Remove/install cab

AR60.80-W-1000D

Remove/install cab

12.02.2019

Model

375.3 with body 375.810

Model

950.5/6, 952.5/6, 953.6, 954.5 with body 940.899

1

Shift control unit

10

Electrical connector

19

Hose clamp

2

Screw

11

Electrical connector

20

Bolt with nut

3

Bracket

12

Cable tie

21

Primary shaft

4

Bracket

13

Dust boot

22

Universal joint

5

Screw

14

Coolant filler neck

23

Screw

6

Nut

15

Top part of radiator

24

Connector - only on vehicles with code H61 (Webasto Air Top 2000 warm air auxiliary heater)

7

Cable tie

16

Filler neck

25

Fuel line - only on vehicles with code H61 (Webasto Air Top 2000 warm air auxiliary heater)

8

Electrical connector

17

Hose clamp

26

Compressed air distributor

9

Vent hose

18

Bellows

27

Connection plate

28

Plug

37

Nut

46

Refrigerant line - only on vehicles with code H03 (Air conditioning in front end)

29

Screw

38

Electrical connector

47

Cable guide tubes

30

Cab mounting

39

Bracket (noise damper)

48

Inlet duct end piece

31

Nut

40

Screw

49

Nut

32

Screw

41

Electrical connector

50

Screw

33

Suspension strut

42

Coolant hoses

51

Cover

34

Screw

43

Refrigerant line - only on vehicles with code H03 (Air conditioning in front end)

52

Cab-chassis connector plate

35

Pedal bracket

44

Bolt - only on vehicles with code H03 (Air conditioning in front end)

53

Bellows

36

Bracket

45

Bracket - only on vehicles with code H03 (Air conditioning in front end)

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

 Danger

Risk of death caused by improper lifting of cab. Risk of injury caused by body parts being trapped and crushed when lowering cab

Only used approved lifting cradles. Ensure that the mounts are securely seated. Stay out from underneath a hanging cab.

AS60.80-Z-0002-01A

 Danger

Risk of death caused by falling from vehicle roof. Risk of injury to other persons caused by falling objects during work in roof area.

AS65.00-Z-0002-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on safety-relevant components

AH00.00-Z-0019-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A

 

Remove/install

1

Disable alarm system

If present.

 Observe the operator's manual.

2

Disconnect battery ground line

AR54.10-W-0003A

3

Detach dust toot (13) on gearshift lever from engine tunnel and pull upward

4

Disconnect connector (11) from gearshift lever

5

Tilt cab

6

Remove bracket (3, 4) for hydraulic lines on hydropneumatic power shift (HPS) from engine tunnel

7

Remove bleed hose (9) from hydraulic liquid reservoir on shift control unit (1)

 Plug connection fitting on hydraulic liquid reservoir with suitable cap.

8

Disconnect electrical connectors (8, 10)

9

Remove cable tie from electrical and hydraulic lines on shift control unit (1)

10

Remove shift control unit (1) downward and place on transmission toward rear

 Do not remove hydraulic lines.

 Transmission 715.510/561Sensor unit to engine tunnel

*BA26.60-N-1004-01KL

11

Fasten free ends of disconnected cables and lines at cab end to cab underbody

12

Release boot (18) at steering gear and slide upwards

13

Check whether marking on primary shaft (21) on steering gear and assembly slot of universal joint (22) are flush

If the assembly slot has moved.



Mark installation position of universal joint (22) relative to primary shaft (21).

14

Remove universal joint (22) of lower steering shaft from steering gear

 Installation: The contact surface for screw and nut at universal joint (22) must be free of grease. Note marking or identification.

 Fit bolt/nut, universal/constant velocity joint

*BA46.10-N-1001-07B

15

Separate fuel line (25) to auxiliary heater

Only on vehicles with code H61 (Webasto Air Top 2000 warm air auxiliary heater)

 Catch leaking fuel in a suitable vessel.

16

Remove lower end of line together with connector (24) from cab floor and seal off line

Only on vehicles with code H61 (Webasto Air Top 2000 warm air auxiliary heater)

17

Remove connection plate (27) from compressed-air distributor (26) and place to one side with compressed-air lines

18

Remove filler neck (16)

19

Detach coolant filler neck (14)

 Unclip clamping ring on coolant filler neck (14) with flat tip screwdriver from rear.

20

Lower cab


Make sure that the disconnected cables and lines are not trapped between the cab and the vehicle chassis.
To prevent damaging lines.

21

Remove trim piece from radiator

22

Detach middle paneling over bumper

23

Remove right and left turn signal lamps

24

Remove right and left turn signal lamp frames

25

Remove bracket (36, 39) from firewall

26

Remove lead seal at electrical connector (38)

 Installation: Check tachograph according to § 57b.

27

Disconnect electrical connector (38) and push top end of cable inside together with rubber grommet

28

Disconnect electrical connectors (41) from service brake valve

29

Remove left top footwell trim section on driver side

30

Cut cable ties to secure tachograph cable on rear of pedal bracket (35)

31

Detach pedal bracket (35) from firewall and carefully hang over front of bumper with cables still connected

32

Remove inlet duct piece (48)

33

Remove cover (51) from cab/chassis connector plate (52)

34

Disconnect electrical connectors at cab/chassis connector plate (52)

 Installation: Observe row and gap markings on connectors.

35

Remove ground and positive lines from cab/chassis connector plate (52)

36

Remove cable guide tubes(47) from brackets on firewall

 Installation: Plug markings indicate sequence.

37

Partially drain coolant at radiator



Vehicles without code BA1 (Voith retarder, performance-optimized) or code BA9 (Voith secondary retarder R 115)

AP20.00-W-2080-01A



Vehicles with code BA9 (Voith secondary retarder R 115)

AP20.00-W-2080-01B



Vehicles with code BA1 (Voith retarder, performance-optimized)

AP20.00-W-2080-01C

 Coolant drain plug to radiator

*BA20.20-N-1001-01D

 Coolant

*BF20.00-N-1001-01C

38

Detach coolant hoses (42) on firewall bottom edge from lines to heater heat exchanger

39

Drain air conditioning system

Only on vehicles with code H03 (Air conditioning in front end)

AR83.30-W-1760A

40

Detach bracket (45) for refrigerant line (46) behind step in bumper

Only on vehicles with code H03 (Air conditioning in front end)

41

Disconnect refrigerant lines (43, 46) and immediately plug both line ends

Only on vehicles with code H03 (Air conditioning in front end)

 If the lines are not plugged, the refrigerant drier will absorb moisture from the surrounding atmosphere until its saturation limit is reached. The refrigerant drier then ceases to function correctly.

42

Guide ends of refrigerant lines (43, 46) upward and fasten to cab with cable tie

Only on vehicles with code H03 (Air conditioning in front end)

43

Fold back foot mats on both sides and remove plugs (28) from cutouts in floor panel

44

Unscrew bolts (29) from cab floor on both sides

 Bolt, cab floor to front cab mount

*BA60.80-N-1001-01B

45

Adjust jib length of cab assembly cradle to fit the roof height



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

46

Attach crane or forklift hook to assembly cradle



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

 Lift assembly cradle slightly with crane and take off casters.

47

Open door

48

Release rear cab locks with a few strokes of the pump

49

Position front lifting cradle in door cutouts and raise cab until front suspension struts (33) of cab mounting are released as far as possible



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

 Position cab assembly cradle level with cab's approximate center of gravity.

50

Unscrew nut (31) on upper suspension strut mounts

 Nut, suspension strut to front cab mounting

*BA60.80-N-1007-01B

51

Push down suspension struts (33) until bolts (32) can be pulled out

52

Fold suspension struts (33) over towards the front

53

Remove cab mounts (30) from firewall

 Bolt, cab mount to firewall

*BA60.80-N-1012-01B

54

Lift off cab


When lifting off, guide the cab so that the cab or cab components do not catch on the chassis.
In order to prevent damage.

 Installation: Align cab above frame and lower only until bolts (29, 34) can be positioned and screwed in. Then lower completely.

55

Remove assembly cradle from cab

 Installation: Position lifting cable so that cab hangs slightly toward front.

56

Install in the reverse order

57

Check electrical system for proper function as well as cooling system and hydraulic system for leakage

58

Normalize time on modular tachograph (MTCO)

59

Set time of auxiliary heater

Only on vehicles with code H61 (Webasto Air Top 2000 warm air auxiliary heater)

 Radiator, coolant hoses

Number

Designation

ENGINE 904.9, 906.9

ENGINE 926.9

BA20.20-N-1001-01D

Coolant drain plug to radiator

Nm

4

4

 Radiator, coolant hoses

Number

Designation

ENGINE 902.9

BA20.20-N-1001-01D

Coolant drain plug to radiator

Nm

4

 Shift

Number

Designation

Transmission 715.500/507/510/513/520/540

Transmission 715.561

BA26.60-N-1004-01KL

Sensor unit to engine tunnel

Nm

30

-

 Steering wheel, steering column bracket, steering shaft

Number

Designation

Model 375.3/4, 940, 942, 943, 944, 950.5/6, 952.5/6, 953.6, 954.5, 958.2/4

BA46.10-N-1001-07B

Fit bolt/nut, universal/constant velocity joint

Nm

30

 Cab mounting

Number

Designation

Body 375.810/820 in model 375.3

Body 940.890/899 in model 950.5/6, 952.5/6, 953.6, 954.5

BA60.80-N-1001-01B

Bolt, cab floor to front cab mount

M14x1.5

Stage 1

Nm

150

150

Stage 2

°

45

45

M16x1.5

Stage 1

Nm

­

­

Stage 2

°

­

­

 Cab mounting

Number

Designation

Body 375.810/820 in model 375.3

Body 940.890/899 in model 950.5/6, 952.5/6, 953.6, 954.5

BA60.80-N-1007-01B

Nut, suspension strut to front cab mounting

M14x1.5

Nm

163

163

 Cab mounting

Number

Designation

Body 375.810/820 in model 375.3

Body 940.890/899 in model 950.5/6, 952.5/6, 953.6, 954.5

BA60.80-N-1012-01B

Bolt, cab mount to firewall

M12x1.5

Stage 1

Nm

92

92

Stage 2

°

45

45

M16x1.5

Stage 1

Nm

­

­

Stage 2

°

­

­

 Engine cooling

Number

Designation

ENGINE 902.9 in MODEL 375.3, 950, 952, 953, 954 except CODEBA1

ENGINE 902.9 in MODEL 950, 952, 953, 954 with CODE BA1

BF20.00-N-1001-01C

Coolant

Total filling capacity

l

22

37,0

Anticorrosion/antifreeze agent down to -37 °C

l

11

18,5

Anticorrosion/antifreeze agent down to -45°C

l

12,0

20,5

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-05A

BB00.40-P-0325-05A

 Engine cooling

Number

Designation

ENGINE 906.9 in MODEL 374.5, 375.3, 950, 952, 953, 954, 958.2 except CODE BA1 except CODEBA9

ENGINE 906.9 in MODEL 950, 952, 953, 954, 958.2 with CODE BA1

BF20.00-N-1001-01C

Coolant

Total filling capacity

l

22

37

Anticorrosion/antifreeze agent down to -37 °C

l

11

18,5

Anticorrosion/antifreeze agent down to -45°C

l

12,0

20,5

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-05A

BB00.40-P-0325-05A

 Engine cooling

Number

Designation

ENGINE 906.9 in MODEL 950, 952, 953, 954 with CODE BA9

ENGINE 926.9 in MODEL 950, 952, 953, 954, 958.2 except CODE BA1 except CODE BA9

BF20.00-N-1001-01C

Coolant

Total filling capacity

l

40

22

Anticorrosion/antifreeze agent down to -37 °C

l

20

11

Anticorrosion/antifreeze agent down to -45°C

l

22

12,0

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-05A

BB00.40-P-0325-05A

 Engine cooling

Number

Designation

ENGINE 926.9 in MODEL 950, 952, 953, 954, 958.2 with CODE BA1

ENGINE 926.9 in MODEL 950, 952, 953, 954, 958.2 with CODE BA9

BF20.00-N-1001-01C

Coolant

Total filling capacity

l

37

40

Anticorrosion/antifreeze agent down to -37 °C

l

18,5

20

Anticorrosion/antifreeze agent down to -45°C

l

20,5

22

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-05A

BB00.40-P-0325-05A