Remove/install entry assembly

AR61.10-W-5814A

Remove/install entry assembly

15.3.10



Removing

1

Remove front side part of bumper

AR88.20-W-2000C

2

Remove windshield washer fluid reservoir

 Only on passenger side.

3

Remove front corner part

AR88.00-W-3300A

4

Remove front door

 Only with hinged door.

AR72.10-W-0500C

5

Remove folding door

AR72.10-W-2000A

6

Remove rubber seal at A and B-pillar

 Only if folding door fitted.

7

Remove cover rail (1, 2) at A and B-pillar

8

Remove cover for cable duct at entrance box

 Only on driver's side.

9

Remove bolts of cable duct at entrance box

 Only on driver's side.

10

Remove cover (3) for top tilt cylinder mount at entrance box

 Only on passenger side.

11

Remove bottom guide rail (4) of folding door

12

Remove entrance lamp (5)

13

Turn back floor panel in area of entrance box

14

Cut off entrance box

AR61.10-W-5814-01A

Cutting wire

Multicutter

Cutting blade

Saw blade

Deep stop ring for saw blade,

Firma Fein GmbH D-70176 Stuttgart



Install

15

Cut off remaining adhesive material at cab with scraper knife

 Cut off glue residues down to approx. 0.2 to 0.3 mm. Pull off loose adhesive material (remaining pieces which are not completely cut off). Clean bonded area with activator.

Touch up damaged primer layer at cab as specified in the methods of use for the market-specific national packages.

*BR00.45-Z-1023-04A

16

Cut off remaining adhesive material at cable duct with scraper knife

 Only on driver's side.

Scraper

17

Attach spacers (arrows) to bonded surface of cab

 Spacers are available in different thicknesses and must be combined accordingly for the specified dimension.

*BE61.10-N-1001-01A

*BE61.10-N-1002-01A

*BR00.45-Z-1001-10A

*BR00.45-Z-1002-10A

18

Prepare entry assembly for installation

AR61.10-W-5814-02A

*BR00.45-Z-1018-02A

*BR00.45-Z-1021-02A

*BR00.45-Z-1023-04A

19

Prepare cartridge gun

Electric cartridge gun

20

Apply adhesive bead evenly along the remaining adhesive bead on the cab

 Height of adhesive bead approx. 12 mm

The adhesive bead must be applied immediately after airing the cleaner and primer. It is then necessary to glue in the paneling within 30 min. before the adhesive force of the glue decreases.

*BR00.45-Z-1018-02A

21

Apply adhesive bead evenly along the remaining adhesive bead at the cable duct

 Height of adhesive bead approx.

12 mm.

*BR00.45-Z-1018-02A

22

Fit entrance box onto adhesive bead

 Press on entrance box until it is touching the spacers.
The curing time is approx. 12 h calculated from the time the entrance box is installed.

23

Screw in bolts for attaching cable duct at entrance box

 Only on driver's side.

 Danger!

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 with the safety strut.

AS60.80-Z-0001-01A

24

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

25

Seal off the gap point between entrance box and floor panel at the underfloor

*BR00.45-Z-1027-01A

26

Lower cab

27

Fit on floor panel

28

Install entry light (5)

29

Install bottom guide rail (4) of folding door

30

Install cover (3) for top tilt cylinder mount at entrance box

 Only on passenger side.

31

Install cover for cable duct at entrance box

 Only on driver's side.

32

Install cover rail (1, 2) at A and B-pillar

33

Install rubber seal at A and B-pillar

 Only if folding door fitted.

34

Install folding door

AR72.10-W-2000A

35

Install front door

 Only with hinged door.

AR72.10-W-0500C

36

Install front corner part

AR88.00-W-3300A

37

Install windshield washer fluid reservoir

 Only on passenger side.

38

Install front side part of bumper

AR88.20-W-2000C

Number

Designation

Model series 957

BE61.10-N-1001-01A

Distance between entrance box and B-pillar

Dimension "D"

mm

6

BE61.10-N-1002-01A

Distance between entrance box and floor panel

Dimension "E"

mm

2

See picture

AR61.10-W-5814A

Number

Designation

Order number

BR00.45-Z-1027-01A

Sealant, gray, No.7121; 310 ml

A 001 989 64 20

BR00.45-Z-1018-02A

Adhesive, Sikaflex 252, 330 ml

A 005 989 36 71

BR00.45-Z-1021-02A

Loctite 3295 adhesive

Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

BR00.45-Z-1023-04A

Sika activator

A 005 989 58 71

BR00.45-Z-1001-10A

Spacer for 613 640 11 09/613 640 12 09

A 357 616 01 90

BR00.45-Z-1002-10A

Spacer, hinge at flap 510653 01

A 357 616 02 90