Remove/install equipment carrier of rear cooling system

AR20.50-W-1020J

Remove/install equipment carrier of rear cooling system

08.11.2018

Engine

473.9 in model 963, 964

with rear cooling system

1

Air filter housing

2

Exhaust pipe

3

Coolant hoses

4

Coolant lines

5

Coolant hose

6

Coolant pipe

7

Turbo retarder connector (for code G3Y (Turbo retarder connector))

8

Coolant pipe

9

Coolant pipe

10

Coolant hose

13

Coolant hose

8

Coolant pipe

11

Coolant hose

12

Cab carrier

14

Propeller shaft

15

Hydraulic pump

12

Cab carrier

18

Implement carrier

A18

Electronic Air Processing Unit (EAPU) control unit

16

Electrical line

21

Fuel lines

Pfeil A

Compressed air line set

17

Jump start connector

22

Fuel prefilter (for code M8Y (Fuel prefilter, fixed to the chassis, additional))

18

Implement carrier

25

Hydraulic lines

28

Hydraulic hose

23

Fuel line

26

Step plate

B39

Fuel level sensor

24

Clutch carrier

27

Hydraulic hose

Pfeil B

Separating point

18

Implement carrier

19

Screw/bolts

18

Implement carrier

19

Screw/bolts

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 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 with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A

 

Remove/install

1

Tilt cab

2

Remove soundproofing

3

Drain coolant out of rear cooling system

AR20.50-W-0001J

4

Discharge compressed-air system

5

Disconnect ground line of battery

AR54.10-W-0003H

6

Remove air filter housing (1).

Only for vehicles without code M8A (Air intake from the front).

AR09.10-W-1050-01H

 Bolt/nut, air intake duct to bracketBolt/nut, air intake pipe to bracket

*BA09.10-N-1002-01D

 Clamp, air intake hose to turbocharger

*BA09.20-N-1001-01E

7

Remove exhaust pipe (2)

8

Remove coolant hose (5) from coolant pipe (6).

 Installation: Replace sealing rings on the banjo bolt.

9

Remove coolant pipe (8) from coolant hose (11)

 Installation: Replace coolant hose (11).

10

Remove coolant pipe (9) together with the coolant hoses (10, 13)

AR20.20-W-7470-01H

 Installation: Replace coolant hose (13). Replace sealing ring on coolant hose (10). Coat sealing ring with lubricant. Click safety clamp onto coolant hose (10).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

11

Remove drive shaft (14) for power take-off at the hydraulic pump (15)

12

Remove electrical lines (16) for battery at the jump start connector (17)

13

Expose electrical lines (16) on device carrier (18)

14

Remove cab carrier (12)

Only on vehicles with code F1R(L cab).

AR60.80-W-0075-01H

 Bolt, rear cab support mounting console to vehicle frame

*BA60.80-N-1025-01B

15

Remove fuel lines (21) on fuel prefilter (22)

Only for vehicles with code M8Y (Fuel prefilter, fixed to the chassis, additional).

 Installation: Install new sealing rings on the banjo bolts.

16

Expose fuel lines (21) on device carrier (18)

17

Mark air lines on EAPU control unit (EAPU) (A18)

18

Remove air lines on EAPU control unit (EAPU) (A18)

19

Mark all connections on the still to be removed air lines on the major assemblies in the device carrier (18)

20

Remove the associated air lines on the major assemblies in device carrier (18)

21

Expose compressed air line set (arrow A) and electrical lines on device carrier (18)

22

Remove fuel lines on fuel level sensor (B39)

Fuel lines with securing clamp.

AR47.50-W-0110-01H

Fuel lines with plug coupling.

AR47.50-W-0110-01HA

 Screw-in fitting VOSS 203

*BA47.25-N-1006-01N

 Torque wrench

*001589862100

 Box wrench bit

*001589000300

23

Disconnect fuel line (23) at connecting point (arrow B) and expose at device carrier (18)

24

Remove clutch carrier (24) from device carrier (18)

25

Remove hydraulic lines (25) at connections in clutch carrier (24)

26

Remove associated socket on clutch carrier (24)

27

Expose electrical wiring harness and air lines to clutch carrier (24) on the device carrier (18) at the rear

28

Expose air lines to the clutch carrier (24) on device carrier (18) at the rear

29

Remove step plate (26)

30

Disconnect hydraulic hoses (27, 28)

 Collect hydraulic fluid which flows out in a suitable vessel.

31

Hook on device carrier (18) using a suitable shackle on workshop crane

32

Remove screw/bolts (19) on device carrier (18)

 Installation: Note different lengths of screw/bolts (19).

 Frame sections to frame

*BA31.30-N-1001-01D

33

Raise device carrier (18) from frame using the workshop crane


Carefully lift device carrier (18.
Detachable parts on the device carrier (18) or on the vehicle can be damaged otherwise.

34

Place device carrier (18) on a suitable base and secure


Carefully lower device carrier (18.
Detachable parts on the device carrier (18) can get damaged otherwise.

35

Install in the reverse order

 Air filter

Number

Designation

Engine 470.9, 471.9, 473.9 in model all
except code M8A (Air intake, from front)
Engine 936.9 in model 963, 964
except code M8A (Air intake, from front)

BA09.10-N-1002-01D

Bolt/nut, air intake pipe to bracket

Nm

20

 Intake manifold

Number

Designation

Engine 470.9, 471.9, 473.9, 934.9, 936.9

BA09.20-N-1001-01E

Clamp, air intake hose to turbocharger

Nm

6

 Frame

Number

Designation

Model 963, 964

BA31.30-N-1001-01D

Frame sections to frame

M10x1.5

Nm

80

M12x1.5

Nm

95

M14x1.5

Stage 1

Nm

150

Stage 2

°

90

M16x1.5

Stage 1

Nm

225

Stage 2

°

90

M18x1.5

Stage 1

Nm

330

Stage 2

°

90

 Fuel lines/hoses

Number

Designation

Engine 470.9, 473.9

BA47.25-N-1006-01N

Screw-in fitting VOSS 203

M8

Plastic

Nm

2

Metal

Nm

5

 Cab mounting

Number

Designation

Model 963, 964

BA60.80-N-1025-01B

Bolt, rear cab support mounting console to vehicle frame

M14x1.5

Nm

­

M18x1.5

Stage 1

Nm

330

Stage 2

°

90

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67