Our ex-Army U1700L Unimog Servicing notes

3.4 Regular Servicing

This servicing section started to end up monsterous, so I have moved it to a seperate page. I will add details here, and probably short videos. The primary source of information here is the ADF G609 Unimog Servicing Instruction, however I found that you need to look at several documents, and then check Facebook. The ADF used NATO or Military stock numbers and references for inter-operability and Integrated Logistic Support reasons, but these reasons dont apply to the now civilian-ised trucks. I have tried to keep the original details, but add civilian equivalent products and practices.

3.4.1 Servicing Sequence

The following servicing sequence is to be applied:

1. Technical Inspection (TI) – 5 000 km or 12 months after the last service (this TI is to include a brake and clutch fluid change);
2. Minor Service – 5 000 km or 12 months after the last TI;
3. TI – 5 000 km or 12 months after the last Minor Service;
4. Major Service – 5 000 km or 12 months after the last TI;
5. TI – 5 000 km or 12 months after the last Major Service;
6. Minor Service – 5 000 km or 12 months after the last TI;
7. TI – 5 000 km or 12 months after the last Minor Service; and
8. Alternate Major Service – 5 000 km or 12 months after the last TI.

I found the above statement confusing. This might help:
0km --- 5,000km Tech Inspect --- 10,000 Minor Service --- 15,0000 Tech Inspect --- 20,000 Major Service (repeat ... but) 40,000

Alternate

Major Service

Servicing Requirements (based on G609 Unimog all types Servicing Instruction)

Serial	Item or Assembly	Technical Inspection (TI)	Minor Service	Major Service	Alternate Major Service	Capacity (litres)	Lubricant See notes on Lubricants	Comments
First Parade Servicing
FP1	Check Engine oil & top up as necessary	-	-	-	-	15	SAE GRADE 40, (OMD-115), Castrol RX Super 15W-40 CJ-4/E9	First Parade (i.e. daily) servicing
FP2	Check Coolant Level & top up as necessary	-	-	-	-	-	PGXL (Cummins or Penrite)	First Parade (i.e. daily) servicing
FP3	Check Windscreen Washer Level & top up as necessary	-	-	-	-	-	Water + Bar's Bugs	First Parade (i.e. daily) servicing
FP4	Check Fuel Level & top up as necessary	-	-	-	-	-	Diesel	First Parade (i.e. daily) servicing
FP5	Security. Check Spare Wheel is securely mounted.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP6	Truck Servicablity. Inspect the truck for any damage, and loose or missing parts.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP7	Tyres. Check tyre pressures and inspect treads and sidewalls.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP8	Leakage. Check under trucks for signs of coolant, oil or fuel leakage.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP9	Crane (if fitted), check that it is stowed, check oil level, and check hoses.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP10	Dump (if fitted),check Oil and top up if necessary, check all hoses.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP11	Air Pressure Check. Start the engine and check that pressure rises above 12bar and light extinguish.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP12	Accessories. Check horn, headlights, stop lights, indicators, hazard lights, windsreen washers & wipers work.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP13	Brakes. Allow the truck to move forward slightly and check that the foot brake works.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP14	Steering. Whilst moving slowly, check that the steering is free and responsive.	-	-	-	-	-		First Parade (i.e. daily) servicing
FP15	General. Check all lashings and tie downs.	-	-	-	-	-		First Parade (i.e. daily) servicing
Halt Parade Servicing
HP1	Engine. Check engine oil and top up as necessary.	-	-	-	-	-		Halt Parade (i.e. after 4 hours, or when stopped for a break) servicing
HP2	Radiator. Check coolant level and top up as required.	-	-	-	-	-		Halt Parade (i.e. after 4 hours, or when stopped for a break) servicing
HP3	Fuel. Check fuel level and top up / refuel as required.	-	-	-	-	-		Halt Parade (i.e. after 4 hours, or when stopped for a break) servicing
HP4	Tyres. Check tyre pressures and inspect treads and sidewalls.	-	-	-	-	-		Halt Parade (i.e. after 4 hours, or when stopped for a break) servicing see Unimog Notes Tyre Pressures
Last Parade Servicing
LP1	Fuel. Fill the fuel tank.	-	-	-	-	-		Last Parade (i.e. at end of day or end of trip) servicing
LP2	Engine. Check oil level and top up as necessary.	-	-	-	-	-		Last Parade (i.e. at end of day or end of trip) servicing
LP3	Radiator. Check the coolant level and top up as necessary.	-	-	-	-	-		Last Parade (i.e. at end of day or end of trip) servicing
LP4	Parking. Ensure the truck is parked correctly, out of gear, forward-reverse out of gear, park brake on.	-	-	-	-	-		Last Parade (i.e. at end of day or end of trip) servicing
LP5	Crane (if fitted). Controls at neutral and crane and stabalisers stowed.	-	-	-	-	-		Last Parade (i.e. at end of day or end of trip) servicing
LP6	General. Ensure truck is clean.	-	-	-	-	-		Last Parade (i.e. at end of day or end of trip) servicing
1	Engine oil	-	Drain & Refill	Drain & Refill	Drain & Refill	15	SAE GRADE 40, (OMD-115), Castrol RX Super 15W-40 CJ-4/E9
2	Engine oil filter	-	Replace	Replace	Replace
3	Transmission oil	-	Top Up	Drain & Refill	Drain & Refill	10.5	SAE GRADE 40, (OMD-115), Castrol RX Super 15W-40 CJ-4/E9
4	PTO transmission oil	-	Top Up	Drain & Refill	Drain & Refill	5.75	SAE GRADE 40, (OMD-115), Castrol RX Super 15W-40 CJ-4/E9	For Mogs with PTO Winches
5	Front and rear differential oils	-	Top Up	Drain & Refill	Drain & Refill	2.5	OEP-220, CASTROL AXLE AP 85W-140, Gear oil SAE 90
6	Front and rear reduction hub oils	-	Top Up	Drain & Refill	Drain & Refill	0.6	OEP-220, CASTROL AXLE AP 85W-140, Gear oil SAE 90
7	Park brake lever	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
8	Power steering reservoir	-	Top Up	Top Up	Drain & Refill	2.25	OX-47, CASTROL AGRI TRANS PLUS 80W
9	Steering system	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
10	Clutch to transmission drive shaft	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
11	PTO transmission shaft joints	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature	For Mogs with PTO Winches
12	PTO winch driveshaft	-	Lubricate	Lubricate	Lubricate		XG-291	For Mogs with PTO Winches
13	Winch dog clutch shaft	-	Lubricate	Lubricate	Lubricate		Molybond 122L (NSN 9150- 66-089-5365)	For Mogs with PTO Winches
14	Winch mounting pins	-	Lubricate	Lubricate	Lubricate		Molybond 122L (NSN 9150- 66-089-5365)	For Mogs with PTO Winches
15	Winch oil	-	Top Up	Drain & Refill	Drain & Refill	2.0	OEP-220, CASTROL AXLE AP 85W-140, Gear oil SAE 90
16	Winch fairleads and rollers	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
17	Winch rope	-	Clean & Lubricate	Clean & Lubricate	Clean & Lubricate		XG-291, Castrol Lithium Grease High Temperature
18	Engine brake linkage	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
19	Door locks and hinges	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
20	Fuel tank	-	Drain & Refill (Check for Water)	Drain & Refill (Check for Water)	Drain & Refill (Check for Water)
21	Fuel pre-filter	-	Clean	Clean	Clean
22	Main Fuel filters	-	-	Replace	Replace
23	Air filter	-	Clean	Clean	Clean
24	Spare wheel carrier operation	-	Inspect	Inspect	Inspect
25	Bonnet locks and hinges	-	Lubricate	Lubricate	Lubricate		SAE GRADE 40 (OMD-115)
26	Accelerator cross shaft and pedal pivot	-	Clean & Lubricate	Clean & Lubricate	Clean & Lubricate		XG-291, Castrol Lithium Grease High Temperature
27	Tailgate hinges, catches - and latches	-	Lubricate	Lubricate	Lubricate		SAE GRADE 40, (OMD-115), Castrol RX Super 15W-40 CJ-4/E9
28	Battery compartment - slides	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
29	Battery electrolyte level (bottom of the filler spouts), security and cleanliness of terminals and posts	-	Top Up & Clean	Top Up & Clean	Top Up & Clean			Spray battery Terminal posts with CRC Battery Terminal Protector.
30	Seat slides	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
31	Driving mirrors and window glasses	-	Clean & Inspect	Clean & Inspect	Clean & Inspect		XG-291, Castrol Lithium Grease High Temperature
32	Tyre pressures	-	Inspect	Inspect	Inspect			See Tyre Pressures section.
33	Wheel nut security	-	Inspect	Inspect	Inspect
34	Spare wheel security	-	-	Inspect	Inspect
35	Spare wheel winch operation	-	Inspect	Inspect	Inspect
36	Pintle Hook	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature
37	Tray twist locks	-	Lubricate	Lubricate	Lubricate		SAE GRADE 40, (OMD-115), Castrol RX Super 15W-40 CJ-4/E9	If fitted.
38	CES	-	Inspect	Inspect	Inspect			Need to find out what CES stands for.
39	Vehicle jack classification tag	-	Inspect	Inspect	Inspect
40	Vehicle fire extinguisher inspection tag	-	Inspect	Inspect	Inspect
40	Vehicle cleanliness	-	Clean	Clean	Clean
42	Hydraulic oil reservoir	-	Top Up	Drain & Refill	Drain & Refill		OM-33, Castrol OM-33	Dump Truck only
43	Hydraulic oil filter	-	-	Replace	Replace			Dump Truck only
44	Hoist cylinder and tailgate trunnions	-	Lubricate	Lubricate	Lubricate		XG-291, Castrol Lithium Grease High Temperature	Dump Truck only
45	Tailgate cylinder	-	-	Clean & Lubricate	Clean & Lubricate		XG-291, Castrol Lithium Grease High Temperature	Dump Truck only
46	Tailgate hinge lever	-	Clean	Clean	Clean		XG-291, Castrol Lithium Grease High Temperature	Dump Truck only
47	Dump system operation incl. locks and gauges	-	Action Required	Action Required	Action Required			Dump Truck only
48	Engine mounting bolts	-	-	Inspect	Inspect			Tradesperson Task. Inspect the engine mounting bolts for the correct tension in accordance with EMEI Vehicle G 603.
49	Exhaust manifold bolts security	-	-	Inspect	Inspect			Tradesperson Task
50	Valve clearance	-	-	Inspect	Inspect			Tradesperson Task
51	Engine breather filter	-	-	-	Replace			Tradesperson Task
52	Front and rear axle stabiliser bar mounting bolts security (bracket to chassis)	-	Inspect	Inspect	Inspect			Tradesperson Task
53	Front and rear strut - securing bolts security (axle to torque tube)	-	-	Inspect	Inspect			Tradesperson Task
54	Front and rear pan hard rod securing bolts security (axle to chassis)	-	Inspect	Inspect	Inspect			Tradesperson Task. The panhard rod securing bolt is not to be over-tightened. If the bolt is over-tightened, the bush inner sleeve may collapse. Tighten the bolt to 315 N.m.
55	Transmission mounting - bolts security	-	-	Inspect	Inspect			Tradesperson Task
56	Transmission shift - mechanism	-	-	Inspect	Inspect			Tradesperson Task. Confirm the transmission shift mechanism operates correctly and that the expansion plug is present and secure in accordance with EMEI Vehicle G 617-29.
57	Power steering reservoir	-	-	Inspect	Inspect		OX-47, CASTROL AGRI TRANS PLUS 80W	Tradesperson Task
58	Power steering oil filter	-	-	-	Replace			Tradesperson Task
59	Steering system	-	Inspect	Inspect	Inspect			Tradesperson Task
60	Steering box mounting bolts security	-	-	Inspect	Inspect			Tradesperson Task
61	Compressed air system - including pipes and hoses	-	Inspect	Inspect	Inspect			Tradesperson Task
62	Drive belts	-	Inspect	Inspect	Inspect			Tradesperson Task
63	Fuel lines for chaffing, - leaks and security	-	Inspect	Inspect	Inspect			Tradesperson Task
64	Air filter	-	Inspect	Inspect	Inspect			Tradesperson Task. Clean the air filter in accordance with EMEI Vehicle A 591-1.
65	Air system operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
66	Brake hydraulic system	Drain & Refill, then Bleed	Drain & Refill, then Bleed	Drain & Refill, then Bleed	Drain & Refill, then Bleed	1.0	OX-8, CASTROL AGRI TRANS PLUS 80W	OX-8 is a rust inhibiting hydraulic fluid. Tradesperson Task.
67	Brake system operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
68	Brake pad wear	-	Inspect	Inspect	Inspect			Tradesperson Task.
69	Clutch hydraulic system	Drain & Refill, then Bleed	Drain & Refill, then Bleed	Drain & Refill, then Bleed	Drain & Refill, then Bleed	0.2	OX-8, CASTROL AGRI TRANS PLUS 80W	OX-8 is a rust inhibiting hydraulic fluid. Tradesperson Task.
70	Clutch system operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
71	Tray to chassis mounting bolts security	-	-	Inspect	Inspect			Tradesperson Task.
72	Cab to chassis mounting bolts security	-	-	Inspect	Inspect			Tradesperson Task.
73	Engine brake operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
74	Generator mounting bolts security	-	Inspect	Inspect	Inspect			Tradesperson Task.
75	Brake caliper shroud securing bolts security	-	Inspect	Inspect	Inspect			Tradesperson Task.
76	Fuel pre-filter	-	Inspect	Inspect	Inspect			Tradesperson Task.
77	Accelerator linkage and pedal stop bolt	-	-	Inspect	Inspect			Tradesperson Task. Remove the accelerator cross shaft cover. Clean and lubricate the shaft. Inspect the accelerator pedal for the presence of an accelerator stop bolt. If the stop bolt is not fitted, modify the accelerator pedal in accordance with EMEI Vehicle G 617-4. If required, set the throttle linkage in accordance with EMEI Vehicle G 603 (adjust as required).
78	Radiator coolant	-	Inspect	Drain & Refill	Drain & Refill			Tradesperson Task. Inspect and pressure test the cooling system in accordance with EMEI Vehicle G 603.
79	Suspension components	-	Inspect	Inspect	Inspect			Tradesperson Task.
80	Drive shafts and universal joints	-	Inspect	Inspect	Inspect			Tradesperson Task.
81	Cabin heating and ventilation system filter	-	Inspect	Inspect	Inspect			Tradesperson Task. Clean the air filter in accordance with EMEI Vehicle A 591-1.
82	Spare wheel winch and cable	-	Inspect	Inspect	Inspect			Tradesperson Task.
83	PTO driveshaft	-	Inspect	Inspect	Inspect			Tradesperson Task.
84	Winch dog clutch operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
85	Winch mounting pins	-	Inspect	Inspect	Inspect			Tradesperson Task.
86	Winch operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
87	Winch rope and CES recovery items	-	Inspect	Inspect	Inspect			Tradesperson Task. The winch rope is to be cleaned using mains pressure fresh water. The winch rope is not to be cleaned using high pressure cleaners. Once cleaned, the winch rope is to be inspected in accordance with EMEI Vehicle D 108 prior to lubricating. A winch rope that is fully functional can be wound back onto the winch drum. The recovery items, e.g. chain, shackles etc that are part of the vehicle CES are to be inspected in accordance with EMEI Vehicle D 108. Inspection of the winch rope and recovery CES items is a part of this check/service and must be completed if the vehicle is to be classified ‘Fully Functional’.
88	Winch torque limiter	-	-	Inspect	Inspect			Tradesperson Task. Calibrate the winch torque limiter in accordance with EMEI Vehicle G 619-29.
89	Tyres	-	Inspect	Inspect	Inspect			Tradesperson Task. Inspect the tyres in accordance with EMEI Vehicle A 298-2.
90	Wheel alignment	-	Inspect	Inspect	Inspect			Tradesperson Task. Carry out a wheel alignment in accordance with EMEI Vehicle G 603.
91	Body/chassis condition	-	Inspect	Inspect	Inspect			Tradesperson Task.
92	Seat belts, mountings and inertia reel operation	-	Inspect	Inspect	Inspect			Tradesperson Task. Inspect the seat belts in accordance with EMEI Vehicle A 548-1.
93	Headlight alignment	-	Inspect	Inspect	Inspect			Tradesperson Task. Carry out the head light alignment in accordance with EMEI Vehicle G 603.
94	Operation of lights, gauges, warning lights and horn	-	Inspect	Inspect	Inspect			Tradesperson Task.
95	Tailgate/sidegate hinges and hinge mounts	-	Inspect	Inspect	Inspect			Tradesperson Task. Inspect all tail/sidegate hinge pins and mounts for signs of damage, deformation and cracking. Check the hinge pin and hinge gap in accordance with EMEI Vehicle G 609-7.
96	Safety chain mounts secure and complete	-	Inspect	Inspect	Inspect			Tradesperson Task.
97	Pintle hook	-	Inspect	Inspect	Inspect			Tradesperson Task. Inspect the pintle hook in accordance with EMEI Vehicle A 049-1.
98	NATO plug operation	-	Inspect	Inspect	Inspect			Tradesperson Task.
99	Vehicle jack	-	Inspect	Inspect	Inspect			Tradesperson Task. Inspect the vehicle jack in accordance with EMEI Workshop H 149-1.
100	Hydraulic oil pump and mounting bracket	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
101	Hydraulic oil pump drive	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
102	Tailgate locking switch	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
103	Dump system operation incl. locks and gauges	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
104	Airlines, hoses, bushes and clamps	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
105	Hoist cylinder mounting - bolts	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
106	Hoist valve connections	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
107	Tailgate cylinder	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
108	Tailgate hinge lever	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
109	Hoist valve mounting bolts	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
110	Chassis sub-frame mounting bolts	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
111	Dumpbody	-	Inspect	Inspect	Inspect			Tradesperson Task. Dump Truck Only.
112	Crane useability	Inspect	Inspect	Inspect	Inspect			Tradesperson Task. Cargo with Crane Only. The crane is to be inspected for useability in accordance with EMEI Vehicle A 028-1 and serviced in accordance with EMEI Vehicle G 629.
113	Road test	Action Required	Action Required	Action Required	Action Required			Tradesperson Task. All variants. Road test the vehicle in accordance with EMEI Vehicle A 029-2.

3.4.1 Check Engine Oil

3.4.2 Greasing

The Unimog is old school, and it requires greasing of many points. A few users on Facebook report that this 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 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.

3.4.3 Change Engine Oil

3.4.4 Check / Change Portal Oil

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