. One user reported that they purchased a Makita grease gun kit, only to find that "it does not clip onto the nipple properly and none of the grease actually got into where it needs to go." Several users indicated the need for high pressure quick release coupler and flexible high pressure whip hose. The amount of grease points / volume of grease makes little 'hand grease pumps' fairly hard work. Most owners appear to have gone for a battery powered grease gun with or without a quick release coupler.

3.4.3 Change Engine Oil

A quick look at the Regular Servicing details shows that checking and changing the engine oil are two of the most common tasks. Jele, of the YouTube PatandJele team, has a great video of this: Jele changing the engine oil.

3.4.4 Check / Change Portal Oil

The Portals, while providing a substantial improvement in off-road capability, also appear to be one of the areas that can cause trouble in the Mogs. The oil is 75W-140 and it should be syringed into the portal. (see Manual Oil Syringe Tool) There are four tasks that need to be done here:

1. Check Portals temperature. Hand temperature probes are cheap, and hand held infra-red video probes are coming down in price. I purchased one for $89 on Ebay that seems to do the job. (see Infra-red thermometer tool)
2. Check Portal Oil Level. Mogs and Dogs check (and change) portal oil
3. Change Portal Oil. Mogs and Dogs change portal oil
4. Change Portal Seals. YouTube Chasing the Dog Portal Seal Replacement video. YouTube Locked and Lifted 4x4 Portal Seal Rebuild

3.4.5 Check / Change Transmission Oil

3.4.6 Replace Oil Filter

3.4.7 Replace Fuel Filter

3.4.8 Replace Air Filer