Remove/install cab

AR60.80-W-1000G

Remove/install cab

15.02.2018

Model

374.6, 940.1/2/3, 942.1/3, 943.1/3, 944.0/1/2 with body 944.890

with code FL6 (Rough road cab suspension (6 HZ))

Model

375.4 with body 375.860

with code FL6 (Rough road cab suspension (6 HZ))

1

Cover

6

Electrical connector

10

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

2

Bracket

7

Bracket

11

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

3

Pedal bracket

8

Coolant lines

5

Electrical connectors

9

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

16

Gearshift lever

17

Hydraulic line

18

Gearshift linkage

19

Bellows

20

Universal joint

21

Steering gear

22

Connection plate

23

Compressed air distributor

24

Fuel line - only on vehicles with code HZ3 (Warm air auxiliary heater 2000W)

25

Shock absorber

26

Screw

27

Nut

28

Bearing bolt

29

Bearing sleeve

30

Hydraulic line

31

Screw

32

Pin

33

Tilt cylinder

34

Hydraulic line

 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

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

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

Disconnect battery ground line

AR54.10-W-0003A

2

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-1003-01E

 Coolant

*BF20.00-N-1001-01B

3

Remove right and left wind guide on front end

AR77.25-W-1005A

4

Remove center bumper paneling

5

Drain air conditioning system

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

AR83.30-W-1760A

6

Disconnect pressure side refrigerant line (9) and intake side refrigerant line (10) in area of condenser

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

 Union nut, refrigerant lines

*BA83.30-N-1009-01B

7

Disconnect coolant lines (8) from firewall

8

Remove cab-chassis connector plate cover (1)

9

Disconnect connectors from cab-chassis connector plate

10

Remove positive/negative lines from terminal points on cab-chassis connector plate

11

Remove bracket (2)

12

Remove wiring harnesses together with bracket (2) from firewall

 Lay wiring harness down with bracket (2) above bumper.

13

Tilt cab

14

Remove hydraulic line (17) from gearshift linkage (18)

15

Disconnect gearshift linkage (18) from gearshift lever (16) and slide back

16

Remove hydraulic line (34) from tilt cylinder (33)

 Plug hydraulic line (34) connection on tilt cylinder (33) with blind plug.
The hydraulic line (34) connection must be plugged, otherwise it is not possible to tilt the cab.

17

Loosen boot (19) on steering gear (21) and push upward

18

Check whether marking on primary shaft of steering gear and assembly slot of universal joint (20) are in alignment

If the assembly slot has moved.



Mark installation position of universal joint (20) to primary shaft.

19

Remove universal joint (20) on lower steering shaft from steering gear (21)

 Installation: The contact surface for screw and nut at universal joint (20) must be free of grease. Note marking or identification.

 Fit bolt/nut, universal/constant velocity joint

*BA46.10-N-1001-07B

20

Disconnect terminal plate (22) from compressed air distributor (23) and lay lines down to side with compressed air lines

21

Loosen bolt (31)

 Do not unscrew bolt (31).

22

Disconnect fuel line (24) on additional air heater from hose

Only on vehicles with code HZ3 (Warm air auxiliary heater 2000W)

23

Remove lower bracket on wiring harnesses

24

Lower cab


Ensure that the separated lines, subharnesses and lower steering shafts are not pinched between the cab and the chassis.
Otherwise they may be damaged.

25

Disconnect electrical connectors (5) from brake value sensor

26

Disconnect electrical connector (6)

 Press upper section of electrical connector (6) through pedal bracket (3) inward.

27

Disconnect cable tie on inside of pedal bracket (3)

28

Remove bracket (7) of compressed air lines

29

Disconnect hydraulic line (30) from connection

30

Remove pedal bracket (3)

 Do not remove compressed air lines or clutch line.

31

Unscrew bolt (26) on both sides and fold bumper (25) upward

 Nut, shock absorber to front cab mounting

*BA60.80-N-1022-01B

32

Unscrew nut (27) on bearing pin (28) on both sides

 Nut, bearing pin to front cab mounting

*BA60.80-N-1023-01B

33

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



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

34

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.

35

Open door

36

Position front lifting cradle in door cutouts and slightly lift cab



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

37

Loosen compressed air horns from cab roof at side

Only on vehicles with code J76 (Air horns on cab roof)

 Do not disconnect compressed air connection.

38

Unlock cab lock by actuating the tilt cylinder several times and lift cab out of lock



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

39

Lift cab until bearing pins (28) are free of tension

40

Remove both bearing bolts (28)

41

Unscrew bolt (31) and remove bolt (32) o tilt cylinder (33)

 The tilt cylinder (33) must be free of tension.

42

Lift off cab


Raise cab carefully to prevent damage to cab and adjacent components. When lifting the cab, check whether all connections to the chassis have been disconnected.
Otherwise the lines can be damaged.

 Installation: Align cab and lower until bushings (29) are flush with lower cab mounting. If one or more bearing bushings (29) cant, pretension with C-clamp.

43

Remove assembly cradle from cab



000 588 06 80 00 Lifting cradle

WS60.80-N-0001B

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

44

Install in the reverse order

45

Check electrical system for proper operation

46

Check cooling system and hydraulic system for leakage

47

Synchronize modular tachograph (MTCO)

48

Set time of auxiliary heater

Only on vehicles with code HZ3 (Warm air auxiliary heater 2000W)

 Radiator, coolant hoses

Number

Designation

Engine 457.9

BA20.20-N-1003-01E

Coolant drain plug to radiator

Nm

4

 Steering wheel, steering column bracket, steering shaft

Number

Designation

Model 374

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

30

 Cab mounting

Number

Designation

Body 375.840/860 in model 375.4

Body 944.890 in model 374.6, 940, 942, 943, 944

BA60.80-N-1022-01B

Nut, shock absorber to front cab mounting

M12x1.5

Nm

96

96

 Cab mounting

Number

Designation

Body 375.840/860 in model 375.4

Body 944.890 in model 374.6, 940, 942, 943, 944

BA60.80-N-1023-01B

Nut, bearing pin to front cab mounting

M16x1.5

Nm

170

170

 Air conditioning

Number

Designation

Model 374.6 with code H03

Model 375.4 with body 375.860 with code H03

BA83.30-N-1009-01B

Union nut, refrigerant lines

Size 19

Nm

20

–

Size 27

Nm

30

25

Size 32

Nm

40

28

 Air conditioning

Number

Designation

Model 940, 942, 943, 944 with body 944.890 with code H03

BA83.30-N-1009-01B

Union nut, refrigerant lines

Size 19

Nm

–

Size 27

Nm

25

Size 32

Nm

28

 Filling capacities for engine cooling system

Number

Designation

Engine 457.9 except code BA1, except code BA9

BF20.00-N-1001-01B

Coolant

Total filling capacity

Liter

33,5

Anticorrosion and antifreeze agent down to -37 °C

Liter

17,0

Anticorrosion and antifreeze agent down to –45 °C

Liter

18,5

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-05A