Remove/install front crossmember

AR31.30-W-4115A

Remove/install front crossmember

18.06.2020

Model

963, 964

with code F3A (Cab mountings, standard, steel-sprung)

except code F3B (Cab mountings, comfort, steel-sprung)

except code F3C (Cab mountings, comfort, air-sprung)

Old and new as-built configuration

1

Crossmember (old, with 5 holes at top and M16 bolts at bottom)

2

Bearing bracket (old)

3

Crossmember (new, with 4 holes at top and M18 bolts at bottom)

4

Bearing bracket (new, integrated in new reinforcement (7))

5

Fastening bracket

6

Reinforcement (old)

7

Reinforcement (new)

14

Bolt (M18x1.5x120)

A

Old as-built configuration

B

New as-built configuration

Mixed as-built configuration

2

Bearing bracket (old, separate)

3

Crossmember (new, with 4 holes at top and M18 bolts at bottom)

6

Reinforcement (old)

8

Bolts (M16x1.5x70)

9

Bolt (M16x1.5x60)

10

Stop plate (12 mm) (only with mixed as-built configuration (C))

11

Bolt (M18x1.5x80)

12

Bolt (M18x1.5x80)

13

Bolt (M18x1.5x70)

14

Bolt (M18x1.5x120) (only with mixed as-built configuration (C) or old as-built configuration (A))

15

Bolt (M16x1.5x70)

16

Washers (for M16 bolts) (only with mixed as-built configuration (C))

C

Mixed as-built configuration

Pfeil

Direction of travel

 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

 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

Topical note

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

AH00.00-P-0020-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Open maintenance flap.

2

Remove middle part of front bumper.

AR88.20-W-2003A

3

Remove side parts of front bumper.

Model 963 with code F7A (bumper, corners made of plastic)

AR88.20-W-2002A

Model 963, 964 with code F7B (bumper, corners made of steel)

AR88.20-W-2002B

4

Remove detachable parts from crossmember (1, 3).

5

Remove transmission oil cooler from holders on crossmember (1, 3).

Only on vehicles with code N6Z (Transmission cooling).

 Do not separate connected lines.

6

Remove holders for transmission oil cooler from crossmember (1, 3).

Only on vehicles with code N6Z (Transmission cooling).
Only if crossmember (1, 3) is to be replaced.

7

Hook in cab lifting cradle and adjust to cab.

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

8

Lift front of cab far enough until lifting cradle is slightly tensioned.

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

 When doing so, leave the cab in the rear mount.

9

Remove mounting supports (5) from bearing brackets (2).

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

10

Lift cab further and provide additional support.

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

11

Remove bearing brackets (2).

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

12

Remove crossmember (1, 3).



Install

13.1

Install crossmember (1) and bearing brackets (2).

Old as-built configuration (A)

 First tighten the lower bolts (8, 9) and then the upper bolts (11, 12, 13, 14, 15).
Observe tightening sequence.
The tightening sequence of the bolts (11, 12, 13, 14) corresponds to the sequence of their numbering.

 Frame sections to frame

*BA31.30-N-1001-01D

13.2

Install the crossmember (3).

New as-built configuration (B)

 First tighten the lower bolts (8, 9) and then the upper bolts (11, 12, 13, 15).

 Frame sections to frame

*BA31.30-N-1001-01D

13.3

Install crossmember (3) and bearing brackets (2) with stop plates (10).

Mixed as-built configuration (C)


Also use washers (16) for the lower screws (8, 9).
Otherwise sufficient strength of the threaded connections cannot be assured.

 First tighten the lower bolts (8, 9) and then the upper bolts (11, 12, 13, 14, 15).
Observe tightening sequence.
The tightening sequence of the bolts (11, 12, 13, 14) corresponds to the sequence of their numbering.
Part number of stop plates (10)
A 960 317 00 76
Part number of washers (16)
A 010 990 80 82 or
A 005 990 68 82

 Frame sections to frame

*BA31.30-N-1001-01D

14

Remove supports and lower cab.

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

15

Attach mounting supports (5) to bearing brackets (2).

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

 Nut, mounting console to bearing bracket

*BA60.80-N-1039-01B

16

Remove cab lifting cradle.

Only on vehicles in old as-built configuration (A) or in mixed as-built configuration (C).

17

Attach holders for transmission oil cooler to crossmember (1, 3).

Only on vehicles with code N6Z (Transmission cooling).
Only if crossmember (1, 3) has been replaced.



Holder for transmission oil cooler on front crossmember modified

BT31.30-W-0001-01A

18

Attach transmission oil cooler to holders on crossmember (1, 3).

Only on vehicles with code N6Z (Transmission cooling).

19

Attach detachable parts to crossmember (1, 3).

20

Install side parts of front bumper.

Model 963 with code F7A (bumper, corners made of plastic)

AR88.20-W-2002A

Model 963, 964 with code F7B (bumper, corners made of steel)

AR88.20-W-2002B

21

Install middle part of front bumper.

AR88.20-W-2003A

22

Close maintenance flap.

 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

 Cab mounting

Number

Designation

Model 963, 964

BA60.80-N-1039-01B

Nut, mounting console to bearing bracket

Stage 1

Nm

330

Stage 2

0

90