Group 1 - Cab

1 STRUCTURE
ΧΦ65/75/85 series
TECHNICAL DATA
Structure
0
DIAGNOSTICS
1
INTERNAL CAB COMPONENTS
2
CAB HEATING
3
EXTERNAL CAB COMPONENTS
4
CAB SUSPENSION
5
CAB TILTING MECHANISM
6
SEATS
7
ACCESSORIES
8
9
PREWAX TREATMENT
10
© 200346
1 TECHNICAL DATA
ΧΦ65/75/85 series Contents
CONTENTS
0 Tech nical data
Page Date 0
1. INTERNAL AND EXTERNAL CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 . . . . 200346
2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200346
3. CAB TILTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200346
4. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346

5. ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346
© 200346 1
TECHNICAL DATA 1
Contents ΧΦ65/75/85 series
2 © 200346
1 TECHNICAL DATA
ΧΦ65/75/85 series Internal and external cab components
1. INTERNAL AND EXTERNAL CAB COMPONENTS

1.1 GENERAL 0
1 2
3
K1 01 008
Legend
1. Day cab
2. Sleeper cab
3. High sleeper cab
© 200346 1-1
TECHNICAL DATA 1
Internal and external cab components ΧΦ65/75/85 series
Main dimensions and weights

0 B2 L(slaap)
B1 L(dag)
H SH
K1 01 010
K
K1
Cab dimensions in mm: Day cab (D) Sleeper cab (SL) High sleeper cab (SH)
length (L) 1760 2190 2190
width (B1) 2300 2300 2300
width (B2) 2490 2490 2490
max. height (H) 1730 1703
height (SH) 2400
tilting (K) 1290 (1) 1290 (1)
tilting (K1) 1690 (1)
Cab weights
day cab (D) 820 (2)
sleeper cab (SL) 965 (2)
high sleeper cab (SH) 1085 (2)
(1) Dimensions (K) and (K1) measured from the front of the
bumper
(2) Cab weights for fully equipped cabs, including windscreen
washer reservoir but excluding suspension
1-2 © 200346
1 TECHNICAL DATA
Permissible cab weights, day and sleeper cab

Item
A
Description
Roof loading above
Max. load
150 kg
A 0
B Roof console 15 kg B
C Bunk 100 kg
D Under bunk storage box 50 kg
C
D
25 kg
(2x)
K1 00 997
Permissible cab weights, high sleeper:

A
Item Description Max. load
A Roof loading above 40 kg E
B Roof console 20 kg D
B
C Below roof console 15 kg
C
D Upper bunk 100 kg
E Upper bunk (folded away) 50 kg
F Bunk 100 kg F
G Under bunk storage box 50 kg
H Tool storage 2 x 25 kg G
Cab side members H

Welding on cab side members is NOT permitted.
When repairing the cab side member, you must
use sheet-metal trimming panels.
These must be fitted by spot welding.
K1 00 998
© 200346 1-3
TECHNICAL DATA 1
Recommended dimensions
0
,
A A
N
O
B ,
B
I P’
A’ P
A
J
I
B
I B
J
O
P
P’ O
O
N
K1 01 645
Recommended dimension between measuring points on the same side.

A-B 818 mm
I-I 2070 mm
J-J 2185 mm
O-O 2247 mm
Recommended dimension between measuring points on opposite sides.

Short cab Long cab
A' - N 1367 mm 1797 mm
B' - P 1660 mm (1)
B' - P' 2110 mm (2)
(1) Measurement area between the brackets
(2) Measurement area under the bracket
1-4 © 200346
1 TECHNICAL DATA
,
0
F
G
K
,
F
,
F F
H ,
G
F
K
F
H
K
G
K1 00 928
Recommended dimension between measuring points on the same side.
F - F' 1524 mm
F' - H 1419 mm
G-K 1662 mm
F' - G 708 mm
Recommended dimension between measuring points on opposite sides.

G' - G 2030 mm
G-F 2612 mm
G-K 2649 mm
© 200346 1-5
TECHNICAL DATA 1
X X
Z Z
S
R(D)
R(S)
R X
K1 01 012
X-X 1175 mm
Z-Z 1080 mm
R(D) (short cab) R(S) (long cab)
L-R 1176 mm 1606 mm
S-R 621 mm 1051 mm
T-R 1604 mm 2034 mm
1-6 © 200346
1 TECHNICAL DATA
Windscreens
Setting times for windscreen adhesive 0

Product name Vehicle mobile Cab can be Vehicle usable DAF number
in workshop tilted after: after:
after:
Sikaflex 255 FC 6 hours 8 hours 12 hours 1271129
2 hours 4 hours 6 hours 1241020
Sika Tack Ultrafast
Sika Tack plus booster 1 hour 1 hour 2 hours 1357925
A relative humidity of less than 50% delays

setting, as does a temperature lower than 20C.
Products applied for bonded windscreens

Product Properties Applications DAF
name number
Sikaflex 255 Application time 20 min. Adhesive (cold process) for 1271129
FC bonding windscreens
Sika Tack Application time 10 min. Adhesive (warm process) for 1241020
Ultrafast bonding windscreens
Sika Tack plus Application time 5 min. Adhesive (warm process) for 1357925
booster bonding windscreens
Sika Aktivator Minimum drying time 5 min. Cleaning and activating the glass 1312362
and the frame.
Sika remover Removal of adhesive which has 1241019
208 not yet set. Do not use on
surfaces to be bonded.
High sleeper cab
Products for gluing high sleeper cab

name number
Scotch brite Abrasive 1387923
very fine A
(red)
Sika Cleaner Minimum drying time 5 min. Cleaning surface of raised roof 1240548
Sika Primer Minimum drying time 15 min. Application to raised roof 1240547
209 Maximum drying time 24 hours
Sika Activator Minimum drying time 5 min. Cleaning and activating the cab 1312362
roof edge to be glued
Sikaflex 252 Application time within 10 min. Gluing raised roof on cab 1286578
(white) Setting time 2 days
© 200346 1-7
TECHNICAL DATA 1
Windscreen wiper motor

0 Fitting new rods
Motor speed 1
Fina Ceran grease
35 rpm
Motor speed 2 50 rpm
Heater fan
Fan setting series resistors
1 R1 + R2 + R3
2 R2 + R3
3 R3
4 no series resistors
Resistor rating:
R1 4.2 ≥ 0.15
R2 1.4 ≥ 0.15
R3 2.2 ≥ 0.15
Heater control
Heater valve black
Defroster valve LHD red
Defroster valve RHD blue
Foot valve LHD green
Foot valve RHD brown
Doors
Products for gluing anti-whistle weatherstrip

name number
Scotch brite Abrasive 1387923
very fine A
(red)
}
Sika Cleaner Minimum drying time 5 min. Cleaning door edge 1240548
Loctite 401 Dries within a few Securing anti-whistle 0632192
(superfast seconds weatherstrip to door edge
adhesive)
Setting time 12 hours
Adjustment dimensions:
Entire perimeter (except the lower edge) 8 mm clearance
Bottom 11 mm clearance
Frame depth 0.5 mm within the cab to 1.5 mm outside the cab
1-8 © 200346
1 TECHNICAL DATA
Adjustment dimensions of door lock rods

0
507
410
92 89
K1 01 023
© 200346 1-9
TECHNICAL DATA 1
Adjustment dimensions of mirrors without

0 dead angle exterior mirror
D E
C
A
B
B A B
K1 01 027
Size Normal (mm) Normal adjustment angle

A 114 45
B 326 36
C 9
D (main mirror) 1374
E 1406
1-10 © 200346
1 TECHNICAL DATA
Adjustment dimensions of mirrors with dead

angle exterior mirror
0
E F
A
B
C D
B A
C D
K1 01 333
Size Normal (mm) Normal adjustment angle

A 326 9
B 396 45
C 219 35
D 47 31
E (main mirror) 1379
F 1406
© 200346 1-11
TECHNICAL DATA 1
Dimensions of compulsory field of vision

0
D1
A
A2
D
C3
A A3
B1 1 C4
B5
B
B2
C C1
B4
B3
C2
K100237
Mirror size 1 size 2 size 3 size 4 size 5

Pavement mirror [A] 1m 1m 1.25 m
Wide-angle exterior mirror [B] 2.5 m 15 m 12.5 m 25 m 3m
Main exterior mirror, co-driver side [C] 30 m 3.5 m 0.75 m 4m
Main exterior mirror, driver side [D] 10 m 2.5 m
1-12 © 200346
1 TECHNICAL DATA
1.2 TIGHTENING TORQUES
The tightening torques specified in this section

0
are different from the standard tightening torques
cited in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque cited in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Windscreen wiper motor

Attachment on bulkhead 20 - 25 Nm
Motor shaft nut 40 - 50 Nm
Windscreen wiper arm nut 16 - 20 Nm
Roof hatch
Fixing bolts for roof hatch edging 10 Nm
Clutch pedal
Sealant for end of clutch pedal spindle silicone sealant
Locking bolt according to standard (1)
(1) Use Loctite 243 to secure
Engine brake switch

Sealant for bolts silicone sealant
Steering column
Attachment bolt for steering shaft universal joint 54 Nm (1)
Attachments nuts at underside of steering column 23 Nm
Steering wheel attachment nut 65 Nm
(1) Always replace the attachment bolt and nut
Doors
Striker plate Torx screws 23 Nm
Exterior mirrors
Lower pivoting point of D-shaped support, M8 nut 32 Nm
Pavement mirror adjusting nut 7.0 - 8.1 Nm
Raised roof
Attachment bolts for raised roof frame 30 Nm
© 200346 1-13
TECHNICAL DATA 1
1-14 © 200346
1 TECHNICAL DATA
ΧΦ65/75/85 series Cab suspension
2. CAB SUSPENSION
2.1 GENERAL 0
The F230 cab is mounted to the chassis at four
points with adjustable coil spring/air suspension
elements. These have integral shock absorbers.
Adjusting the coil spring elements:

Front (size A) 318 ≥ 5 mm
K1 01 013
Rear (size B) 272 ≥ 5 mm
The sizes given above are from the top centre to

the support of the spring element (top).
The spring elements can be adjusted in 4 steps of
3 mm.
K1 01 014
Spring distance of the coil spring elements:

front approx. 80 mm (+40/-40)
rear approx. 60 mm (+30/-30)
© 200346 2-1
TECHNICAL DATA 1
Cab suspension ΧΦ65/75/85 series
Adjusting the air suspension elements:

0 Front (size A) 318 ≥ 5 mm
K1 01 413
Rear (size B) 272 ≥ 5 mm
The sizes given above are from the top centre to

the support of the spring element (top).
K1 01 000
Spring distance of the air suspension

elements:
front approx. 80 mm (+40/-40)
rear approx. 60 mm (+30/-30)
The cab height can be adjusted at the front.
2-2 © 200346
1 TECHNICAL DATA

0
tightening torques.
Cab suspension front
A B
E
C
D
K1 01 077
A M8 attachment bolt for tilt assist mechanism/

cab support 24 Nm (1)
B M14 cab support bolt 170 Nm
C M18 locating bolt for cab stabiliser vibration
damper 235 Nm (2)
D M14 nut for underside of spring (coil spring
and air suspension) 50 Nm
E M14 rearmost bolt for cab stabiliser bearing
support (left/right) 170 Nm
F M14 foremost bolt for cab stabiliser bearing
support (left and right) 170 Nm
G M8 prestressed bolt for cab stabiliser bearing
support 35 Nm
H M14 attachment bolt for top of spring
(coil spring and air suspension) 170 Nm
(1) Use Loctite 243 to secure
(2) Use Loctite 243 to secure and tighten with cab in fully
tilted position.
© 200346 2-3
TECHNICAL DATA 1
Rear cab suspension

0
B
A
C
F
G
K1 01 078
A M14 attachment bolt for top of spring

(coil spring and air suspension) 170 Nm
B M14 attachment bolt for horizontal damper 170 Nm
C M14 attachment bolt for horizontal damper 170 Nm
D M16 attachment bolts for chassis support 300 - 450 Nm
E M12 attachment bolt for chassis 110 Nm
F M14 attachment bolt for chassis 170 Nm
G M14 attachment bolt for day cab spring
element 170 Nm
M14 attachment nut for sleeper cab
spring element 50 Nm
2-4 © 200346
1 TECHNICAL DATA
ΧΦ65/75/85 series Cab tilting mechanism
3. CAB TILTING MECHANISM

3.1 GENERAL 0
Lifting cylinder
Nominal pressure 400 bar
Cab tilting pump

Nominal pressure 400 bar
Displacement 4 cm3
Pressure limiting valve 400 + 50 bar
Pressure relief valve, level check/filler plug 2.5 bar
© 200346 3-1
TECHNICAL DATA 1
Cab tilting mechanism ΧΦ65/75/85 series

0 The tightening torques specified in this section
tightening torques.
Lifting cylinder
Lifting cylinder attachment bolt on cab 170 Nm
Lifting cylinder attachment bolt on chassis 60 Nm
Non-return valve seat 40 - 45 Nm
3.3 FILLING CAPACITIES
Cab tilting pump

Capacity of reservoir 480 cm3
3-2 © 200346
1 TECHNICAL DATA
ΧΦ65/75/85 series Seats
4. SEATS
4.1 TIGHTENING TORQUES 0
tightening torques.
Seats
Seat attachment bolts M8 20 - 25 Nm
Attachment of seat belt mechanism 7/16", UNF-
2B 30 - 40 Nm
© 200346 4-1
TECHNICAL DATA 1
Seats ΧΦ65/75/85 series
4-2 © 200346
1 TECHNICAL DATA
ΧΦ65/75/85 series Accessories
5. ACCESSORIES
5.1 GENERAL 0
The roof spoiler height of the 'aerodynamic' roof
spoiler can be adjusted with the adjusting P
mechanism (B).
B
K1 01 355
Roof spoiler setting range [mm]

basic aerodynamic
Day cab 525 - 775 760 - 1040
Sleeper Cab 525 - 775 760 - 1060
High sleeper cab N/A 215 - 775
Note:
The size stated in the table represents the
distance measured between the highest roof
spoiler edge (P) and the cab roof plate local to the
vehicle centreline.
© 200346 5-1
TECHNICAL DATA 1
Accessories ΧΦ65/75/85 series
5-2 © 200346
1 DIAGNOSTICS
CONTENTS
1 Diagnostics
Page Date
1. CAB HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346

1.1 Fault finding table, cab heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346
1
2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.1 Fault-finding table, cab suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Fault-finding table, cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200346
3. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

3.1 Fault-finding table, Isringhausen 6800 series . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
© 200346 1
DIAGNOSTICS 1
2 © 200346
1 DIAGNOSTICS
ΧΦ65/75/85 series Cab heating
1. CAB HEATING
1.1 FAULT FINDING TABLE, CAB HEATING
SYMPTOM: CAB TEMPERATURE TOO HIGH 1

Possible cause Remedy
Heater valve cannot be fully closed. Check the setting of the heater valve.
© 200346 1-1
DIAGNOSTICS 1
Cab heating ΧΦ65/75/85 series
1-2 © 200346
1 DIAGNOSTICS
2. CAB SUSPENSION
2.1 FAULT-FINDING TABLE, CAB SUSPENSION
Air-sprung cab
SYMPTOM: SUSPENSION TOUCHES BUMP STOP
1
Incorrectly adjusted suspension. Check setting.
Leaking spring element. Replace spring element.
Defective height control valve. Replace height control valve and adjust
suspension.
Defective valve. Replace valve.
SYMPTOM: INSUFFICIENT LATERAL DAMPING

Worn or damaged horizontal dampers at the rear Replace both dampers.
of the cab.
Worn or damaged silentblocks in front cab Replace both silentblocks.
suspension.
SYMPTOM: AIR LEAKAGE

Damaged air bellows. Replace air bellows.
Leakage in line connections. Check line connections.
Internal leakage of height control valve. Replace height control valve.
© 200346 2-1
DIAGNOSTICS 1
2.2 FAULT-FINDING TABLE, CAB TILTING MECHANISM
SYMPTOM: TILTING CYLINDER FAILS TO RESPOND
1 Possible cause Remedy

Damaged or broken pipe. Replace pipe or connection.
Pump reservoir empty. Top up reservoir and check for leaks.
Worn or damaged cylinder seal. Replace the cylinder or fit a reconditioning set.
SYMPTOM: PUMP ROD REBOUNDS

Return stroke leakage. Replace the tilting pump.
SYMPTOM: PUMP ONLY FUNCTIONS IN THE LAST PART OF THE STROKE

Low oil level in oil reservoir. Top up oil reservoir.
Leaking inlet valve (ball). Remove the two-way valve and check the inlet
valve. Clean it or fit a reconditioning set.
Polluted inlet strainer. Clean reservoir and strainer.
SYMPTOM: PUMP OPERATES WITH DIFFICULTY, CYLINDER DOES NOT RESPOND

Two-way valve incorrectly fitted after repair. Remove the notched pin from the two-way valve
and turn it 180|. Refit the notched pin in the two-
way valve.
SYMPTOM: PUMP FAILS TO GENERATE PRESSURE

Reservoir level too low. Top up the reservoir.
Leaking inlet valve (ball). Remove the two-way valve and check the inlet
valve. Clean it or fit a reconditioning set.
Worn or damaged O-rings on the two-way valve. Fit a reconditioning set.
Pressure limiting valve incorrectly set. Check the pressure limiting valve (using a
pressure gauge only) and adjust, if necessary.
2-2 © 200346
1 DIAGNOSTICS
SYMPTOM: CAB LOCK CANNOT BE OPENED

Damaged or broken pipe. Replace pipe or connection.
Jammed piston in locking mechanism. Repair or replace the locking mechanism. 1
SYMPTOM: CAB CANNOT BE TILTED
Jammed piston in cab locking mechanism. Repair or replace the locking mechanism.
Pump fails to generate pressure. Check the operation of the pump.
© 200346 2-3
DIAGNOSTICS 1
2-4 © 200346
1 DIAGNOSTICS
ΧΦ65/75/85 series Seats
3. SEATS
3.1 FAULT-FINDING TABLE, ISRINGHAUSEN 6800 SERIES
SYMPTOM: SEAT FAILS TO RISE 1

Insufficient system pressure. Check air supply to the seat.
Blocked bleeding system. Check bleeding system.
The level control valve pins do not touch the Place seat in its highest position.
running surface of the control discs.
SYMPTOM: SEAT MOVES UP AND DOWN INDEPENDENTLY (LOADED)

Leaking pneumatic system Check level control valve, air suspension and air
pipes for leakage. Replace components or repair
air pipe.
Cylinder in control disc unit fails to return to the Loosen cylinder attachment screws and tighten
original position. slightly (2 Nm).
Not a functioning fault, but excessive resistance in
the system itself.
SYMPTOM: SEAT HEIGHT CANNOT BE ADJUSTED FOR HEIGHT

Adjustment cylinder does not move. During upward operation of the height control
valve, check whether the pipe (16) blows off and
during downward operation, whether the pipe (16,
17) blows off.
If so, replace the adjustment cylinder.
Defective height adjustment valve (E). Detach air pipes (9) and (11) from valve (D). Check
whether air is blown off during operation. If not,
check whether the control button is controlling the
valve.
Replace the valve or control button (depending on
the fault).
Defective switch valve (C). Disconnect air pipes (5) and (6) and operate height
control up and down.
If air escapes from the pipes (5) and (6), replace
the valve (C).
SYMPTOM: SEAT MOVES TO TOP-MOST POSITION AND IS NOT SPRUNG

Air connections not installed according to diagram. Correct the incorrect connection(s).
© 200346 3-1
DIAGNOSTICS 1
Seats ΧΦ65/75/85 series
SYMPTOM: BLOWS OFF CONTINUOUSLY AND IS PERMANENTLY IN TOP POSITION

Air connections not installed according to diagram. Correct the incorrect connection(s).
1
SYMPTOM: SEAT FUNCTIONS BUT CANNOT MOVE DOWN
Kinks in air pipe. Check the air pipes for kinks.
3-2 © 200346
1 INTERNAL CAB COMPONENTS
CONTENTS
2 Internal cab compon ents
Page Date
1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 Overview drawing, interior cab components . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Overview drawing, steering column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Overview drawing, vents in cab (other users) . . . . . . . . . . . . . . . . . . . . . .
2-2 . . . . .
2-3 . . . . .
200346
200346
2
2.4 System description, steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200346
3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

3.1 Inspecting steering column setting valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
3.2 Checking fastening of universal joint to steering box input shaft . . . . . . . . 3-2 . . . . . 200346
4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346

4.1 Removal and installation, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346
4.2 Removal and installation, dashboard panel, top . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200346
4.3 Removal and installation, instrument panel . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200346
4.4 Removal and installation, radio panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200346
4.5 Removal and installation, engine tunnel storage tray . . . . . . . . . . . . . . . . 4-5 . . . . . 200346
4.6 Removal and installation, central console control panel . . . . . . . . . . . . . . 4-6 . . . . . 200346
4.7 Removal and installation, dashboard panels on co-driver side . . . . . . . . . 4-7 . . . . . 200346
4.8 Removal and installation, pneumatic steering column setting switch/valve 4-8 . . . . . 200346
4.9 Removal and installation, steering column panels. . . . . . . . . . . . . . . . . . . 4-9 . . . . . 200346
4.10 Removal and installation, steering column . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . 200346
4.11 Removal and installation, steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . 200346
4.12 Removal and installation, door panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . 200346
4.13 Removal and installation, interior door foils . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . 200346
4.14 Removal and installation, manually operated window mechanism . . . . . . 4-22 . . . . 200346
4.15 Removal and installation, electrically operated window mechanism . . . . . 4-23 . . . . 200346
4.16 Removal and replacement, roof console (day/sleeper/high sleeper). . . . . 4-24 . . . . 200346
4.17 Removal and installation, interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 . . . . 200346
4.18 Removal and installation, accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . 4-27 . . . . 200346
4.19 Removal and installation, brake pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . 200346
4.20 Removal and installation, clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . 200346
4.21 Removal and installation, ignition lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . 200346
4.22 Removal and installation, immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 . . . . 200346
4.23 Removal and installation, steering angle sensor . . . . . . . . . . . . . . . . . . . . 4-33 . . . . 200346
4.24 Removal and installation, door lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . 200346
4.25 Removal and installation, door locking mechanism. . . . . . . . . . . . . . . . . . 4-35 . . . . 200346
4.26 Removal and installation, fixed door window. . . . . . . . . . . . . . . . . . . . . . . 4-36 . . . . 200346
4.27 Removal and installation, drop glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 . . . . 200346
4.28 Removal and installation, engine brake switch . . . . . . . . . . . . . . . . . . . . . 4-41 . . . . 200346
4.29 Removal and installation, floor plate on co-driver side . . . . . . . . . . . . . . . 4-42 . . . . 200346
4.30 Removal and installation, parking brake switch/brake light switch . . . . . . 4-43 . . . . 200346
4.31 Removal and installation, headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 . . . . 200346
4.32 Removal and installation, rear wall lining. . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 . . . . 200346
4.33 Removal and installation, side wall lining . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 . . . . 200346
4.34 Removal and installation, storage bins behind seats in sleeper cab . . . . . 4-47 . . . . 200346
© 200346 1
INTERNAL CAB COMPONENTS 1
2 © 200346
ΧΦ65/75/85 series Safety instructions
1. SAFETY INSTRUCTIONS
1.1 SAFETY INSTRUCTIONS
} A short-circuit can occur when

removing the steel floor plate on the
co-driver side. Therefore when
working on the floor plate,
disconnect the earth cable from the
2
battery terminal.
} You can stop the cab tilting forward

at any time by turning the cock to the
reverse tilting position.
} If the vehicle has been involved in a

collision, the cab must under no
circumstances be tilted without due
precautions. The internal
mechanism of the lifting cylinder
may have been damaged to such an
extent that the cylinder is no longer
locked by the internal stop collar. In
that case there is a danger of the cab
no longer being held back and falling
forward to the ground.
© 200346 1-1
Safety instructions ΧΦ65/75/85 series
1-2 © 200346
ΧΦ65/75/85 series General
2. GENERAL
2.1 OVERVIEW DRAWING, INTERIOR CAB COMPONENTS
1
3 2
4
5
6
14 13 12 11 10 9 8 7
K1 00 936
Legend
1. Outlet grilles on window side
2. Dashboard panel, top
3. Dashboard panel on co-driver side
4. Central box cover
7. Engine tunnel storage tray
8. Dashboard panel underneath centre
console
9. Ashtray and ashtray holder
10. Centre console
11. Radio panel
12. Instrument panel
13. Dashboard panel with light switches
14. Dashboard panel with vents to door
© 200346 2-1
General ΧΦ65/75/85 series
2.2 OVERVIEW DRAWING, STEERING COLUMN
2 A B
D
E
J
F
I
F
H
K
G
K1 01 637
Legend
A. Steering column cover panels, top
B. Steering column switches
C. Steering angle sensor (if present)
D. Bracket for steering angle sensor (if present)
E. Attachment bolt for steering angle sensor
bracket
F. Attachment of steering column cover panels,
bottom
G. Steering column cover panels, bottom
H. Panel clamp
I. Steering shaft grommet
J. Steering column
2-2 © 200346
2.3 OVERVIEW DRAWING, VENTS IN CAB (OTHER USERS)
1
2
3
4
2
5
K1 01 152
Legend
1. Supply (air)
2. Supply for driver's seat and air horn
3. Supply for G.V. valve
4. Supply for steering column
5. Supply for co-driver's seat
© 200346 2-3
2.4 SYSTEM DESCRIPTION, STEERING COLUMN
The height and the tilt angle of the steering

column can be adjusted manually. An 85-mm
difference in height can be achieved between the
A
lowest and highest positions by pulling the
steering wheel upwards. There is a 15| angle
between the two most extreme tilting positions.
B
2 A spring-loaded clamping mechanism fixes the
steering column in position. An air cylinder
located behind the steering column serves to
release the steering column pneumatically. Once B
the steering column has been released, its
movements are cushioned by a gas damper. The
gas damper ensures that the steering column
cannot drop after being released and that it can
easily be pulled upwards.
The control valve (switch) is located on the front
of the steering column. The valve is equipped
with a calibrated vent. Should you forget to
secure the column, this vent ensures that the air
cylinder is bled in approximately 30 seconds. This
gradual bleeding will take place whether the 1
switch is unloaded or loaded.. In the top position
(convex shape on switch) the cylinder is being
vented, whereas in the bottom position the
cylinder is being bled rapidly.
A
K1 01 040
2-4 © 200346
ΧΦ65/75/85 series Inspection and adjustment
3. INSPECTION AND ADJUSTMENT

3.1 INSPECTING STEERING COLUMN SETTING VALVE
1. Check if the height and the angle of the

steering column can be adjusted after the
switch (convex top) is pressed.
2. Check whether the adjustment mechanism is

securely locked again when operating the 2
bottom of the switch.
3. Check whether the operating valve is bled

after the s has been operated. Press the
convex side of the switch and wait until the
adjustment mechanism is blocked again
(approx. 10 seconds).
4. If this is not the case, check that no air pipe

is trapped. If not, replace the valve (switch).
5. Check whether the air pipe is attached to the

cross member.
K1 01 559
© 200346 3-1
Inspection and adjustment ΧΦ65/75/85 series
3.2 CHECKING FASTENING OF UNIVERSAL JOINT TO STEERING BOX INPUT

SHAFT
Checking fastening of universal joint to

steering box input shaft
1. Check the universal joint for perceptible play.
If perceptible play is detected, the affected
2
part must be replaced.
2. Check whether there is any perceptible play

between the spline connection of the
universal joint and the steering box input
shaft. If perceptible play is detected, the
splines on the universal joint and those on
the input shaft must be checked for wear. If
wear is detected, the affected part must be
replaced.
If there is noticeable play but the parts are
not worn, the attachment bolt and nut must
be replaced. Tighten the attachment bolt and
nut to the specified torque, see "Technical
data".
S7 00 639
3-2 © 200346
ΧΦ65/75/85 series Removal and installation
4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, SWITCHES
Removing switches
1. Insert a feeler gauge of approx. 1 mm
thickness between the switch and the panel
at the side of the finger-sized depression (A),
until it touches the inside of the panel.
2
2. Remove the switch from its locked position
by carefully moving the feeler gauge in the
direction of the arrow (B).
3. Carefully remove the switch from the panel.

In doing so, ensure that the connector lock
A
does not catch behind the panel, causing the
connector to fall behind the panel.
4. If necessary, remove the switch from the

connector. B
K1 01 334
Installing switches
1. Fit the connector.
2. Insert the switch into the opening in the panel

and press until you can feel it lock.
A B
K1 01 335
© 200346 4-1
Removal and installation ΧΦ65/75/85 series
4.2 REMOVAL AND INSTALLATION, DASHBOARD PANEL, TOP
Removing dashboard panel, top
Note:
1 2
Do not pull the dashboard panel away from the
Velcro at the top before the ventilation grilles in
the window edges have been removed.
2 1. Remove the ventilation grilles (1) from the
window edges.
2. Carefully pull (push) the dashboard panel (2)

up at the front (Velcro fixings).
3. Tip the panel (2) towards the window and

remove it.
Installing dashboard panel, top

1. Check that the Velcro is still glued to the
cover and the frame. K1 01 030
2. Put the cover in place and press firmly onto

the Velcro.
3. Install the ventilation grilles and secure them

using the attachment bolts.
4-2 © 200346
4.3 REMOVAL AND INSTALLATION, INSTRUMENT PANEL
Removing instrument panel

1. Remove the ventilation grilles (1) from the
2
window edges.
2. Remove the dashboard panel (2) at the top. 1
3. Remove the grommet (3) from the parking

brake and remove the radio panel (4). 2
4. Remove the dashboard panel (6).
5. Remove the flywheel housing attachment

bolts. Remove the connectors from the
instrument panel and remove the instrument
panel (5).
Installing instrument panel

1. Fit the connectors. 6 5 4 3
K1 00 914
2. Fit the instrument panel (5).
3. Fit the radio panel (4) and the dashboard

panel (6).
4. Fit the grommet (3) around the hand brake

valve.
5. Fit the dashboard panel (2) at the top
6. Fit the ventilation grilles (1) in the window

edges.
© 200346 4-3
4.4 REMOVAL AND INSTALLATION, RADIO PANEL
Removing radio panel

1. Remove the central console panel. 2 2
2. Remove the rubber grommet (1) around the
parking brake valve.
2 3. Remove the attachment bolts (2) and

remove the radio panel. If necessary, mark
the location of the connectors.
Installing radio panel

1. Fit the connectors.
2. Put the radio panel in place and fix with the

attachment bolts (2). 2 2 1
K1 00 934
3. Fit the rubber grommet (1) around the
parking brake valve.
4. Fit the central console panel.
4-4 © 200346
4.5 REMOVAL AND INSTALLATION, ENGINE TUNNEL STORAGE TRAY
Removing storage tray

1. Remove the rubber inset mat and remove
the attachment bolts (1) from the storage
tray.
2. Remove the storage tray
Installing storage tray 2

1. Put the storage tray in place and secure it
using the attachment bolts (1).
1
2. Fit the rubber mat.
K1 00 916
© 200346 4-5
4.6 REMOVAL AND INSTALLATION, CENTRAL CONSOLE CONTROL PANEL
Removing central console control panel

1. Remove the panel underneath the ashtray.
2. Remove the ashtray and the ashtray holder
3. Remove the attachment bolts from the top

2 and put the control panel to one side.
4. Remove the connectors from the control

panel and remove the control panel.
Installing central console control panel

1. Fit the connectors in the control panel.
K1 00 927
2. Put the control panel in place and fasten it
with the attachment bolts.
3. Fit the ashtray and the ashtray holder.
4. Fit the panel underneath the ashtray.
4-6 © 200346
4.7 REMOVAL AND INSTALLATION, DASHBOARD PANELS ON CO-DRIVER

SIDE
Removing dashboard panels on co-driver

side
1. Remove the ventilation grille from the
1 2 3 4
window edge.
2. Carefully pull (push) the dashboard panel (2)

up at the front (Velcro fixings).
2
5
3. Remove the dashboard panel (1) at the top.
4. Remove the cover from the central box (3).
5. Remove the attachment bolts from the

dashboard panels (2, 4, 5, 6 and 7) and 6
remove these panels.
7
6. Put the floor mat to one side and remove the
plastic panel that rests on the floor plate. K1 01 068
Installing dashboard panel on co-driver side

1. Fit the plastic panel that rests on the floor
plate and reposition the floor mat.
2. Fit the dashboard panels (2, 4, 5, 6 and 7)

and tighten them with the attachment bolts.
3. Fit the cover of the central box (3).
4. Fit the dashboard panel (1) at the top. Press

the dashboard panel well onto the Velcro.
5. Fit the ventilation grilles in the window

edges.
© 200346 4-7
4.8 REMOVAL AND INSTALLATION, PNEUMATIC STEERING COLUMN SETTING

SWITCH/VALVE
Removing pneumatic steering column setting

switch/valve
1. Remove the steering column panels.
2
2. Remove the bracket with the steering
column switch, disconnect the air pipes and
push the switch from the bracket.
Installing pneumatic steering column setting

switch/valve
1. Connect the air pipes to the switch.
K1 01 559
2. Press the switch into the bracket and fit the

bracket to the steering column.
3. Tie the air pipe to the cross member.
4. Install the steering column panels.
K1 01 007
4-8 © 200346
4.9 REMOVAL AND INSTALLATION, STEERING COLUMN PANELS
Removing steering column panels

1. If necessary, remove the floor mat.
2. Using the steering column setting, move the C

steering wheel to its highest possible
position.
3. Remove the two halves of the cover (A)

A B E
D 2
under the steering wheel. The right-hand
side of the upper cover (A) (ignition lock side)
must be released by lifting and sliding it
across the left handle (direction indicator/
windscreen wiper side). A
4. Remove the storage tray from the engine

tunnel.
5. Remove at the bottom the dashboard panels

to the left and right of the steering column.
6. Remove the panel from the underside of the

steering column (G) by removing the
attachment bolts (F) and (K) and the panel
clamp (H). J
F
I
F
H
K
G
K1 01 636
© 200346 4-9
Installing steering column panels

1. Check if the air pipe is attached to the cross
member.
C
2. Fit the panel (G) on the steering column and
fix it with the panel clamp (H) and the
attachment bolts (F) and (K). D
A B E
2
3. Fit the dashboard panels underneath the
steering column (left and right).
4. Fit the storage tray on the engine tunnel.

A
5. Fit the two halves of the cover (A) beneath
the steering wheel.
6. If applicable, position the floor mat.
J
F
I
F
H
K
G
K1 01 636
4-10 © 200346
4.10 REMOVAL AND INSTALLATION, STEERING COLUMN
Removing steering column

1. Set the steering gear in the central position;
check this using the marks on the steering
box.
2. Remove the steering column panels.
3. Disconnect the earth terminal from the 2

batteries.
4. Remove the radio panel.
5. Remove the steering wheel.
6. Detach the connector of the steering angle

sensor, if the latter is fitted.
S7 00 024
7. Remove the steering angle sensor, if fitted.
8. Detach the connectors of the combi

switches, the immobiliser and the ignition
switch behind the radio panel.
9. Remove the bracket holding the height

setting switch.
10. Remove the air pipe of the pneumatic

steering column setting from the manifold by
pushing on the yellow ring and removing the
pipe.
11. Remove the attachment bolt of one universal

joint of the steering shaft (depending on the
operations to be performed; either the
universal joint beneath the steering wheel or
the universal joint on the steering box).
Before loosening, mark the position of the
universal joint in relation to the steering
shaft.
K1 01 136
© 200346 4-11
12. Remove the upper lock nuts on the side of

the steering column.
K1 01 559
13. Remove the attachment bolts at the bottom

of the steering column.
14. Remove the steering column.
K1 00 919
Installing steering column

1. Place the steering shaft on the universal
joint. Line up the groove (A) in the clutch with
the mark (B) on the steering shaft.
} Check that the steering shaft is

correctly in place in the universal
joint so that the bolt can be put in the
notch (C).
2. Only fit a new attachment bolt and

attachment nut to the universal joint. Tighten B
the attachment bolt to the specified torque. A
See "Technical data".
C
K1 01 353
4-12 © 200346
3. Position the steering column by tightening

the top attachment bolts by hand.
K1 01 559
4. Attach the air pipes to the connection block

behind the dashboard. Check to see that the
air pipe does not touch any moving parts.
5. Fit the bracket holding the height setting

switch.
6. Fit all steering column connectors behind the

radio panel.
7. If present, fit the steering angle sensor with

its connector.
8. Fit the steering wheel.
K1 01 136
9. Replace the lower attachment bolts and

tighten the steering column.
10. Tighten the upper attachment bolts.
11. Install the steering column panels.
12. Fit the radio panel.
13. Connect the earth terminal to the batteries.
K1 00 919
© 200346 4-13
4.11 REMOVAL AND INSTALLATION, STEERING WHEEL
Note:
The special tools that are required to remove the
steering wheel cannot be obtained from DAF.
These tools should be manufactured by yourself
according to the drawing.
2 Removing steering wheel
S7 00 065
1. Place the steering gear in the central position
using the marks on the steering box.
S7 00 024
4-14 © 200346
2. Remove the cover plate (1) from the steering

wheel (2).
1
3. Remove the attachment nut (3) of the
steering wheel.
4. Fit the special tool, steering wheel puller (A), 2

to the steering wheel using its two outer
bolts. Screw in the central bolt of the steering
wheel puller until the steering wheel is
released.
3 2
A
B
4
K1 01 144
Installing steering wheel

1. Check whether the steering gear is still in the
central position using the marks on the
steering box or the steering gear.
S7 00 024
© 200346 4-15
2. Fit the steering wheel (2) on the steering

shaft (4) so that the marks on the steering
wheel and the steering shaft "align", (see the 1
arrows B) in the drawing.
3. Fit the steering wheel attachment nut (3).

Tighten the nut to the specified tightening 2
torque, see "Technical data".
2 4. Fit the cover plate (1).

3
A
B
4
K1 01 144
4-16 © 200346
4.12 REMOVAL AND INSTALLATION, DOOR PANEL
Removing door panel

1. If a manual window mechanism is fitted,
remove the cover (1) using a sharp 2
screwdriver.
1
2. If a manual window mechanism is fitted,
remove the attachment bolt (2) and remove
the handle. 2
K1 00 913
3. Remove the door knob by lifting it (open

door) and pressing the locking clip
underneath the knob. Pull the knob off the
mechanism.
K1 01 024
4. Remove the alignment plate for the door lock

by pushing it upward slightly with a small
screwdriver. The alignment plate can then be
pulled from the panel by hand.
K1 01 025
5. Remove the control panel from the door

panel (electric window and mirror). Mark the
position of the connectors and remove them.
K1 01 026
© 200346 4-17
6. Remove the cover from the speaker and

remove the fixing bolts from the door panel.
K1 01 336
7. Stick a screwdriver into the openings on the

sides of the panel and pull the spring clips
from the clamping sleeves. Avoid damaging
the paintwork.
Installing door panel

1. Put the door panel in place (push into place)
2. Fit the door panel attachment bolt.
3. Fit the handle and secure it using the

attachment bolts.
4. Fit the speaker cover.
5. Fit the unlocking handle on the door lock K1 00 918

(push into place).
6. If applicable, fit the control for the window

mechanism. Fit the attachment bolt (2) and 2
the cover (1).
1
7. Replace the connectors for the control panel
and fit the control panel in the door panel
(push into place).
K1 00 913
4-18 © 200346
4.13 REMOVAL AND INSTALLATION, INTERIOR DOOR FOILS
Removing front foil

1. Remove the drop and fixed glass.
2. Partly remove the inner foil.
3. Remove the foil (A).

2
A
B
K1 00 619
Installing front foil

1. Fit the foil (A).
2. Position the foil (2) between the window

guide rail (1) and the inner door panel.
3. Fit the fixed door window.
4. Fit the inner window seal.
K1 00 620
© 200346 4-19
Removing rear foil

1. Remove the door panel.
7
2. Remove the window seal on the inside (7)
and detach the foil (B) at (C).
D
3. Remove the upper attachment bolts of the
window mechanism and loosen the lower
2
attachment bolts.
4. Remove the foil (B).
K1 00 622
Installing rear foil

1. Fit the foil (B).
A
B
K1 00 619
2. Position the foil (3) between the door lock

control rod (1) and the window
mechanism (2).
3. Pierce the foil in the places where it covers

the upper attachment holes of the window
mechanism. Fit the attachment bolts and
tighten the lower attachment bolts.
1
K1 00 621
4-20 © 200346
4. Fit the window seal on the inside (7). Attach

the foil at C, using tape. 7
5. Install the door panel.
D
2
C
K1 00 622
© 200346 4-21
4.14 REMOVAL AND INSTALLATION, MANUALLY OPERATED WINDOW

MECHANISM
Removing manually operated window

mechanism
2
2. Detach the foil at (A).
3. Lower the glass, remove the attachment

bolts (1) and raise the glass.
4. Remove the attachment bolts (2) and (3) and

remove the window mechanism from the
door through the opening.
Installing manually operated window

mechanism
1. Fit the window mechanism in the door and fit
the attachment bolts (2) and (3).
A 2
K1 00 908
2. Lower the glass and fit it to the window

mechanism using attachment bolts (1).
3. Raise the glass. Close the glass almost

completely. Check whether the top edge of
the drop glass is parallel to the window
frame. Loosen the attachment bolts (1), if
necessary. Move the glass to the correct
position and re-tighten the attachment bolts. 1
4. Use tape to attach the foil at (A).
K1 01 089
4-22 © 200346
4.15 REMOVAL AND INSTALLATION, ELECTRICALLY OPERATED WINDOW

MECHANISM
Removing electrically operated window

mechanism
2
2. Detach the foil at (A).

bolts (1) and raise the glass.
4. Detach the electric motor connector.
5. Remove the attachment bolts (2) and

attachment nuts (3) and remove the window
mechanism from the door through the
opening.
Installing electrically operated window

mechanism
1. Fit the window mechanism in the door and 2
fit the attachment bolts (2) and attachment
nuts (3).
2. Connect the electric motor connector.

3
A 2
K1 00 909
3. Lower the glass and fit it to the window

mechanism using attachment bolts (1).
4. Operate the window switch. Close the glass

almost completely. Check whether the top
edge of the drop glass is parallel to the
window frame. Loosen the attachment
bolts (1), if necessary. Move the glass to the
correct position and re-tighten the 1
attachment bolts.

K1 01 089
© 200346 4-23
4.16 REMOVAL AND REPLACEMENT, ROOF CONSOLE (DAY/SLEEPER/HIGH

SLEEPER)
Removing roof console

1. Remove the roof rails from the fixings using
a screwdriver.
K1 01 070
2. Remove the rail fixings.

3
3. Remove the covers (1) and (2) on both sides
of the roof console and remove the 1
connectors if necessary.
K1 00 586
K1 00 587
4-24 © 200346
4. Support the roof console and remove the

attachment bolts (4) at the front of the roof
console.
5. Support the roof console and remove the

bolts (5) on the window side.
6. Remove, if necessary, the connectors and

remove the roof console.
Installing roof console

4 2
2. Put the roof console in place and position it

5
using a few bolts.
K1 00 588
3. Place the attachment bolts at the front of the
roof console and tighten.
4. Fit the attachment bolts in the window edges.
5. Fit the front cover panels.
6. Fit the rail fixings.
7. Attach the roof rails to the fixings.
© 200346 4-25
4.17 REMOVAL AND INSTALLATION, INTERIOR LIGHTING
Removing interior lighting

1. Remove the covers (1) and (2).
2 1
K1 01 071
2. Use a screwdriver to push the lug (B) of the

lamp holder.
3. Take the lamp holder out of the headlining.
4. Unplug the connectors and remove the lamp

holder.
Installing interior lighting

1. Bend back the lug (B) of the lamp holder.
B
2. Connect the connectors.
3. Fit the frame in such a way that the directable

spotlight is located on the door side.
K1 01 643
4. Fit the covers (1) and (2).
4-26 © 200346
4.18 REMOVAL AND INSTALLATION, ACCELERATOR PEDAL
Removing accelerator pedal

1. Remove the dashboard panel from above
the accelerator pedal. 2
2. Remove the connector (1) from the 1
accelerator pedal. 2
3. Remove the attachment bolts (2) and 2
remove the accelerator pedal.
Installing accelerator pedal

1. Fit the accelerator pedal with the attachment
bolts (2).
2. Install the connector (1).
3. Fit the dashboard panel above the

accelerator pedal.
K1 01 088
© 200346 4-27
4.19 REMOVAL AND INSTALLATION, BRAKE PEDAL
Removing brake pedal

1. Remove the clamping bushes (1) with a
punch in the direction indicated.
2
2. Remove the sealing plug out of the hinge pin
(3) using a screwdriver.
2 3. Put an M5 bolt (4) in the hinge pin and
1
remove the hinge pin in the direction shown.
3 4
4. Remove the brake pedal (2) and fittings.
Installing brake pedal

1. Fit the brake pedal (2) and fittings.
2. Fit the hinge pin (3).

K1 00 912
3. Fit the sealing plug.
4. Fit the clamping bushes (1) in the driving

direction of the vehicle.
5. Check the operation of the brake pedal.
6. Check that the locked nut underneath the

brake pedal has adequate play.
4-28 © 200346
4.20 REMOVAL AND INSTALLATION, CLUTCH PEDAL
Removing clutch pedal

tunnel.
2. Remove the dashboard panels to the left and

right of the steering column.
3. Remove the steering column panel. 2

4. Remove the spring from the clutch pedal.
5. Remove the bolt that controls the clutch

cylinder.
6. Loosen the recessed locking bolt (1) on the

outside of the vehicle and push the clutch
pedal spindle to the left.
7. Remove the clutch pedal from the inside.
Installing clutch pedal

1. Put the clutch pedal in place.
K1 00 945
© 200346 4-29
2. Apply locking compound to the recessed

locking bolt (1). See "Technical data".
3. Push the spindle to the right and tighten the

recessed locking bolt. Put silicone sealant on
the end of the clutch pedal spindle (2).
4. Replace the bolt that controls the clutch

cylinder (take care with the ring).
2 5. Install the clutch pedal spring.
1
2
6. Fit the dashboard panels to the left and right
of the steering column.
7. Fit the steering column panel.
K1 01 065
4-30 © 200346
4.21 REMOVAL AND INSTALLATION, IGNITION LOCK
Removing ignition lock

1. Remove the covers (A) from the steering
column below the steering wheel.
3. Unplug the ignition lock connectors behind

the radio panel.
A
2
4. Drill off the head of the security bolt, use a bit
with the same diameter as the hole where A
the head goes into and remove the ignition
lock.
Installing ignition lock

1. Fit the ignition lock.
2. Tighten the security bolts with such a torque

that the heads break off.
4. Fit the radio panel. K1 01 646
5. Fit the covers (A) around the steering

column.
© 200346 4-31
4.22 REMOVAL AND INSTALLATION, IMMOBILISER
Removing immobiliser
1. Remove the cover panels from the steering
column.
2 3. Remove the connector of the immobiliser.
4. Push the housing of the immobiliser aside.
5. Remove the immobiliser.
Installing immobiliser
1. Fit the immobiliser. Push the immobiliser into
the housing.
2. Fit the connector. K1 01 153
4. Fit the cover panels around the steering

column.
Note:
If the immobiliser is replaced then the
following procedure must be carried out
using DAVIE XD.
5. The new immobiliser must be adjusted to the

electronic unit of the engine management
system.
6. The new ignition keys must be adjusted to

the new immobiliser. The 'old' keys cannot
be adjusted to the new immobiliser and
therefore can no longer be used.
4-32 © 200346
4.23 REMOVAL AND INSTALLATION, STEERING ANGLE SENSOR
Removing steering angle sensor

1. Remove the battery earth clamps.
2. Remove the covers of the steering box (A) C

right below the steering wheel.
3. Remove the steering wheel.

A B E
D
2
4. Disconnect the connector from the steering
angle sensor (C).
5. Carefully remove the steering angle sensor A

(C) from the sensor bracket (D).
6. Remove the attachment bolt (E) of the

sensor bracket.
7. Remove the sensor bracket (D) from the

steering box.
Installing steering angle sensor

1. Fit the sensor bracket to the steering box
using the attachment bolt. J
F
I
F
H
K
G
K1 01 636
2. Fit the steering angle sensor to the steering

shaft. Make sure that the projecting part on
the inner ring of the steering angle sensor
falls into the groove in the steering shaft.
Carefully press the steering angle sensor in
the attachment holes in the sensor bracket.
3. Install the connector on the steering angle

sensor.
4. Fit the covers.
5. Fit the steering wheel.
6. Attach the earth clamps to the batteries.

K1 01 649
© 200346 4-33
4.24 REMOVAL AND INSTALLATION, DOOR LOCK
Removing door lock

1. Remove the door handle.
2. Insert the key in the cylinder lock, use a

screwdriver to turn the ring (1) outwards and
remove the cylinder lock from the door
2 handle. A
Installing door lock
1. Turn the ring (1) outwards and position the
cylinder lock. Pay attention to the position of
the projection (A). Check whether ring (1)
makes proper contact.
2. Check the operation of the cylinder lock.
3. Fit the door handle.
1
K1 00 670
4-34 © 200346
4.25 REMOVAL AND INSTALLATION, DOOR LOCKING MECHANISM
Removing door locking mechanism

2. Remove the foil (A) from the inside of the

1 2
door.
3. Remove the attachment bolt (4) from the rod

guides (1). 3 2
8
unlocking handle (2) and put the unlocking 4
handle to one side.
5. Remove the control rod (3) from the

unlocking handle. 7
6. If necessary, remove the locking mechanism

from the central door lock (5) and remove it.
6
7. Remove the attachment bolts (7) from the B
lock plate and remove the lock plate (8).
5 A K1 00 911
8. Take the door lock with the rods and rod

guides out of the door through the opening
(B).
Installing door locking mechanism

1. Check the length of the rods and adjust
them, if necessary. See "Technical data".
2. Put the door lock with the rods and rod

guides into the door through the opening (B).
Note:
The rods for the handle should run between
the door panel and the window mechanism.
3. Fit the lock plate.
4. Fit the control rod for unlocking the door and

attach the unlocking handle.
5. If necessary, fit the locking mechanism of the

central door locking system.
6. Fit the guides for the unlocking rod.
7. Fit new foil on the inside of the door.
© 200346 4-35
4.26 REMOVAL AND INSTALLATION, FIXED DOOR WINDOW
Removing fixed door window

1. Remove the drop glass.
2. Remove the window guide rail (1).
3. Push the inner edge of the weatherstrip on

2 the inside over the groove.
4. Push the window glass with the weatherstrip

from the inside to the outside out of the
groove.
5. Remove the attachment bolts (2). Push the A

window frame upwards and remove it by
lifting it out of the inside of the door. 2 3
6. Remove frayed pieces and granules of old
sealant and clean the frame thoroughly with A
a cleaner. 2
7. Repair any paint damage in the groove.
1
K1 00 906
Installing fixed door window

1. Make sure that the guide rail is smooth and
flat (no major irregularities).
2. Check the window glass for damage.
3. Position the window frame (3) in the door

frame. Hold the window frame at the curved
edge and push it upwards as far as possible
until it fits into the inside of the door. Lower
the window frame and fit the attachment
bolts (2).
4. Apply sealant between the window frame

and the sheet metal (A).
5. Fit the weatherstrip around the window

glass.
K1 00 614
4-36 © 200346
6. Smear the weatherstrip with a rubber

lubricant.
7. Fit the pulling cord.
8. Smear weatherstrip and pulling cord again

with lubricant.
9. Insert the window glass from the outside in

the frame, using a suction pad. Make sure
that the two ends of the cord are at the top
2
and on the inside of the glass.
10. Locate the window glass from the outside in

relation to the frame, pressing it firmly to the
frame. Now pull the cord while pressing the
glass against the frame.
11. Check that the weatherstrip makes a good

seal with the whole circumference of the cab
body. Knock on the window glass, if
necessary.
K1 00 615
12. Fit the window guide rail in the door frame.
13. Fit the drop glass.
15. Clean the two windows (for example with a

window cleaning agent) and the parts of the
cab body which have become dirty during
the fitting of the window.
© 200346 4-37
4.27 REMOVAL AND INSTALLATION, DROP GLASS
Removing drop glass

1. Remove the door panel and remove the foil
at (A).
2. Remove the attachment bolt (1) and remove

the window guide.
2 3. Remove the squeegee strips.
K1 00 910

bolts (2) and lower the mechanism.
K1 00 907
4-38 © 200346
5. Raise the glass, tilt the window inwards and

remove it from the door.
K1 00 612
Installing drop glass

1. Position the drop glass in the door.
K1 00 612
2. Secure the drop glass to the window

mechanism, using the attachment bolts (2).
K1 00 907
© 200346 4-39
3. Fit the squeegee strips.
4. Position the window guide rail and the

attachment bolt (1).
5. Close the glass almost completely. Check

whether the top edge of the drop glass is
parallel to the window frame. Loosen the
attachment bolts (2), if necessary. Move the
2 glass to the correct position and re-tighten
the attachment bolts (2).
7. Install the door panel. B
K1 00 642
4-40 © 200346
4.28 REMOVAL AND INSTALLATION, ENGINE BRAKE SWITCH
Removing engine brake switch

1. Remove the cover in the door strut.
2. Put the floor mat to one side.
3. In the RHD version, remove the storage tray

from the engine tunnel and the lower
dashboard panel with the cigarette lighter. 2
4. Remove the attachment bolts (1) from the
mounting plate and remove the mounting
plate with the engine brake switch.
5. Remove the lock nut from the engine brake

switch and remove the switch.
1
Installing engine brake switch
1. Fit the engine brake switch in the mounting
plate and fix it in place with the lock nut.
2. Fit the mounting plate and apply locking

compound to the attachment bolts (1) and
tighten them to the specified torque. See
"Technical data".
K1 00 933
3. Fit the dashboard panel and the storage tray
on the engine tunnel.
4. Reposition the floor mat.
5. If applicable, fit the cover in the door strut.
© 200346 4-41
4.29 REMOVAL AND INSTALLATION, FLOOR PLATE ON CO-DRIVER SIDE
} Remove the earth lead from the

battery terminal; the steel floor plate
may cause a short circuit.
Removing floor plate on co-driver side

1. Remove the cover in the door strut.
2 2. Put the floor mat to one side.

floor plate and remove it.
Installing floor plate on co-driver side

1. Fit the floor plate and secure it using the
attachment bolts.
1
2. Reposition the floor mat.
3. Fit the cover in the door strut.
K1 00 935
4-42 © 200346
4.30 REMOVAL AND INSTALLATION, PARKING BRAKE SWITCH/BRAKE LIGHT

SWITCH
Removing parking brake switch

1. Remove the dashboard panel at the top.
3. Remove the connectors (1). 2

4. Position the parking brake in the parking
position.
1
5. Remove the switch (2) from the holder.
Installing parking brake switch 3

1. Fit the switch (2) in the holder.
2
2. Fit the connectors (1).
3. Fit the radio panel. 4
Removing brake light switch (conventional

braking system) K1 01 015
3. Remove the connectors (3).
4. Remove the switch (4) from the holder.
Place the brake light switch (conventional

braking system)
1. Fit the switch (4) in the holder.
2. Fit the connectors (3).
© 200346 4-43
4.31 REMOVAL AND INSTALLATION, HEADLINING
Removing headlining
1. Remove the roof console.
Note:
Work on the headlining with clean hands or
with clean gloves. Use the correct tools to
2 remove the panel clamps.
2. Remove the sun visor on the co-driver side.
3. Remove the panels above the doors
4. If necessary, remove the cord that operates

the valve for the air horn.
5. Remove the roof trim from the roof hatch,

disconnect the lighting connector.
6. Remove the panel clamps from the head

panel above the driver's position. Lower the
head panel and disconnect the connectors.
7. Remove the headlining.
Installing headlining
1. Fit the headlining and fasten it with the panel
clamps.
2. Reconnect the lighting and refit the trim on

the roof hatch.
3. If necessary, fit the cord that operates the

valve for the air horn.
4. Fit the panels above the doors
5. Fit the sun visor on co-driver side.
6. Fit the roof console.
4-44 © 200346
4.32 REMOVAL AND INSTALLATION, REAR WALL LINING
Note:
Use the correct tools to remove the panel clamps.
Removing rear wall lining

1. Remove the panel clamps on the rear wall of
the cab.
2. If necessary, remove the thermostat and the 2

clock from the framework using a small
screwdriver.
3. Remove the rear wall supports.
4. Remove the (mounting) handle.
5. Remove the rear wall lining, think of the

connectors for the sensor for the cab heater
and lighting.
Installing rear wall lining

1. Fit the rear wall and fasten it with panel
clamps. Think of the connectors for the
sensor for the cab heater and lighting.
2. Replace the (mounting) handle.
3. Fit the supports on the rear wall.
4. If applicable, fit the thermostat and clock.
5. If applicable, fit the storage trays.
6. Fit the panel clamp on the rear wall of the

cab.
© 200346 4-45
4.33 REMOVAL AND INSTALLATION, SIDE WALL LINING
Removing side wall lining

1. Remove the covers in the door strut.
2. Remove the steel plates that are fixed to the

rear wall.
2 3. If the vehicle has a sleeper cab, then the

storage trays under the bed need to be
removed.
Note:
Use the correct tools to remove the panel
clamps.
4. Remove the panel clamps and the side wall

lining.
Installing side wall lining

1. Attach the side wall lining with panel clamps.
2. If applicable, fit the storage trays.
3. Fit the steel panels on the side walls.
4. Fit the covers in the door strut.
4-46 © 200346
4.34 REMOVAL AND INSTALLATION, STORAGE BINS BEHIND SEATS IN

SLEEPER CAB
Removing storage trays

1. Remove the wooden bed base.
2. Remove the rear wall panel and the side

panels.
3. Remove the attachment bolts in the bottom

2
of the storage trays.
4. Remove the storage tray
Installing storage trays

1. Put the storage trays in place.
2. Fit the attachment bolts in the bottom of the

storage trays.
3. Fit the rear wall panels and the side panels.
4. Fit the wooden cover.
© 200346 4-47
4-48 © 200346
1 CAB HEATING
CONTENTS
3 Cab heating
Page Date

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 System description of heater, heater control . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

3.1 Inspection and adjustment, heater valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Removal and installation, interior filter. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 . . . . .
4-1 . . . . .
200346
200346
3
4.2 Removal and installation, heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200346
4.3 Removal and installation, heater control panel . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . 200346
4.4 Removal and installation, heater radiator . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . 200346
4.5 Removal and installation, electric motor for heating unit . . . . . . . . . . . . . . 4-12 . . . . 200346
4.6 Removal and installation, recirculation valve control . . . . . . . . . . . . . . . . . 4-15 . . . . 200346
4.7 Removal and installation, series resistor . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 . . . . 200346
© 200346 1
CAB HEATING 1
2 © 200346
1 CAB HEATING
} The air conditioning system may

only be opened and filled by a
specialist. Furthermore, many
countries require official
certification to carry out such
activities.
© 200346 1-1
CAB HEATING 1
1-2 © 200346
1 CAB HEATING
2. GENERAL
2.1 SYSTEM DESCRIPTION OF HEATER, HEATER CONTROL
The heater is installed in the central console as a

complete unit.
There are two versions available for the F230
cab:
- Heating/ventilation system
- Heating/ventilation system combined with air
3
conditioning.
The control panel has three rotary knobs.
Knob 1
Five-position switch to control fan speed.
1
K100395
Knob 2
Air distribution in the cab.
A B
0 = 0 position (leg area and windscreen closed)
A = leg area
B = windscreen and leg area
C = windscreen (demister)
C
2
K1 01 126
Knob 3
Temperature control: offers a continuously
variable supply of hot air from 0 to 100%.
3
K100397
© 200346 2-1
CAB HEATING 1
Air distribution
Optimal air distribution in the cab can be
achieved by means of knob 2 in combination with F
the rotating and adjustable vents on the central E
console and at the sides of the dashboard. G
H
After passing through an air filter, outside air D
enters the heater housing through recirculation
valve (A). Incoming air passes over the
evaporator (B) of the air conditioning (if present)
to the heater fan (C). The air is guided through the
heater radiator (D) and in the manifold (E) it is C
guided to the vents on the central console (F), the
3 regulating valve (H) for the windscreen demisting
and the regulating valves (G) for the floor and
A B
door heating.
K1 00 993
2-2 © 200346
1 CAB HEATING

3.1 INSPECTION AND ADJUSTMENT, HEATER VALVE
Inspecting heater valve

1. Remove the heater control panel.
1
2. Turn the temperature knob on the control
panel fully counterclockwise (cold). Check at
the rear of the control panel that the bowden
cable (1) (red for LHD and blue for RHD)
abuts against the stop (2).
3
2 K1 01 350
3. Turn the control knob fully clockwise (warm)

once and fully counterclockwise again (cold).
Check that the control arm (1) of the heater
valve abuts fully against the stop (2).
If this is not the case, the heater valve must
be adjusted. 1
2
4. Fit the heater control panel.
Adjusting the heater valve

1. Remove the heater control panel.
K1 01 352
2. Turn the temperature knob on the control

panel fully counterclockwise (cold). Remove 1
the fastening clip and press the bowden
cable (1) against the stop (2) and fit the
fastening clip.
2 K1 01 350
© 200346 3-1
CAB HEATING 1
3. Turn the temperature knob fully

counterclockwise (cold) and then 10 mm
clockwise (warm).
10mm
3 K1 01 351
4. Take the fastening clip off the bowden cable

and remove the heater valve.
5. Press the control arm (1) of the heater valve

against the stop (2) and fit the fastening clip.
1
6. Turn the control knob fully clockwise (warm) 2
once and fully counterclockwise again (cold).
Check that the control arm of the heater
valve abuts fully against the stop.
7. Fit the heater control panel.
K1 01 352
3-2 © 200346
1 CAB HEATING

4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER
Removing interior filter

1. Open the grille.
2. Push the locknut on the filter casing to one

side and remove the filter element.
Fitting interior filter

1. Fit the filter element.
2. Push the filter element into the locknut on the

3
filter casing.
3. Close the grille.
K1 01 033
© 200346 4-1
CAB HEATING 1
4.2 REMOVAL AND INSTALLATION, HEATER UNIT
Removing heater unit

1. Remove the central console control panel.
3
K1 00 927
2. Remove the dashboard panel (1) at the top.

1 2 3 4
3. Remove the dashboard panels (2 to 7) on co-
driver side.
7
K1 01 068

steel connecting piece of both dashboard
frames.
1
1
K1 01 099
4-2 © 200346
1 CAB HEATING
5. Remove the grommet (1) and the attachment 2 2

bolts (2). Remove the radio panel.
2 2 1 3
K1 00 934

heater control panel and put it to one side.
1
K1 00 944
Note:
When removing the entire heater unit it may be
necessary to remove an air pipe from the parking
brake valve.
7. Remove the dashboard panel (1) and 1

remove the panel clamp (2) that is behind the
dashboard panel (1).
2
8. Remove the attachment bolts from the foot
air duct and remove the right part of the air
duct from below.
9. Remove the left part of the air duct that is still

attached to the heater.
K1 01 127
© 200346 4-3
CAB HEATING 1

frames.

central box and put it to one side.
1
12. Remove the attachment bolts from the steel 1
frame over the central box and remove the
frame. K1 01 099
Note:
3
If the vehicle has air conditioning fitted, any
work done on that must be done by a
qualified person.
13. Partially drain the coolant.
14. If relevant, empty the air conditioning unit.
15. Remove the coolant hoses and, if relevant,

the air conditioning pipes at the front of the
cab. Block off the connections to the coolant
hoses to prevent any coolant escaping into
the cab.
16. Remove the interior filter and remove the

plastic filter casing from the interior filter.
17. Remove the bolts from the heater fixings at

the front of the cab (exterior).

heater fixings on the engine tunnel.
Note:
At the front of the heater, through the
bulkhead, is the condensation drain for the
air conditioning. If the heater is not first
moved straight backwards (≥ 3 cm) and then
removed sidewards, this condensation drain
will break off.
19. Remove the connector from the heater.
20. Remove the heater unit.
Installing heater unit

1. Fit the heater unit from the side and then
move it the last 3 cm straight back towards
the bulkhead.
2. Fasten the heater unit in place with

attachment bolts on the engine tunnel and on
the exterior of the bulkhead.
3. Attach the heater connector.
4-4 © 200346
1 CAB HEATING
4. Remove the blocks from the coolant hoses

and attach the hoses.
5. If applicable, fit the air conditioning pipes at

the front of the cab.
6. Fit the plastic filter casing of the interior filter

and fit the interior filter.
7. Fit the air ducts. Fix these under the central

box with the attachment bolts and at the end
with the panel clamp (2). Fit the dashboard
3
panel (1).
1
K1 01 127
8. Fit the steel joining piece between the

dashboard frames. Attach with the
attachment bolts (1).
1
1
K1 01 099
9. Put the control panel in place and fasten it

with the attachment bolts (1).
1
K1 00 944
© 200346 4-5
CAB HEATING 1
11. Fit the dashboard panels (2 to 7) on co-driver

1 2 3 4
side.
12. Fit the dashboard panel (1) at the top
13. Fit the dashboard panel on the central 5

console.
15. Fill the cooling system.

6
3
16. If applicable, fill the air conditioning system.
7
K1 01 068
4-6 © 200346
1 CAB HEATING
4.3 REMOVAL AND INSTALLATION, HEATER CONTROL PANEL
Removing control panel

1. Turn all control knobs fully counterclockwise
(0 and cold respectively).

control panel.
Note:
If the heater unit is removed: Remove the
attachment bolts from the control panel and 3
put the panel to one side. Do not disconnect
the control cables.
4. Remove the control panel from the frame

and turn the panel until the control cables
can be reached.
1
5. Remove the clips from the control cables.
K1 00 944
6. Remove the control cables.
7. Disconnect all electrical connections.
8. Remove the control panel.
Installing control panel

1. Turn all control knobs fully counterclockwise
(0 and cold respectively).
Note:
For the colours of the control cables for the
heater refer to "Technical data".
2. Attach one side of the control cable of the

foot valve to the innermost lever of the heater
manifold, push the outer cable against the
white stop and fix the clip.
K1 01 149
© 200346 4-7
CAB HEATING 1
3. Attach one side of the control cable of the

defroster valve to the outermost lever of the
heater manifold, push the outer cable
against the stop and fix the clip.
4. Attach one side of the Bowden cable of the

water tap to the temperature control lever,
push the outer cable against the stop and fix
the clip.
5. Close the valve or tap completely.

K1 01 148
3
6. Put the clip on the outer cable, positioning
the outer cable so that the valve or tap is just
pushed closed.
7. Check the settings by setting the control

knobs to various positions. In the zero
position the relevant valve or tap must be
closed and the knob must be easily
adjustable over its entire range.
8. Reconnect all electrical connections.
9. Fit the control panel and the radio panel.
K1 01 150
4-8 © 200346
1 CAB HEATING
4.4 REMOVAL AND INSTALLATION, HEATER RADIATOR
Removing heater radiator

3. Remove from the underside the panels to the

left and right of the steering column.
4. Remove the attachment bolts from the air

duct.
5. Remove the air duct from the underside. 3

6. Remove the panel clamp (2) that is behind
the dashboard panel (1).
2
K1 01 086
7. Partially drain the coolant.
8. Remove the clips from the hoses.
9. Remove the clip from the aluminium pipes.
Note:
Pull the aluminium pipes first straight back
before making a turning movement.
K1 01 140
© 200346 4-9
CAB HEATING 1
10. Put the aluminium pipes to one side.
11. Drill out the pop rivets from the support and
push the support backwards.
3
K1 01 143
12. Remove the heater radiator from the heating

unit.
K1 01 139
Installing heating radiator

1. Install the heater radiator in the heating unit.
2. Fit the support behind the radio panel and fix

it with pop rivets.
3. Put new O-rings on the aluminium pipes.
4. Install the aluminium pipes and secure them

using the clips.
K1 01 138
4-10 © 200346
1 CAB HEATING
5. Clamp the pipes in place.
3
K1 01 140
6. Reconnect the air duct to the heating unit.
7. Attach the air duct at the bottom with the

attachment bolts and fix the panel clamp (2)
to the outer end.
8. Fit the dashboard panel (1).
9. Fasten the support behind the radio panel

with pop rivets.
10. Fit the radio panel. 1
11. Fit the dashboard panel at the top.

2
K1 01 086
© 200346 4-11
CAB HEATING 1
4.5 REMOVAL AND INSTALLATION, ELECTRIC MOTOR FOR HEATING UNIT
Removing electric motor for heating unit

1. Remove the panel underneath the ashtray,
the ashtray and the ashtray holder.
3. Remove the connector of the heating unit.

3 frames.
1
1
K1 01 099
5. Slide the sliding sections to the right and

remove the lid.
K1 01 130
6. Mark the connectors before removing them

from the series resistor, if there are not
already any wire markings.
2
4
3
K1 01 142
4-12 © 200346
1 CAB HEATING
7. Remove the heater motor completely with

housing and series resistor from the heating
unit.
8. Remove both covers of the heater housing.
9. Remove the attachment screws from the

bracket over the heater motor and remove
the motor from the housing.
Installing electric motor for heating unit

1. Install the heater motor.
2. Fix the bracket around the heater motor in

place with the attachment screws.
3
3. Fit both covers on the heater motor housing. K1 01 098
4. Push the heater motor together with the

series resistor and housing into the heating
unit.
K1 01 137
5. Reconnect the series resistor as shown.

Note the markings or the wire numbers.
2
4
3
K1 01 142
© 200346 4-13
CAB HEATING 1
6. First hook the heater motor cover behind the

sliding bits at the top and then push the
bottom into place. Slide the sliding sections
to the left.
3
K1 01 130
7. Fit the steel joining piece of both dashboard

frames and fasten it with the attachment
bolts (1).
8. Attach the heating unit connector.
9. Fit the control panel on the central console.

1
1
10. Fit the panel underneath the ashtray, the
ashtray and the ashtray holder. K1 01 099
4-14 © 200346
1 CAB HEATING
4.6 REMOVAL AND INSTALLATION, RECIRCULATION VALVE CONTROL
Removing recirculation valve control

Note:
In a RHD vehicle remove the dashboard
panels on co-driver side.
2. Remove the foot air duct on driver side.
3. Remove the connector to the recirculation

valve control.
3
recirculation valve control.
5. Remove the recirculation valve control (2).
Installing recirculation valve control

1. Install the recirculation valve control (2) and
secure it using attachment bolts (1).
2
3. Fit the foot air duct. 1
4. Fit the steering column panels underneath

the steering column (left and right).
K1 01 141
© 200346 4-15
CAB HEATING 1
4.7 REMOVAL AND INSTALLATION, SERIES RESISTOR
Removing series resistor

tunnel.
2. Remove the panel underneath the ashtray,

the ashtray and the ashtray holder.

3 steel connecting piece of both dashboard
frames
1
1
K1 01 099
5. Slide the sliding sections to the right and

remove the lid.
K1 01 130
6. Remove the connectors from the series

resistor (1).
7. Using a screwdriver push the lock to one side

and remove the series resistor (1) including
its support. 1
2
4
3
1
K1 01 096
4-16 © 200346
1 CAB HEATING
Installing series resistor

1. Push the series resistor into place, including
its support.
2. Fit the connectors. Note the markings or the

wire numbers.
1
4
3
3
K1 01 142
3. Slide the sliding sections to the left.
K1 01 130
4. Fit the steel connecting piece of both

dashboard frames and fasten it with the
attachment bolts (1)
5. Fit the panel underneath the ashtray, the

ashtray and the ashtray holder.
1
6. Fit the control panel on the central console. 1
7. Fit the storage tray on the engine tunnel. K1 01 099
© 200346 4-17
CAB HEATING 1
4-18 © 200346
1 EXTERNAL CAB COMPONENTS
CONTENTS
4 Extern al cab componen ts
Page Date

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 Description of exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Description of windscreen wiper and washers. . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200346
2.3 Description of headlight levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200346

3.1 Adjusting doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
3.2 Inspection and adjustment, exterior mirrors. . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200346
3.3 Inspection and adjustment, headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200346
4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346 4

4.1 Removal and installation, windscreen wiper system . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346
4.2 Removal and installation, windscreen wiper motor . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200346
4.3 Removal and installation, stepwell and entrance step support . . . . . . . . . 4-4 . . . . . 200346
4.4 Removal and installation, doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . 200346
4.5 Removal and installation, corner piece . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200346
4.6 Removal and installation, windscreen wiper panel . . . . . . . . . . . . . . . . . . 4-7 . . . . . 200346
4.7 Removal and installation, cab grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . 200346
4.8 Removal and installation, vehicle grille . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . 200346
4.9 Removal and installation, roof hatch assembly . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . 200346
4.10 Removal and installation, roof hatch glass . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . 200346
4.11 Removal and installation, windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . 200346
4.12 Removal and installation, sleeper cab side window/rear window . . . . . . . 4-19 . . . . 200346
4.13 Removal and installation, exterior mirrors complete with arms . . . . . . . . . 4-24 . . . . 200346
4.14 Removal and installation, exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . 200346
4.15 Removal and installation, mirror glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . 200346
4.16 Removal and installation, pavement mirror . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . 200346
4.17 Removal and installation, headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . 200346
4.18 Removal and installation, headlight bracket . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . 200346
4.19 Removal and installation, headlight levelling control . . . . . . . . . . . . . . . . . 4-31 . . . . 200346
4.20 Removal and installation, mudguard assembly . . . . . . . . . . . . . . . . . . . . . 4-32 . . . . 200346
4.21 Removal and installation, bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . 200346
4.22 Removal and installation, squeegee strips . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . 200346
4.23 Removal and installation, anti-whistle weatherstrip . . . . . . . . . . . . . . . . . . 4-35 . . . . 200346
4.24 Removal and installation, raised roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 . . . . 200346
© 200346 1
EXTERNAL CAB COMPONENTS 1
2 © 200346
General
The cab is equipped with a hydraulic tilting
mechanism. The pump is located on co-driver's
side at the rear of the cab. The cab locks are
opened hydraulically during pumping.
Before tilting the cab, make sure that the doors
are closed, that there are no loose items in the
cab and that the gear lever is in neutral. Tilt the
cab fully forward if work must be carried out
underneath the cab.

4
} When working on a tilted cab (for

example when welding, spray-
painting or applying bitumen
coatings), be sure to cover the
piston rod of the lifting cylinder.
Welding spatter and paint on the
piston rod will inevitably cause
damage to the oil seal.
Inspection after a collision

Before tilting the cab after a collision, check the
cab rests, the cab hinges and the attachment of
the lifting cylinder to the chassis member and cab
for cracks.

precautions. The end stop in the
lifting cylinder may be damaged,
which might cause the cab to shoot
past its end stop.
If possible, suspend the cab in slings and put a

stand in front of the cab. Make sure that there is
no one in front of the cab while it is being tilted.
After a collision, always check the lifting cylinder
for internal damage. Replace the lifting cylinder if
damaged or if in doubt.
© 200346 1-1
1-2 © 200346
2. GENERAL
2.1 DESCRIPTION OF EXTERIOR MIRRORS
All exterior mirrors and exterior mirror arms used

are factory set for average driving conditions.
After the superstructure has been constructed on
the vehicle, it is required by law that all exterior
mirrors and exterior mirror arms should be re-
adjusted in accordance with EC Directive 88/321.
This critical adjustment depends entirely on the
width of the vehicle's superstructure.
To ensure proper adjustment of the exterior
mirror/exterior mirror arms as provided for in the
Directive, it is important to follow all adjustment
procedures closely.
Mirror classification
4
This section describes the different types of
vehicle exterior mirrors according to the standard
EC mirror classification. The following vehicle
mirror categories apply to trucks over 7.5 tonnes:
"Category 2" - Main exterior mirror
"Category 4" - Wide-angle mirror (/dead angle
exterior mirror)
"Category 5" - Close-up exterior mirror
Note: Category 1 (interior) and category 3
(exterior) mirrors are intended for passenger
cars.
The exterior mirror consists of convex glass and
an aerodynamically shaped mirror housing. The
main exterior mirror and wide-angle exterior
mirror (only on co-driver side) are fitted to a D-
shaped arm on the door.
A dead angle exterior mirror can also be fitted on
the D-shaped arm, depending on national legal
regulations. Amongst other things, the dead
angle exterior mirror gives vision of the section
beside the vehicle that is outside the fields of
vision of the main exterior mirror, the wide-angle
exterior mirror and the pavement mirror.
The pavement mirror is attached to the upper part
of the door on a separate bracket. The mirror
bracket returns to its original position if it gets
flapped back. On several models there is an extra
mirror on co-driver side giving the driver a better
view of the trailer.
© 200346 2-1
The heating for the exterior mirrors can be

switched on by a switch on the dashboard. When
the exterior mirror heating is switched on a white
mark is visible on the switch.
The exterior mirrors can be subdivided into:
- Non-heated mirrors
- Heated exterior mirrors (except for the
pavement mirror)
- Electrically adjustable main exterior mirrors
(always heated).
2.2 DESCRIPTION OF WINDSCREEN WIPER AND WASHERS

4 There are two windscreen wipers on the
windscreen which are equipped with nozzle tips,
each of which has three sprayer nozzles.
The reservoir for the windscreen washers is in the
wheel arch on the right-hand side of the vehicle.
The filling point is at the front behind the grille.
2.3 DESCRIPTION OF HEADLIGHT LEVELLING
The cab is equipped with an internal device for

adjusting the angle of the headlight beam.
Control is by a rotary knob located in the cab.
The headlights are levelled by electric motors
located in the headlight unit.
2-2 © 200346

3.1 ADJUSTING DOORS
1. Check whether the gaps marked (C) (see

"Technical data") to the left and right of the
door are equally wide. If necessary, adjust C
the door, with the door hinges, ensuring that
the gaps are equally wide.
2. Check that the bottom of the door aligns with

the bottom of the corner section at A, and
with the cab body at B. If necessary, adjust
the door, with the door hinges.
3. Look and feel whether there is a smooth A

transition between the door and corner
section and between the door and roof. If
4
necessary, adjust the door inwards or
outwards with the door hinges K1 00 645
K1 00 644
4. Check that the surface of the door handle

area continues smoothly into that of the cab
body, see "Technical data". If necessary, 1 2
adjust the door, using the striker plate (1).
Loosen the Torx screws (2) and socket head 3
screw (3) and move the striker plate. For the
tightening torques of the Torx screws, see
"Technical data".
B
K1 00 743
© 200346 3-1
3.2 INSPECTION AND ADJUSTMENT, EXTERIOR MIRRORS
Height/angle adjustment of exterior mirrors

Check that the driver and co-driver exterior
mirrors have been adjusted to the values stated
in 'Technical data'. If necessary, adjust the height
and/or angle as follows:
1. Remove the cover panel on the back of the
exterior mirror. This panel can be loosened
by sticking a wide screwdriver into the
openings (do not turn it) and moving the
screwdriver backwards.
K1 01 094
3-2 © 200346
2. Unscrew the clamping bracket bolts (1). This

allows the mirrors to move freely over the
bracket.
3. Position the mirror at the proper height and

angle (see 'Technical data').
4. Tighten the clamping bracket bolts (1).

1
1
4
K1 01 095
Adjusting the pavement mirror

1. Remove the cap of adjusting nut (C) at the
top of the mirror.
2. Slacken the nut a few turns until the mirror

can move freely. C
3. Adjust the mirror until it forms a right angle
(angle A) to the floor (angle B = 45|).
Lengthways the mirror should run parallel to
the side of the vehicle.
4. Tighten the bolts to the specified tightening

torque. See "Technical data".
A B
K100236
© 200346 3-3
3.3 INSPECTION AND ADJUSTMENT, HEADLIGHTS
Note:
Use adjustment equipment to check and adjust
the headlights.
Adjusting the headlights

1. Prior to adjusting the headlights, check that:
- the vehicle is unladen and the tyres are
inflated to the specified pressure.
- the vehicle is standing on a flat and level
surface.
- the height adjustment of the headlights
inside the cab is in "0" position.
2. The headlight is adjustable by means of four

4 knurled knobs at the back of the headlight
housing; main beam and dipped beam are
separately adjustable:
- To adjust the dipped beam horizontally
turn knob 1.
- To adjust the dipped beam vertically
turn knob 2.
- To adjust the main beam vertically turn
knob 3.
- To adjust the main beam horizontally
turn knob 4.
The specified height adjustment is also
shown on a sticker on the inside of the corner
section around the headlight.
1 2 3 4
K1 01 354
3. As clear headlight glass is used the image of

the asymmetrical light beam deviates
somewhat from the usual image. The beam
of light is not a straight line that slants
upwards, but is slightly convex.
4. Adjust the headlight so that the intersection

of the convex and horizontal light beam
coincides with the intersection of the
asymmetric diagonal and horizontal
adjustment line. It does not make any K1 01 473
difference if the convex beam is above the
asymmetric diagonal.
3-4 © 200346

4.1 REMOVAL AND INSTALLATION, WINDSCREEN WIPER SYSTEM
When replacing the wiper linkage, the following

points must be observed.
If the balls of the wiper linkage are worn, replace
them as well as the wipers.
Use the proper tools when removing the old
wipers to avoid damaging the seals.
When installing new wipers, use the specified
grease. See "Technical data".
When fitting new wipers, never hit the sealing
covers on the wipers with a hammer or other hard
object. The covers are only 1 mm thick and might
4
be damaged.
If the motor spindle shows axial play, replace the
motor. This play will cause excessive wear to the
wiper linkage.
Removing windscreen wiper system

1. Open the windscreen wiper arm covers.
2. Remove the attachment nuts of the

windscreen wiper arms.
3. Remove the windscreen washer fluid hoses

and remove the windscreen wiper arms.
K1 00 654
4. Remove the cab grille.
5. Remove the corner pieces.
6. Remove the windscreen wiper panel.
7. Unplug the connector of the windscreen

wiper system.
K1 01 038
windscreen wiper system and remove the
entire system.
© 200346 4-1
Installing windscreen wiper system

1. Install the complete windscreen wiper
system and secure it using the attachment
bolts.
2. Attach the connector of the windscreen wiper

motor.
3. Position the windscreen wiper panel.

K1 01 038
4. Fit the corner pieces.
5. Fit the cab grille.
6. Put the windscreen wiper motor in the

neutral position by turning it on and off
4 7.
quickly using the switch in the cab.
Fit the windscreen wiper arms.
8. Tighten the attachment nuts of the

windscreen wiper arms to the specified
9. Fit the windscreen washer fluid hoses.
10. Close the covers.
K1 00 654
4-2 © 200346
4.2 REMOVAL AND INSTALLATION, WINDSCREEN WIPER MOTOR
Removing windscreen wiper motor

1. Open the cab grille.
2. Turn the windscreen wiper motor crank.

Remove the nut (1) and circlip (2).
3. Disconnect the rod linkage from the spindle

of the windscreen wiper motor (3).
3 2 1 4
K1 01 652
4. Unplug the windscreen wiper motor

connector (4).
5. Remove the windscreen wiper motor

5
windscreen wiper motor bracket.
7. Bend the bracket (7) forward and remove the

windscreen wiper motor.
6
4
6 7
K1 01 653
Installing windscreen wiper motor

1. Install the windscreen wiper motor and
attach it to the bracket (7) using attachment
bolts (5).
2. Connect the windscreen wiper motor

connector (4).
3. Bend the bracket (7) back.
4. Put the bracket (7) against the cab body and

fit the attachment bolts (6). Tighten the
attachment bolts (6) to the specified
tightening torque, see "Technical data". 3 2 1
5. Put the windscreen wiper motor in the K1 01 652
neutral position by turning it on and off
quickly using the switch in the cab.
© 200346 4-3
6. Fit the rod linkage with circlip (2) and nut (1)
to the spindle of the windscreen wiper
motor (3). Hand-tighten the nut.
7. Set the rod linkage in the neutral position, the

windscreen wipers in the horizontal position 5
and tighten the nut (1). Tighten the nut (1) to
the specified tightening torque. See
"Technical data".
8. Switch on the windscreen wiper motor and

check the operation of the windscreen wiper 6
mechanism and the position of the wiper
arms.
4
6 7
9. Close the cab grille. K1 01 653
4
4.3 REMOVAL AND INSTALLATION, STEPWELL AND ENTRANCE STEP
SUPPORT
Removing stepwell and entrance step support

1. Remove the attachment bolts (1) and nuts
(2) from the non-slip plate and plastic
cladding and remove them.
1
entrance step support and remove it.
Installing stepwell and entrance step support

1. Fit the entrance step support.
2. Fit the plastic cladding and the non-slip plate,

using the attachment bolts and nuts.
2
K1 00 932
4-4 © 200346
4.4 REMOVAL AND INSTALLATION, DOORS
Removing doors
1. Disconnect the connectors in the door.
2. Remove the grommet in the A-pillar.
3. Remove the torx bolt (1). Loosen the door

check. Remove the hinge bolt (2).
4. Suspend the door in slings.

1
Note: 2
Protect the door paint by taping the places 3
where the slings will contact the door.
5. Remove all other hinge bolts and take off the

door.
4
Installing doors
1. Suspend the door in the slings and position it
with the hinges in front of the attachment
holes.
K1 00 666
Note:
Protect the door paint by taping the places
where the slings will contact the door.
2. Centre the attachment plate in the A-pillar

and fit all hinge bolts with the exception of
hinge bolt (2).
3. Fit the door check and then hinge bolt (2).
4. Feed the connectors through the A-pillar and

fit the grommet.
5. Connect the connectors in the door and fit

the cover.
6. Close the door carefully and adjust it; see

chapter "Inspection and adjustment"
© 200346 4-5
4.5 REMOVAL AND INSTALLATION, CORNER PIECE
Removing corner piece

1. Open the grille and remove the attachment
bolts (1). 5
2. Open the door and remove the attachment
bolts (4) in the door strut.
3. Remove the corner piece (5). 1

4
Installing corner piece
1. Place the corner piece (5) and fix it in place
in the door strut and at the front of the cab (1) 2
with the attachment bolts (4).
4 2. Close the grille and the door. 3

1
4 2
K1 00 926
4-6 © 200346
4.6 REMOVAL AND INSTALLATION, WINDSCREEN WIPER PANEL
Removing windscreen wiper panel


ends of the windscreen wiper panel.
3. Remove the nuts (8) from the windscreen

wiper arms and remove the arms. 4
3
4. Remove the covers (7). 2
1
5. Remove the nuts (6) and washers (5).
6. Remove the covers (9).

10 4
remove the handles (2). 9
8. Remove the cab grille with the supports (3).
9. Remove the windscreen wiper panel (4).
Installing windscreen wiper panel

1. Install the windscreen wiper panel (4).
8
7 6 5
2. Fit the cab grille with the supports (3). K1 01 057
3. Fit the handles (2) and secure them with the

4. Fit the covers (9).
5. Fit the washer (5) and the nut (6).
6. Fit the covers (7).
7. Put the windscreen wiper arms in place and

secure them using the nuts (8).
8. Fit the attachment bolts (1) to the ends of the

windscreen wiper panel.
© 200346 4-7
4.7 REMOVAL AND INSTALLATION, CAB GRILLE
Removing cab grille

1. Open the grille and support it.
2. Remove the retaining clips from the gas

damper mounting using a screwdriver and
remove the gas dampers.
3. Remove the handles.
4. Remove the dowels using a punch and

remove the cab grille.
Installing cab grille
4
1. Put the cab grille in place and fit the dowels
using a punch.
2. Support the grille in the open position and

install the gas dampers with the retaining
clips.
3. Attach the handles.
K1 01 034
4-8 © 200346
4.8 REMOVAL AND INSTALLATION, VEHICLE GRILLE
Removing vehicle grille

1. Remove the corner pieces around the
headlights.

front of the grille.
3. Open the cover (1) at the front and remove

the rubber tie rods (2).
4. Remove the grille by lifting it out of the

notches at the bottom. 3 2 1 3
Installing vehicle grille
1. Put the top of the grille under the cross
member.
K1 01 097 4
2. Lift the lower edge of the grille and hook into
the notches.
3. Insert the attachment bolts (3).
4. Fit the rubber tie rods (2) and close the cover
(2).
5. Fit the corner pieces around the headlights.
© 200346 4-9
4.9 REMOVAL AND INSTALLATION, ROOF HATCH ASSEMBLY
Removing roof hatch assembly

1. Remove the roof console.
2
2. Disconnect the interior lighting connector
and remove the roof hatch trim.
3. Remove the headlining.

3 5
4. Remove the attachment bolts from around
the roof hatch.
4
5. Remove the roof hatch complete with the

glass. If there is an electric roof hatch,
remove the connector of the adjusting motor.
4 Installing roof hatch assembly 2
1. Install the roof hatch.
2. Attach the roof hatch all around with the

attachment bolts.
3. Connect the lighting.
4. Fit the headlining, roof hatch trim and the

roof console.
K1 01 110
4-10 © 200346
4.10 REMOVAL AND INSTALLATION, ROOF HATCH GLASS
Removing roof hatch glass

1. Open the roof hatch.
2. Remove the attachment bolts (1) in the

handle and remove the roof hatch glass from
the guides.
3. Lift the glass at the rear end of the hatch until

the metal lugs (2) at the front end are fully 1
released from the hinges and move the glass
backwards to remove it.
Installing roof hatch glass K1 00 671
4
1. Position the metal lugs (2) in the hinges and
move the glass downwards.
2. Fit the handle to the glass with the

attachment bolts.
3. Close the hatch.

2
K1 00 672
© 200346 4-11
4.11 REMOVAL AND INSTALLATION, WINDSCREEN
Removing windscreen
1. Remove the windscreen wiper arms.
2. Remove the rubber edging from the

windscreen.
3. Remove the stepwell handles on the window

side.
4. Remove the plastic cover strips on the inside

of the windscreen pillars (A-pillar).
5. Protect the curved areas on the outside of

the windscreen frame with linen tape. Also
4 use tape to protect the plastic parts on the
inside and the defroster openings of the
heating and ventilation system.
Note:
Take care not to damage the paint.
6. Put the wire, special tool (DAF no. 1329415),

approximately in the middle of the top edge
and in the middle of the bottom edge of the K1 00 714
window frame using pliers or a special pull-
through needle, special tool
(DAF no. 1240458), through the sealant.
Note:
Remove the wire pull-through needle before
fitting the wire ends to the handles of the
cutting wire set.
7. The length of the cutting wire should be 1.5

times the height of the windscreen.
8. Then attach the accessory handles, special

tool (DAF no. 0499817), to the cutting wire.
K1 00 715
4-12 © 200346
9. Use tape strips to protect the glass from

falling out accidentally (after the sealant has
been cut through).
K1 00 716
10. Start cutting in the middle. Make sure the

wire is kept moving and tightly stretched all
the time. If the wire gets twisted, it will
inevitably break.
11. Keep the cutting wire as close as possible to

the edge of the glass.
12. Make sure the wire ends are crossed before

the bottom corners are reached. A
13. Remove the windscreen using the two
rubber suction pads, special tool
(DAF no. 0484800), from the window frame.
14. Remove any remaining sealant in the

window frame with a scraper, special tool
(DAF no. 1329417). Make sure the
remaining layer of sealant has a thickness of
at most 1 - 1.5 mm and that it is flat and
smooth.
16. Remove frayed pieces and granules of old K1 00 698

sealant and clean the frame thoroughly.
© 200346 4-13
17. Check that the upper and lower edges of the

windscreen frame in the cab body are
parallel.
A=B
4 B
K1 00 717
Important tips
- If the new glass is fitted at a later time, the
old, fully cured sealant should be cleaned
with the specified activator 15 minutes
before the glass is fitted, to ensure proper
adhesion, see "Technical data".
- Immediately remove any spilt activator or C
splashes from painted areas using paper
towels or tissues.
- Any damage to the paint on the window
frame should be repaired immediately with
the right type of paint, well before the new
windscreen is fitted.
- Always work in a clean area.
- Tolerance (c) between the rubber
windscreen trim and the bottom of the
marker lights must be 2 mm.
- Wear industrial gloves or use a special hand
cream.
- Preferably use paper towels or tissues
instead of cleaning rags.
K1 00 718
4-14 © 200346
}
Installing windscreen
Be careful when using an activator:
the fluid will cause skin irritation and
swallowing will cause burning.
Inhaling may cause breathing
problems. A-B
1. Check that the windscreen frame (A - B) is
parallel.

3. Check the windscreen for damage.
4. Attach two double suction pads, special tool

(DAF no. 0484800), to the outside of the
windscreen. 4
5. Put the glass with the suction pads on a
K1 00 719
completely clean workbench.
6. Fit the rubber trimming to the glass and

secure it with tape on the outside of the
glass.
7. Place the glass in the frame without using

sealant, starting at the bottom and ensuring
that it fits exactly in the frame.
© 200346 4-15
8. Mark the correct position of the glass in the

frame with strips of tape. Cut through the
tape in the frame.
9. Remove the glass from the frame and place

the glass on the workbench.
10. Clean the glass edge where the sealant is to

be applied using the specified activator, see
"Technical data". Apply the activator using a
well moistened ball of crumpled paper towels
or tissue; swipe it off immediately using a ball
of crumpled paper towels or tissues so that
only a thin layer remains. Allow the surface to
dry for at least the specified time, see
"Technical data".
4 11. Clean the cut-back sealant in the frame

using the specified activator, see "Technical
data". Apply the activator using a well
moistened ball of crumpled paper towels or
tissue; swipe it off immediately using a ball of
crumpled paper towels of tissues so that only
a thin layer remains. Allow the surface to dry
for at least the specified time, see "Technical
data".
K1 00 720
4-16 © 200346
Applying sealant
1. For hot working the sealant must be
8 mm
preheated in an oven, special tool
(DAF no. 1329416), for 60 minutes at 80|C.
2. Give the spraying nozzle the shape shown in

the drawing. 12 mm
3. Take note of the processing time when K1 00 721
applying the sealant, see "Technical data".
4. Fit the spraying nozzle to the cartridge and

apply the sealant to the windscreen,
spraying as evenly as possible.
5. Place the sealant gun with the opening 90|/

60| onto the glass and move it evenly to build
up a good layer. 4
6. Avoid air bubbles in the layer of sealant.
Note:
If a pneumatic glue gun is used for sealing,
special tool (DAF no. 1240444), then before
beginning adjust the pressure in the gun (by
spraying several test strips).
K1 00 722
Fitting the glass
1. The glass should be taken from the
workbench by two persons and it should be
placed in the frame in one go. Use the
dimensions on the tape strips (1).
1
K1 00 699
© 200346 4-17
2. Make sure that the rubber windscreen trim at

the bottom catches properly into the upper
grille plate.
3. Use the specified sealant remover to remove

the excess sealant immediately from the
painted parts, see "Technical data".
4. For safety, open the windows to avoid

undesirable pressure build-up on the
windscreen.
4
K1 00 723
5. Depending on the type of sealant used

(setting time), fit straps. See "Technical
data". Protect the paint by fitting linen tape in
the places where the straps touch it.
6. If applicable, pull two strips round the outside

of the windscreen and the cab pillar. Put
strips of wood or Tempex underneath to
avoid damage.
7. Let the sealant cure for the specified time.

8. Remove all tape used for protection and

marking from the cab body.
9. Then clean the entire windscreen and the

parts of the cab body which have been fouled
during the installation of the windscreen
using a (window) cleaning agent.
10. Fit the A-pillar trimming panels in the cab.

K1 00 724
11. Install the dashboard panel at the top.
12. Fit the stepwell handles.
13. Fit the windscreen wipers and adjust them.
4-18 © 200346
4.12 REMOVAL AND INSTALLATION, SLEEPER CAB SIDE WINDOW/REAR

WINDOW
Note:
The removal procedure for the rear window is
identical to that of the side window. Therefore,
only removal and installation of the side window
is described here.
Removing sleeper cab side window
Note:
Take care not to damage the paint.
1. Put the wire, special tool (DAF no. 1329415),
4
approximately in the middle of the top edge
and in the middle of the bottom edge of the
window frame using pliers or a special pull-
through needle, special tool
(DAF no. 1240458), through the sealant.
Note:
Remove the wire pull-through needle before
fitting the wire ends to the handles of the
cutting wire set.
2. The length of the cutting wire should be 1.5

times the height of the window.
3. Then attach the accessory handles, special

tool (DAF no. 0499817), to the cutting wire.
K1 00 715
4. Use tape strips to protect the glass from

falling out accidentally (after the sealant has
been cut through).
K1 01 362
© 200346 4-19
5. Start cutting in the middle. Make sure the

wire is kept moving and tightly stretched all
the time. If the wire gets twisted, it will
inevitably break.
6. Keep the cutting wire as close as possible to

the edge of the glass.
7. Make sure the wire ends are crossed before

the bottom corners are reached.
8. Remove the glass using a suction pad,

special tool (DAF no. 0484800), from the
window frame.
9. Remove any remaining sealant in the
4
window frame with a scraper, special tool
(DAF no. 1329417). Make sure the
remaining layer of sealant has a thickness of
at most 1 - 1.5 mm and that it is flat and
smooth.
10. Remove frayed pieces and granules of old

sealant and clean the frame thoroughly.
K1 01 059
Important tips
- If the new glass is fitted at a later time, the
old, fully cured sealant should be cleaned
with the specified activator 15 minutes
before the glass is fitted, to ensure proper
adhesion, see "Technical data".
- Immediately remove any spilt activator or
splashes from painted areas using paper
towels or tissues.
- Any damage to the paint on the window
frame should be repaired immediately with
the right type of paint, well before the new
glass is fitted.
cream.
Installing sleeper cab side window

2. Check the side window for damage.
3. Attach a rubber suction pad, special tool

(DAF no. 0484800), to the outside of the
window.
4. Put the glass with the suction pads on a

completely clean workbench.
4-20 © 200346
5. Fit the rubber trimming to the glass and

secure it with tape on the outside of the
glass.
6. Place the glass in the frame without using

sealant, starting at the bottom and ensuring
that it fits exactly in the frame.
7. Mark the correct position of the glass in the

frame with strips of tape. Cut through the
tape in the frame.
8. Remove the window from the frame and

place the window on the workbench.
9. Clean the glass edge where the sealant is to
4
be applied using the specified activator, see
"Technical data". Apply the activator using a
well moistened ball of crumpled paper towels
or tissue; swipe it off immediately using a ball
of crumpled paper towels of tissues so that
only a thin layer remains. Allow the surface to
dry for at least the specified time, see
"Technical data".
10. Clean the cut-back sealant in the frame

using the specified activator, see "Technical
data". Apply the activator using a well
moistened ball of crumpled paper towels or
tissue; swipe it off immediately using a ball of
crumpled paper towels or tissues so that only
a thin layer remains. Allow the surface to dry
for at least the specified time, see "Technical
data".
K1 01 347
© 200346 4-21
Applying sealant
1. For hot working the sealant must be
preheated in an oven, special tool
8 mm
(DAF no. 1329416), for 60 minutes at 80|C.
2. Give the spraying nozzle the shape shown in

the drawing.
12 mm
3. Take note of the processing time when
applying the sealant, see "Technical data". K1 00 721
4. Fit the spraying nozzle to the cartridge and

apply the sealant to the glass, spraying as
evenly as possible.
5. Place the sealant gun with the opening 90|/
4 60| onto the glass and move it evenly to build

up a good layer.
6. Avoid air bubbles in the layer of sealant.
Note:
If a pneumatic glue gun is used for sealing,
special tool (DAF no. 1240444), then before
beginning adjust the pressure in the gun (by
spraying several test strips).
K1 00 722
Fitting the glass
1. Pick up the glass and place it in the frame in
one go. Use the tape strips (1) for
dimensions.
2. Use the specified sealant remover to remove

the excess sealant immediately from the 1
painted parts, see "Technical data".
3. For safety, open the windows to avoid

undesirable pressure build-up on the side
window.
K1 01 349
4-22 © 200346
4. To prevent the side window moving, tape it to

the cab with wide tape until the sealant has
cured.
5. Let the sealant cure for the specified time.

6. Remove all tape used for protection and

marking.
7. Then clean the entire window and the parts

of the cab body which have been fouled
during the installation of the window using a
(window) cleaning agent.
4
K1 01 348
© 200346 4-23
4.13 REMOVAL AND INSTALLATION, EXTERIOR MIRRORS COMPLETE WITH

ARMS
Removing main/wide-angle/dead angle

exterior mirrors complete with arms
1. Remove the lower cover by pressing the top
and bottom sides (A) firmly. Tilt the cover
backwards (B), away from the D-shaped
support.
A
2. Remove the connectors to the mirror heater A
and to the adjustment on the inside of the
door.
3. Remove the attachment bolts and remove
4 the entire mirror complete with arm.
Installing main/wide-angle/dead angle

exterior mirrors complete with arms B
1. Install the mirror complete with arm and B A
secure it using the attachment bolts. A
K1 01 226
2. Fit the connectors to the inside of the door.
3. Fit the cover and press it firmly.
4-24 © 200346
4.14 REMOVAL AND INSTALLATION, EXTERIOR MIRRORS
Removing main exterior mirror

1. Remove the cover at the back of the exterior
mirror. This cover can be loosened by
sticking a wide screwdriver into the openings
(do not turn it) and moving the screwdriver
backwards.
2. Unplug the connectors of the exterior mirror

heating and/or exterior mirror adjustment.
K1 01 094
© 200346 4-25
3. Remove the clamping bracket bolts (1) and

remove the exterior mirror from the D-
shaped arm.
Installing main exterior mirror

1. Fit the exterior mirror to the D-shaped arm.
Hand-tighten the clamping bracket bolts (1).
2. Fit the connectors of the exterior mirror

1
heating and/or exterior mirror adjustment.
3. Position the mirror at the proper height and

angle, see "Technical data". 1
4. Tighten the clamping bracket bolts.
4 5. Fit the cover (push into place).

1
K1 01 095
Removing wide-angle exterior mirror/dead

1. Remove the cover at the back of the exterior
mirror. This cover can be loosened by
sticking a wide screwdriver into the openings
(do not turn it) and moving the screwdriver
backwards.
2. Unplug the connectors of the exterior mirror

heating.
K1 01 094
4-26 © 200346
3. Remove the clamping bracket bolts (1) and

remove the exterior mirror from the D-
shaped arm.
Installing wide-angle exterior mirror/dead

1. Fit the exterior mirror to the D-shaped arm.
Hand-tighten the clamping bracket bolts (1).
1
2. Fit the connectors of the exterior mirror
heating.
3. Position the mirror at the proper height and 1

angle, see "Technical data".
4. Tighten the clamping bracket bolts.
5. Fit the cover (push into place).

1
4
K1 01 095
© 200346 4-27
4.15 REMOVAL AND INSTALLATION, MIRROR GLASS
Removing main exterior mirror glass

1. Press in the mirror glass at the top (1).
2. Push the mirror glass upwards (2).
3. Press in the mirror glass at the bottom (3). 1 4
4. Put your fingers in the opening created and

now push the mirror glass (from the bottom
up) out of the fixing and remove the glass (4).
Installing main exterior mirror glass

2
3
1. Put the mirror glass in place.
4 2. Push the mirror glass from the top down into

the fixing. 3
1 2 4
3. Put the mirror in its required position.
Removing wide-angle mirror glass/dead

angle exterior mirror glass
1. Press the mirror glass in at the left side (1).
K1 01 029
2. Push the glass sideways from right to left (2).
3. Press the mirror glass on the right-hand side

(3).
4. Put your fingers in the opening created and

now push the mirror from right to left out of
the fixing and remove the glass (4).
Installing wide-angle mirror glass/dead angle

exterior mirror glass
1. Put the mirror glass in place.
2. Push the mirror glass into the fixing from left

to right.
3. Put the mirror in its required position.
4-28 © 200346
4.16 REMOVAL AND INSTALLATION, PAVEMENT MIRROR
Removing pavement mirror

1
pavement mirror and remove the mirror.
Installing pavement mirror

1. Put the pavement mirror in place and secure
it using the attachment bolts (1).
4
K1 01 064
© 200346 4-29
4.17 REMOVAL AND INSTALLATION, HEADLIGHT
Removing headlight
1. Remove the attachment bolts in the stepwell
and remove the plastic corner piece around
the headlight.
4
K1 00 946
2. Remove the attachment bolts from the front

of the headlight.
3. Pull the headlight forward and disconnect the

connectors at the rear.
4. Remove the headlight.
Installing headlight
1. Connect the headlight.
2. Hook the rubber protuberance in the recess

and fix the headlight in place with the
attachment bolts at the front.
K1 00 947
3. Fit the plastic corner piece around the
headlight and refit the corner piece in the
stepwell.
4-30 © 200346
4.18 REMOVAL AND INSTALLATION, HEADLIGHT BRACKET
Removing headlight bracket

1. Tilt the cab.
2. Remove the headlight.

headlight bracket and remove the bracket
together with the height control valve.
Installing headlight bracket

1. Position the headlight bracket together with
the height control valve and fix it with the
attachment bolts.
2. Fit the headlight. 4

3. Tilt the cab back.
K1 01 031
4.19 REMOVAL AND INSTALLATION, HEADLIGHT LEVELLING CONTROL
Removing headlight levelling control

1. Tilt the cab forwards.
2. Disconnect the headlight levelling connector.
3. Remove the headlight levelling control by

turning it fully counterclockwise out of the
back of the headlight (at the rear).
Installing headlight levelling control

1. Fit the headlight levelling control by screwing
it clockwise into the bayonet catch.
2. Fit the headlight levelling connector.

K1 01 100
© 200346 4-31
4.20 REMOVAL AND INSTALLATION, MUDGUARD ASSEMBLY
Removing mudguard assembly

1. Tilt the cab.
2. Disconnect the stepwell lighting connector

(1). 3
3. Remove attachment bolts (2) and

attachment nuts (3).
4. Support the mudguard, remove the

attachment screws (4) and attachment bolts
(5) and remove the mudguard assembly. 2
4
Installing mudguard assembly
4 1. Position the mudguard assembly and fit the
attachment screws (4) and attachment bolts
(5).
2. Fit the attachment bolts (2) and attachment

nuts (3).
3. Connect the stepwell lighting connector (1). 1

5 K1 00 660
4-32 © 200346
4.21 REMOVAL AND INSTALLATION, BUMPER
Removing bumper
headlights.
2. Remove the vehicle grille.
3. Remove the attachment bolts at the rear

(bottom) of the bumper support on the
chassis.
4. Remove the attachment bolts from the front

of the bumper.
5. Disconnect the connectors and remove the

bumper assembly. 4
Installing bumper
1. Fit the connectors and the bumper.
2. Fit the attachment bolts at the front.

K1 01 080
3. Fit the attachment bolts at the rear (bottom)
of the bumper support.
4. Fit the vehicle grille.
5. Fit the corner pieces around the headlights.
© 200346 4-33
4.22 REMOVAL AND INSTALLATION, SQUEEGEE STRIPS
Removing squeegee strips

1. Fully lower the door glass.
2. Remove the squeegee strips on the inside

and outside of the door by pulling them from
the window frame.
Installing squeegee strips

1. Fit the ends of the squeegee strips on the
inside and outside in the top corner and fix
these ends firmly in place.
2. Then work towards the bottom, while
4
pressing firmly on the squeegee strip.
Ensure that the squeegee strips (1) connect 1
to the weatherstrip (2).
Note:
Make sure the foil (3) on the inside of the
door is over the edge of the window frame
when the squeegee strip is being fitted. 2
3. Fit the squeegee strips firmly by tapping 3

them with a mallet.
K1 00 697
4-34 © 200346
4.23 REMOVAL AND INSTALLATION, ANTI-WHISTLE WEATHERSTRIP
Removing anti-whistle weatherstrip

1. Remove the door and place it on a suitable
work bench.
2. Remove the old anti-whistle weatherstrip

and throw it away.
Note:
Avoid removing anti-whistle weatherstrips, if
possible. Masking is preferred to removing!
If removal of the anti-whistle weatherstrip is
unavoidable, proceed as follows:
Installing anti-whistle weatherstrip

1. Clean the area to be glued (1) with the
specified cleaning agent, see "Technical 1 B
4
data".
2. Lightly roughen the area to be glued with the A

specified abrasive, see "Technical data".
3. After roughening the area, remove any dust

and grease as quickly as possible using the
specified cleaning agent, see "Technical
data".
2 3
Note:
For proper adhesion, the temperature should
be at least 15|C. If necessary, this
temperature can be obtained by using a blow K1 00 694
drier.
3 B
4. Pull the protective foil (2) from the new anti-
whistle weatherstrip (3) beginning by A to
beyond B.
5. Position the new anti-whistle weatherstrip (3)

at the point marked B.
6. Press the rubber, beginning with the point

marked B. Make sure that the "nose" is fitted
over the edge of the door. Remove the rest
of the protective foil (2) and press the rest of
the strip in place.
K1 00 695
© 200346 4-35
7. When the whole anti-whistle weatherstrip is

in place, secure areas A, B and C by
applying a drop of superfast adhesive, see B
"Technical data".
A
8. Using a wallpaper roller for example, press
the anti-whistle rubber over the whole glued
area . Apply a force of approx. 7 kg manually.
9. Install the door. 7 kg.
C
K1 00 696
4-36 © 200346
4.24 REMOVAL AND INSTALLATION, RAISED ROOF
Removing raised roof

1. Remove the interior compartments and
interior upholstery.
2. Disconnect the electrical connections (wiring

harnesses).
3. Remove the electric roof hatch.
4. Saw the polyester roof approximately 10 cm

from the bottom. Remove the polyester roof
from the cab.
5. Remove the attachment bolts from the roof

frame. 4
Notes
- There is still a 10-cm polyester edge
attached to the cab. Cut through the sealing
compound between this edge and the cab.
- After that, break off the polyester edge from
the cab in pieces.
- Cut away as much of the sealant remnants
as you can from the roof edge. A thin layer
may remain.
Important tips
- Check that there is no gel coating on the
inside of the polyester roof edge.
- Check that there is no finishing coat or
bitumen coating on the part to be glued.
- Any damage to the paint on the frame should
be repaired immediately with the right type of
paint, well before the new raised roof is fitted.
- Always used the specified cleaner, adhesive,
activator and primer to glue the raised roof to
the cab, see "Technical data". Note the
drying, processing and curing times.
cream.
- Immediately remove any splashes or spilt
activator or cleaner from painted areas using
paper towels or tissues.
Pre-treating the polyester roof

1. The pre-treatment described below
guarantees that the entire surface which will
come into contact with the adhesive will be
covered with a suitable layer of primer.
© 200346 4-37
2. At places where adhesive is to be applied,

the polyester roof is first cleaned with a ball
of crumpled cleaning towels or tissues that
has been thoroughly moistened with the
data".
3. Lightly roughen the surface to be glued with

the specified abrasive, see "Technical data".
4. Clean the sanded surface once again using

a ball of crumpled cleaning towels or tissues
that has been thoroughly moistened with the
data". Allow the clean surface to dry for the
specified time, see "Technical data".
4 5. Check that the surface is free of abrasives

and other impurities. If necessary, repeat the
cleaning operation.
6. Next apply a single or at most two thin

1
covering layers of the specified primer to the
roughened surface (1) in accordance with
the supplier's instructions. Allow this layer to
dry for the specified time, see "Technical
data".
Note:
Shake the can of primer well before use.
K1 01 072
K1 01 074
4-38 © 200346
Pre-treating cab
Within 30 minutes before gluing, the cab roof
edge should be pre-treated in the following
manner:
- Clean the cut-back sealant and its immediate
surroundings using the specified activator,
see "Technical data". Apply the activator
using a well moistened ball of crumpled
paper towels or tissue; swipe it off
immediately using a ball of crumpled paper
towels or tissues so that only a thin layer
remains. Allow the surface to dry for the
specified time, see "Technical data".
Installing raised roof
4
1. Using a hoist place the polyester roof on the
cab to mark the position of the holes for the
attachment bolts.
2. Remove the polyester roof. Drill the holes in

the polyester roof.
3. Pre-treat the cab.
4. Pre-treat the polyester roof.
Note:
- Once the primer has been applied, the
polyester roof must be glued to the cab
with in the specified time, see "Technical
data".
- Because a film forms on the beads of
adhesive (something which has a very
negative impact on the quality of the
adhesive), application of the beads of
adhesive, gluing of the surface and
fixation of the polyester roof should be
realised within the specified time, see
"Technical data".
- Make sure that the polyester roof fits K1 01 076
securely into the drip channel edge of
the cab. Use stud bolts or guiding pins to
fit the polyester roof correctly onto the
cab.
© 200346 4-39
5. Place the rubber seal all round.
4
K1 01 075
6. Apply the specified sealant, see "Technical

data".
7. Place the steel plates to support the bed, to

prevent the roof edge from deforming.
8. Using a hoist, place the poyester roof in the

correct position on top of the cab in one go.
9. Tension the front of the polyester roof using

a beam at the rear so that it covers the
rubber at the front completely to prevent
black sealant streaks on the cab roof.
10. Fix the polyester roof to the inside ofthe cab

using the attachment bolts; tighten the
attachment bolts to the specified torque, see
K1 01 073
"Technical data".
} Setting
Take note of the full setting time
when applying the sealant. See
"Technical data". Only when it has
fully set will the glued joint be able to
bear the full load.
4-40 © 200346
1 CAB SUSPENSION
CONTENTS
5 Cab suspension
Page Date

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 Cab suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Operation of the cab air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200346
2.3 Sectional drawing of air suspension element . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200346

3.1 Inspection and adjustment, cab suspension with coil spring elements . . . 3-1 . . . . . 200346
3.2 Inspection and adjustment, cab suspension with air suspension elements 3-3 . . . . . 200346

4.1 Removal and installation, cab stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346
4.2 Removal and installation, cab stabiliser bearing bracket. . . . . . . . . . . . . . 4-5 . . . . . 200346
4.3 Removal and installation, cab support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . 200346
4.4 Removal and installation, cab stabiliser silentblocks . . . . . . . . . . . . . . . . .
4.5 Removal and installation, coil spring front suspension . . . . . . . . . . . . . . .
4-8 . . . . .
4-10 . . . .
200346
200346
5
4.6 Removal and installation, rear coil spring suspension. . . . . . . . . . . . . . . . 4-12 . . . . 200346
4.7 Removal and installation, front air suspension . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . 200346
4.8 Removal and installation, rear air suspension . . . . . . . . . . . . . . . . . . . . . . 4-15 . . . . 200346
4.9 Removal and installation, cab locking mechanism . . . . . . . . . . . . . . . . . . 4-16 . . . . 200346
4.10 Removal and installation, complete cab . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . 200346
© 200346 1
CAB SUSPENSION 1
2 © 200346
1 CAB SUSPENSION
General
underneath the cab.


5


for cracks.

past its end stop.

stand in front of the cab. Make sure that there is
no one in front of the cab while it is being tilted.
for internal damage. Replace the lifting cylinder if
damaged or if in doubt.
© 200346 1-1
CAB SUSPENSION 1
1-2 © 200346
1 CAB SUSPENSION
2. GENERAL
2.1 CAB SUSPENSION
The F230 cab is attached to the chassis at four

different points. Various cab suspension versions
are possible.
Day cab
Standard coil spring suspension with optional air
suspension at the front.
Sleeper cab
Standard coil spring suspension with optional air
suspension all round.
Spring suspension
The cab is attached to the chassis both at the
back and the front by coil spring.
elements. These elements are adjustable. There
is a stabiliser at the front.
At the back, the cab is damped laterally by two 5
horizontal dampers.
In the day cab model the horizontal dampers are
pointed outwards.
In the sleeper cab model the horizontal dampers
are pointed inwards.
Air suspension
The cab is attached to the chassis both at the
back and the front by air suspension
elements. The air suspension elements consist of
an air bellows with an internal shock absorber.
The system is equipped with height control
valves. The system has a stabiliser at the front.
At the back, the cab is damped laterally by two
horizontal dampers.
Suspension with coil spring and air
suspension elements (optional on day cab)
The cab is attached to the chassis at the front by
air suspension elements. The air suspension
elements consist of an air bellows with an internal
shock absorber.
The system is equipped with a height control
valve.
At the back, the cab is damped laterally by two
horizontal dampers.
The cab is attached to the chassis at the rear by
coil spring elements. These elements are
adjustable. The system has a stabiliser at the
front.
© 200346 2-1
CAB SUSPENSION 1
Tilting the cab with air suspension

When a cab with air suspension is lifted, the
height control valves register a rise in the cab
level which causes the air bellows to discharge.
Because of its weight the cab drops at the front
onto the stop in the spring element. This means
the cab can be tilted without problem and no extra
valves are necessary. No anti-dive valves are
fitted to the air suspension model.
2-2 © 200346
1 CAB SUSPENSION
2.2 OPERATION OF THE CAB AIR SUSPENSION
The day cab has air suspension at the front as an

option.
The sleeper cab has air suspension all round as
an option.
The air suspension consists of an air bellows with
an internal shock absorber.
The system is equipped with height control
valves.
4 5
3 2
K1 00 922
Legend
Item Description Location Note

1 Height control valve Cab, rear left
2 Air reservoir Front left behind bumper Capacity 5.5 litres
3 Height control valve Front left behind bumper
4 Spring element Left- and right-hand sides under cab front
5 Spring element Left- and right-hand sides under cab rear
6 Horizontal damper Left- and right-hand sides under cab rear
© 200346 2-3
CAB SUSPENSION 1
Pneumatic diagram of front cab suspension

A = Connection for cab suspension, front
5,5 ltr
2 1 A
K1 00 930
Pneumatic diagram of rear

B = Connection for cab suspension, rear
5 B
2 1
K1 00 938
Connection of cab suspension spring

elements
1 = Cab spring elements, front
2 = Cab spring elements, rear
2
1
K1 01 129
2-4 © 200346
1 CAB SUSPENSION
2.3 SECTIONAL DRAWING OF AIR SUSPENSION ELEMENT
1. Fixing ring
2. Rebound-rubber
3. Piston rod
4. Flange seam seal
5. Sealing ring 1
6. Rod guides
2
3
4
5
6
K1 01 451
© 200346 2-5
CAB SUSPENSION 1
2-6 © 200346
1 CAB SUSPENSION

3.1 INSPECTION AND ADJUSTMENT, CAB SUSPENSION WITH COIL SPRING
ELEMENTS
Inspecting and adjusting front cab

suspension
2. Measure distance "A" (centre threaded end

to top of bracket), see "Technical data".
K1 01 013
3. Depending on the increased cab weight,

adjust the spring elements by turning the
ring (1).
The spring elements can be adjusted at four
levels. See "Technical data". 1
K1 00 702
© 200346 3-1
CAB SUSPENSION 1
Inspecting and adjusting rear cab suspension

1. Measure distance "B" (centre threaded end
to top of bracket) See "Technical data".
K1 01 014
2. Depending on the increased cab weight,

adjust the spring elements by turning the
ring (1).
The spring elements can be adjusted at four
levels. See "Technical data". 1
K1 00 702
3-2 © 200346
1 CAB SUSPENSION
3.2 INSPECTION AND ADJUSTMENT, CAB SUSPENSION WITH AIR

SUSPENSION ELEMENTS
Inspecting and adjusting cab front

2. Bring the system up to maximum service

pressure.
3. Measure distance "A"(centre of bolt to top of

bracket). See "Technical data".
}
4.
Risk of being trapped when air
bellows blow off.
Remove the rod for height control between A

the height control valve and the cab. Lift the
siphon of the height control valve. The cab
suspension will now blow off using the height
control valve. 5
K1 01 028
Note:
The air bellows must be vented before each new
measurement. After this, the height control valve
will adjust the cab to the set height.
5. Check the distance "A".
6. If the distance "A" needs to be adjusted, A

loosen the hose clamp on the operating rod
of the height control valve and tighten it at the
correct height.
Inspecting cab rear

1. Bring the system to maximum service
pressure.
K1 01 413
2. Measure distance "B" (centre threaded end

to top of bracket). See "Technical data".
}
3.
Risk of being trapped when air
bellows blow off.
Remove the rubber connection for height B

control between the height control valve and
the cab. Lift the siphon of the height control
valve. The cab suspension will now blow off
using the height control valve.
K1 00 942
© 200346 3-3
CAB SUSPENSION 1
4. Fit the rubber connection. Check the set

distance (B)
Notes
- The height "B" cannot be adjusted.
- The air bellows must be vented before each
new measurement.
B
5 K1 01 112
3-4 © 200346
1 CAB SUSPENSION

4.1 REMOVAL AND INSTALLATION, CAB STABILISER
} When working on the cab

suspension provide extra supports
for the cab to avoid the risk of being
trapped.
Removing cab stabiliser

A B
2. Tilt the cab forward.
3. Loosen both attachment nuts from the

bolts (C).
4. On both sides loosen the two rearmost H

attachment bolts (E) from the cab bearing
5
brackets. G
5. Undo the attachment bolts (A) on both sides F
of the tilt assist mechanism.
E
C
D
K1 01 077
7. Fit the yoke (A) (DAF no. 1329487) at the

front.
8. Remove the spring element on driver side

and put to one side. The air pipes, if relevant,
do not need to be undone.
9. On co-driver side remove the uppermost

attachment bolt (H) from the spring element.
Note:
Do not raise the cab more than 10 cm
because of the available length of piping and
cables.
B A
10. Tilt the cab. K1 01 063
© 200346 4-1
CAB SUSPENSION 1
} Place a block (B) or similar support

under the cab before working
underneath it.
11. Remove the rearmost attachment bolts (A, C

and E). A B
12. Remove the foremost attachment bolts (F)

on both sides of the cab bearing brackets.
13. Remove the stabiliser.

H
5
C
D
K1 01 077
Installing cab stabiliser A

1. Place the stabiliser in position.
2. Fit the attachment bolts (B) of the

silentblocks with the heads pointing
outwards. Apply locking compound to the
attachment bolts. See "Technical data".
Hand-tighten the attachment nuts.
3. Fit the attachment bolts of the tilt assist

mechanism (A) and tighten them to the
specified torque, see "Technical data".
B
K1 01 090
4-2 © 200346
1 CAB SUSPENSION
4. Position the stabiliser bearing brackets in

2 1
relation to the chassis supports.
5. Fit the attachment bolts (2, 3 and 4) on the

right-hand side of the vehicle. Tighten the
bolts but not yet to the specified torque.
6. Tighten the attachment bolts (3 and 4) on the

right-hand side to the specified tightening
3 4
K1 01 021
7. Fit the attachment bolts (2, 3 and 4) on the

1 2
left-hand side of the vehicle but do not yet
tighten these bolts to the specified torque.
The stabiliser still needs to be movable
4 3
K1 01 022
Note:
1
Check that the threaded hole for the prestressed
bolt in the aluminium chassis bracket has a screw
thread.
8. Place an M8x50 mm bolt (1) to apply

prestress to the cab stabiliser bearing
support. Tighten the prestressed bolt to the
specified torque. See "Technical data".
9. On driver side fit the spring element and

tighten the attachment bolt at the top and the
attachment nut at the bottom to the specified
K1 01 066
tightening torque, see "Technical data".
© 200346 4-3
CAB SUSPENSION 1
10. If applicable, fit the operating rod for the

height control valve.
11. On co-driver side fit the uppermost

attachment bolt of the spring element and
tighten it to the specified tightening torque,
see "Technical data".
12. Remove the block or the support from under

the cab and lower the cab. Remove the lifting
yoke.
13. Check whether the gear lever is in neutral.

Tilt the cab forward.
14. Tighten the attachment bolts of the

silentblocks to the specified tightening
K1 01 093
15. Insert the attachment bolt (1) on the right-

5
2 1
hand side of the vehicle and tighten both
attchment bolts (1 and 2) on the rear to the
specified torque, see "Technical data".
3 4
K1 01 021
16. Fit the attachment bolt (1) on the left-hand

1 2
side of the vehicle. Tighten the attachment
bolts (1, 2, 3 and 4) of the stabiliser bearing
bracket in the specified order and to the
specified tightening torque, see "Technical
data".
4 3
K1 00 941
4-4 © 200346
1 CAB SUSPENSION
4.2 REMOVAL AND INSTALLATION, CAB STABILISER BEARING BRACKET

trapped.
Removing cab stabiliser bearing bracket
;;
1. Remove the cab stabiliser.
; ;
;;;;;
1
;;;;;;;;;
;;;;;;
;;
2. Using a punch, remove the outer ring (1) and
; ;
;;;;; ;
rubber seal from the bearing bracket.
; ;
;;;;;
;;;;;;;
;;;;
;;;;;;
;
;
;;;;;
;;;;; ;
;;;;;;
;;;;;
;
;;;;;
;;;;
;;;;;;;;;
;;;;
;
;
;;;;;
;;;;;
5
K1 00 939
3. Remove the bearing bracket (2).
4. Using a punch, remove the inner ring (3)

3 2
from the cab stabiliser.
K1 00 940
© 200346 4-5
CAB SUSPENSION 1
Installing cab stabiliser bearing bracket
; ;
1. Fit the rubber seal on the cab stabiliser using
; ;
;;;;;;
a steel tube.
;;
;;;
; ;
;;;;;;
;;;;;;
; ;;;;
;
;; ;; ; K1 01 069
2. Position the cab stabiliser and bearing

bracket as indicated, using an 80 mm
block (A).
5
A
K1 01 001
;;
3. Pull the outer ring (3) using a pulley puller
; ;
;;;;;
3 2
;
(trade tool) on the bearing bracket (2).
;;;;;
4. Put the cab stabiliser in place.
;;;
; ; ;
;;;;;;
;
;;;;;
;;
; ;
;;;;;
;;
;;;;;
;;;;;;
;;;;;
;;;;
;;;;;
;;;;;
; ;
;;;; ;
;;
;
;;;;;
;
;
;;;;
;;;;
;;;;; ;
;;;;;
;;;;;
K1 01 115
4-6 © 200346
1 CAB SUSPENSION
4.3 REMOVAL AND INSTALLATION, CAB SUPPORT

trapped.
Removing cab support

1. Remove the cab stabiliser.
A
2. Remove the attachment bolts (A) from the
cab support and remove the cab support.
Installing cab support

1. Fit the cab support and tighten the
attachment bolts to the specified torque. See
"Technical data".
2. Put the cab stabiliser in place.
K1 01 091
© 200346 4-7
CAB SUSPENSION 1
4.4 REMOVAL AND INSTALLATION, CAB STABILISER SILENTBLOCKS

trapped.
Removing cab stabiliser silentblocks

1. Remove the cab support.
2. Force the silentblock (1), using the puller (A),

special tool (DAF no. 1329486), from the cab
stabiliser (2).
A 2 1 A
K1 01 410
Installing cab stabiliser silentblocks
Note:
Fit the silentblocks with the marks in vertical
position, as shown in the illustration (cab in
driving position). The arrow (A) shows the driving A
direction.
K1 01 411
4-8 © 200346
1 CAB SUSPENSION
1. Fit the distance ring (B), which is part of the

puller, in puller (A), special tool
(DAF no. 1329486).
2. Using puller (A), force the silentblock (1) into

the cab stabiliser (2) up to distance ring (B). A 1 2 B A
Note:
Immediately stop forcing when the
silentblock touches distance ring (B) to
prevent the inner sleeve of the silentblock
from being damaged (upset).
3. Fit the cab support.
K1 01 412
© 200346 4-9
CAB SUSPENSION 1
4.5 REMOVAL AND INSTALLATION, COIL SPRING FRONT SUSPENSION

trapped.
Removing coil spring front suspension

headlights and the vehicle grille.
Note:
cables.
2. Place the hoist yoke (A) (DAF no. 1329487)

and lift the cab at the front.
5
underneath it.
B A
K1 01 063
3. Remove the attachment nut (B) at the

bottom.
4. Remove the attachment bolt (A) at the top.
5. Remove the spring element.
B
K1 01 092
4-10 © 200346
1 CAB SUSPENSION
Installing coil spring front suspension

1. Put the spring element in place. Fit the
attachment bolt (A) at the top and tighten it to
the specified tightening torque, see
"Technical data".
2. Remove the block (or support)
3. Lower the cab carefully and fit the A

attachment nut (B) at the bottom. Tighten the
attachment nut to the specified torque, see
"Technical data".
4. Remove the lifting yoke.
5. Fit the corner pieces and the vehicle grille.
5
B
K1 01 092
© 200346 4-11
CAB SUSPENSION 1
4.6 REMOVAL AND INSTALLATION, REAR COIL SPRING SUSPENSION
Removing rear coil spring suspension

2. Remove attachment bolt (B) from the B

horizontal damper.
3. Remove attachment bolt (A) from the spring A

element at the top.
4. Lay the cab locking mechanism to one side.
5. If the vehicle is equipped with a day cab,

remove the attachment bolt at the bottom.
If the vehicle is equipped with a sleeper cab,
remove the attachment nut (C) at the bottom.
5 Installing rear coil spring suspension

1. Put the spring element in place. C
2. If the vehicle is equipped with a day cab, fit
the attachment bolt at the bottom. Tighten
the bolt to the specified torque. See
"Technical data".
If the vehicle is equipped with a sleeper cab,
fit the attachment nut (C) at the bottom. K1 01 114
Tighten the nut to the specified tightening
3. Fit the cab locking mechanism. Fit

attachment bolt (A) but do not tighten it yet.
4. Fit attachment bolt (B) of the horizontal

damper. Do not yet tighten the bolt to the
specified tightening torque.
6. Tighten attachment bolt (B) of the horizontal

damper to the specified tightening torque,
7. Tighten attachment bolt (A) of the cab

locking mechanism to the specified
4-12 © 200346
1 CAB SUSPENSION
4.7 REMOVAL AND INSTALLATION, FRONT AIR SUSPENSION

trapped.
Removing front air suspension

headlights and the vehicle grille.
Note:
cables.
2. Place the hoist yoke (A) (DAF no. 1329487)

and lift the cab at the front.

underneath it.
5
B A
K1 01 063
3. Remove the attachment nut from the spring

element (B) at the bottom.
4. Remove attachment bolt (A) from the spring

element at the top.
5. Remove the air pipe from the spring element.
B
K1 01 107
© 200346 4-13
CAB SUSPENSION 1
Installing front air suspension

1. Put the spring element in place. Fit the
attachment bolt (A) at the top and tighten it to
"Technical data".
2. Connect the air pipe.
3. Remove the block (or support)
4. Lower the cab carefully and fit the

attachment nut (B) at the bottom. Tighten the
nut to the specified tightening torque, see
"Technical data".
A
5. Remove the lifting yoke.
6. Fit the corner pieces and the vehicle grille.
5
B
K1 01 107
4-14 © 200346
1 CAB SUSPENSION
4.8 REMOVAL AND INSTALLATION, REAR AIR SUSPENSION
Removing rear air suspension

2. Remove the air pipes
3. Remove attachment bolt (B) from the

horizontal damper.
B
4. Remove attachment bolt (A) from the cab
locking mechanism..
A
5. Lay the cab locking mechanism to one side.
6. Remove the attachment nut (C) at the

bottom.
Installing rear air suspension

1. Put the spring element in place.
5
2. Connect the air pipe.
3. Fit the attachment nut (C) at the bottom.

Tighten the nut to the specified tightening
C
4. Fit the cab locking mechanism. Fit
attachment bolt (A) but do not tighten it yet.
5. Fit attachment bolt (B) of the horizontal K1 01 108

damper. Do not yet tighten the bolt to the
specified tightening torque.
7. Tighten attachment bolt (B) of the horizontal

damper to the specified tightening torque,
8. Tighten attachment bolt (A) of the cab

locking mechanism to the specified
© 200346 4-15
CAB SUSPENSION 1
4.9 REMOVAL AND INSTALLATION, CAB LOCKING MECHANISM
Removing cab locking mechanism

1. Tilt the cab.
2. Switch the tilting pump to reverse tilting.
3. Remove the proximity switch connector (D)

on the right-hand side.
A
4. Remove the hydraulic line (C) and plug it.
Collect any oil flowing out of the system. B
C
5. Remove the attachment bolts (A) and (B).
D
6. Remove the cab lock.
Installing cab locking mechanism

1. Fit the cab locking mechanism. Do not yet
5
tighten the attachment bolts to the specified
tightening torque.
2. Connect the connector (D) of the proximity

switch.
3. Connect the hydraulic line (C).
4. Carefully lower the cab. When doing so,

ensure that the locks are open. K1 01 109
5. Tighten the attachment bolts to the specified

torque. See "Technical data".
6. Bleed the tilting mechanism.
4-16 © 200346
1 CAB SUSPENSION
4.10 REMOVAL AND INSTALLATION, COMPLETE CAB
} Only use approved lifting

equipment. Comply with general
safety instructions when working
with lifting equipment.
Removing complete cab

1. Remove the battery earth cables.
2. Put the gear lever in 2nd or 4th gear. Put the

wheels in the straight-line position.
3. Open the cab grille.
Note:
Work on the air conditioning unit should only
be carried out by qualified personnel.
5
4. If present, drain the air conditioning unit.
5. Drain the clutch fluid.
6. Drain the coolant.
7. Remove the covers from around the

headlights.
9. Remove the cover from the cab lead

through.
10. Check that the wiring harnesses are marked.

If not, mark them.
11. Detach the connectors in the cab lead

through.
12. Remove the cover at the bottom of the cab

lead through.
13. Disconnect the wiring harnesses.
14. Detach the positive and the earth leads in the

cab lead through.
15. Remove the air pipe from the splitter control

valve.
16. Remove the hose from the main clutch

cylinder.
17. Tilt the cab.
18. Loosen the wiring harnesses from the cab

K1 01 035
lead through as much as is necessary.
© 200346 4-17
CAB SUSPENSION 1
19. Loosen the wiring harness (1) from the

lighting unit as much as is necessary.
20. Disconnect the connector (2) from the air 1

supply unit. Loosen the wiring harness as
much as is necessary.
21. If present, release the fuel pipe from the cab

heater at the rubber joint.
5 K1 01 032
22. On the steering box side loosen the wiring

harness that goes to the lighting unit (1) as 1
much as is necessary. Loosen the
connector.
23. Take the pressure off the air system.
24. Remove the attachment bolts (2) from the air

duct block and put the loose half to one side.
25. Loosen one of the universal joints of the

steering shaft (which one depends on the
operation to be performed; either the 2
universal joint beneath the steering wheel or
the universal joint on the steering box).
Before loosening, mark the position of the
universal joint in relation to the steering
shaft.
K1 01 036
26. Remove the clamp bolt from the universal
joint.
27. Remove the universal joint from the steering

box input shaft.
4-18 © 200346
1 CAB SUSPENSION
28. Disconnect the three bleed hoses (1) that are

1
connected to the expansion reservoir.
K1 01 037
29. Remove the heater hoses (1) on the steering
5
box side.
K1 01 067
© 200346 4-19
CAB SUSPENSION 1
30. Remove the heater hose on the side of the

air supply unit.
31. Slacken the attachment bolt that holds the

lifting cylinder to the cab by one turn.
5
K1 01 039
2 1 1 2
3 4 4 3
K1 01 648
32. On both sides remove the rearmost bolts (1)
from the stabiliser bearing bracket and
slacken the bolts (2) on both sides by one
turn
34. Remove the glass from the roof hatch.
35. Open both doors and secure them.
4-20 © 200346
1 CAB SUSPENSION
36. Lower the hoist through the roof hatch and fit
the lifting yoke.
37. With the cab tilting mechanism in the lifting

position, make a number of pump strokes
until both cab locks are disengaged.
38. Slacken the attachment bolts for the cab

suspension.
5
K1 01 076
2 1 1 2
3 4 4 3
K1 01 648
39. On both sides remove the foremost bolts (3
and 4) from the stabiliser bearing bracket
and remove the bolts (2) at the rear.
40. Hoist the cab carefully a little way so that the

bolts can be removed from the cab
suspension.
41. Remove the attachment bolt that attaches

the lifting cylinder to the cab.
42. Hoist the cab carefully a little way and check

that all pipes and wiring harnesses are
disconnected.
43. Carefully lift the cab from the vehicle. Place

the cab on a cab support or another suitable
frame.
© 200346 4-21
CAB SUSPENSION 1
}
Installing complete cab
When working on the cab
trapped.
1. Fit the hoist yoke.
2. Before placing the cab on the chassis

supports check to see if the wiring holes in
the aluminium chassis are accessible. This
makes the work easier.
3. Check that the contact surfaces of the

stabiliser bearing brackets and the chassis
supports are clean.
4. Check that the gear lever is in 2nd or 4th gear.
5. Place the cab above the chassis and lower it

5 carefully onto the chassis supports. Check
that the wiring harnesses and any piping do
not get trapped.
K1 01 076
6. Position the stabiliser bearing brackets in

2 1
relation to the chassis supports.
7. Fit the attachment bolts (2), (3) and (4) on the

right-hand side of the vehicle. Tighten the
bolts but not yet to the specified torque.
8. Tighten the attachment bolts (3) and (4) to

the specified torque. See "Technical data".
3 4
K1 01 021
9. Fit the attachment bolts (2), (3) and (4) on the

1 2
left-hand side of the vehicle but do not yet
tighten these bolts to the specified torque.
The stabiliser bearing bracket must still be
able to move.
10. Position the lift cylinder and fit the bolt.

Tighten the bolt to the specified torque. See
"Technical data".
Note:
Before fitting the prestressed bolt check that
the threaded hole in the aluminium chassis 4 3
bracket has a screw thread. K1 01 022
4-22 © 200346
1 CAB SUSPENSION
11. Fit the prestressed bolt (1). Tighten the

1
prestressed bolt to the specified torque. See
"Technical data".
12. Lower the cab and remove the hoist yoke.
13. Check whether the gear lever is in neutral.
14. Tilt the cab completely forward.
K1 01 066
15. Insert the bolt (1) on the right-hand side of

2 1
the vehicle and tighten both bolts (1) and (2)
on the rear to the specified torque. See
"Technical data".
3 4
K1 01 021
16. On the left side place the bolt (1). Fit the bolts
1 2
(1), (2), (3) and (4) of the stabiliser bearing
support in the specified order and to the
17. Remove the prestressed bolt.
18. Attach the bracket for the height control

valve.
4 3
K1 00 941
© 200346 4-23
CAB SUSPENSION 1
19. Put the coupling block with air pipes in place

and secure it using the attachment bolts (2). 1
20. Connect the connector (1) of the lighting on

the left side. Fasten the wiring harness with
ties.
K1 01 036
5
21. Fit the steering-column shaft to the steering-
box input shaft. The groove (A) in the
coupling must be aligned with the mark (B)
on the input shaft of the steering box.
} Check that the steering shaft is

correctly in place on the input shaft
so that the attachment bolt can be
put in the notch (C).
22. Only fit a new attachment bolt and

attachment nut to the universal joint. Tighten B
the attachment bolt to the specified torque. A
C
K1 01 353
23. Attach the pipe for the clutch cylinder (on

chassis side member). Fasten the pipe with
the special clips for that purpose.
24. Attach the heater hoses (1) to the underside

of the cab and attach the heater hose to the
front of the cab.
1
K1 01 067
4-24 © 200346
1 CAB SUSPENSION
25. Attach the coolant hoses (1) from the engine

1
to the expansion reservoir.
K1 01 037
26. Attach the coolant hose from the expansion
5
reservoir to the engine.
K1 01 039
© 200346 4-25
CAB SUSPENSION 1
27. Connect the connector (1) of the lighting on

the right-hand side.
28. Install the connector (2) on the air supply 1

unit.
29. If present, attach the fuel pipe to the cab

heater.
30. Connect the pipe to the clutch cylinder. Fix

the pipe securely with a clamp to prevent the
pipe from chafing.
31. Install the air conditioning pipes and secure

them using the attachment nuts.
2
32. Fit the lower cover of the cab lead through.
5 K1 01 032
33. Fit the connectors and the cables in the cab

lead through. Seal the tachograph.
34. Fit the cover of the cab lead through.
37. Bleed the clutch cylinder.
38. Connect the air pipe to the splitter control

valve.
39. Fill the cooling system.
40. Fit the earth lead to the battery terminal.

K1 01 035
41. Let the engine idle and top up the cooling

system, if necessary.
42. If applicable, fill the air conditioning system.
4-26 © 200346
1 CAB TILTING MECHANISM
CONTENTS
6 Cab tilting mechan ism
Page Date

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 Operation, tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Overview drawing, cab tilting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200346
2.3 Overview drawing, lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200346

3.1 Inspecting tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
3.2 Inspection and adjustment, pressure limiting valve of cab tilting pump . . . 3-2 . . . . . 200346

4.1 Removal and installation, cab tilting pump . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346
4.2 Removal and installation, lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200346
4.3 Removal and installation, cab tilting pump seals . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200346
4.4 Removal and installation, cab tilting pump two-way valve. . . . . . . . . . . . . 4-9 . . . . . 200346
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346
6
5.1 Disassembly and assembly, lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200346

6.1 Filling and bleeding, tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200346
© 200346 1
CAB TILTING MECHANISM 1
2 © 200346
General
cab and that the gear lever is in neutral.
Always tilt the cab fully forward if work must be
carried out underneath the cab.

at any time by turning the cock of the
cab tilting pump to the reverse tilting
position.

6

for cracks.

past its end stop.
If possible, suspend the cab from a hoist and

place a stand in front of the cab. Also make sure
that there is no one in front of the cab while it is
being tilted.
© 200346 1-1
Replacing lifting cylinder:

for internal damage.
Replace the lifting cylinder if damaged or if in
doubt.
Always replace the lifting cylinder if one of the
following points has occurred during a collision:
- The cab has been pulled out of the cab locks
- The cab locks have been deformed or
damaged
- The rear springs have been deformed or
damaged.
1-2 © 200346
2. GENERAL
2.1 OPERATION, TILTING MECHANISM
General
mechanism. The pump is located on the co-
driver's side at the rear of the cab.
The cab locks are automatically hydraulically
opened when the pump is being operated.
If the vehicle has been involved in a collision,
check the following points before tilting the cab:
- Cab rests
- Cab hinges
- Attachment of the lifting cylinder
- Hydraulic system for leakage.
After this check, continue to proceed with utmost
care.
stand in front of the cab.
for internal damage.
Tilting the cab 6
- Make sure there are no people immediately
in front of the cab.
- Make sure there is sufficient clearance
around the cab.
- Make sure there are no loose objects inside
the cab.
- Apply the parking brake.
- Move the gear lever to the correct position
and turn the engine off.
- Close the doors.
Tilting the cab forward
- Turn the two-way valve of the cab tilting
pump fully clockwise (A).
- Position the pump actuating rod in the pump
and operate the pump.
- You can stop the cab tilting forward at any
time by turning the two-way valve
counterclockwise. A
Tilting back B
- Turn the two-way valve of the cab tilting
pump fully counterclockwise (B).
- Position the pump actuating rod in the pump K1 01 552
and operate the pump.
You can stop the cab tilting back at any time
by turning the two-way valve clockwise (A).
- When the cab has been fully tilted back, the
warning symbol "cab lock open" on the
master display should be extinguished.
© 200346 2-1
Tilting the cab forward
3
A
4
1
2
5
7 8
6 6
6 Turn the two-way valve (2) on the pump (1)

K1 00 706
clockwise (position A).

While pumping, pressure will build up in both
pipes leading to the lifting cylinder (3) and the cab
locks (6).
Any overpressure in the system is returned to the
reservoir via the safety valve (7).
At each pump stroke, the non-return valve (5)
opens.
Oil will now flow underneath the piston of the
lifting cylinder (3).
The pressure in the pipes drops back to zero at
the end of each pump stroke.
As a result, the non-return valve (5) closes.
In spite of the fact that the oil pressure above and
below the cylinder piston is the same, the cylinder
is pumped out, so that the cab is tilted.
This is due to the fact that the same pressure is
acting on two surfaces that are different in area.
The resulting force is the pressure in the system
which is applied to the surface of the plunger
cross section.
Once it has passed top dead centre, the cab will
fall into the full tilt position on its own.
Pumping is not necessary during this time.
2-2 © 200346
Tilting the cab back
B 4
1
2
5
7 8
6 6
Turn the two-way valve (2) on the pump (1)

K1 00 707
6
counterclockwise (position B).
While pumping, the pressure which has built up in
the pump will be passed on to the pressure side
of the cylinder (3) and the non-return valve (5) in
the cylinder (3) will be activated simultaneously.
Each stroke of the pump (1) opens the non-return
valve (5).
When the non-return valve (5) in the cylinder
opens, oil can flow back into the pump reservoir
from the cylinder return side.
The cab will move only when the pump is being
operated.
The pressure in the pump and the pipes
consequently drops back to zero at the end of
each pump stroke. The non-return valve (5) will
now close.
The cab will fall downwards on its own a few
centimetres before it is completely secured in the
locks.
This is due to the fact that the piston of the
cylinder is in a position which allows a leak-off
connection (4) between the areas above and
below the cylinder piston.
The warning symbol "cab lock open" on the
instrument panel goes out as soon as the cab
locks are engaged.
© 200346 2-3
2.2 OVERVIEW DRAWING, CAB TILTING PUMP
Note:
This drawing gives a general view and may differ
from the actual situation.
2 4 5 6 7
1
3
18 19
6 9
10
11
12
13
17 14
15
16
K1 01 553
Legend
1. Two-way valve
2. Filler plug
3. O-ring
4. Pin
5. Holder
6. Gasket
7. Reservoir
8. Pump housing
9. Magnet
10. Filter
11. Notched pin
12. Inlet ball
13. O-ring
14. Teflon ring
15. O-ring
16. Ring
17. Torx bolt
18. Lever
19. O-ring
2-4 © 200346
2.3 OVERVIEW DRAWING, LIFTING CYLINDER
Note:
This drawing gives a general view and may differ
from the actual situation.
Legend
1. Dirt scraper
2. Circlip
3. U-cup
4. Upper bearing
5. O-ring
6. Circlip/stop collar
7. Piston
8. O-ring
9. O-ring
10. Circlip
11. Non-return valve seat
12. Ring
13. O-ring
14. Non-return valve
15. O-ring
16.
17.
Seal
Clutch 6
18. Clutch
19. Plastic ring
20. Plastic ring
K100127
© 200346 2-5
2-6 © 200346

3.1 INSPECTING TILTING MECHANISM
1. Check all pipes and connections for any

leakage.
2. Check the cab tilting pump for leaks.
3. Check the lifting cylinder and the cab locks

for leaks.
4. Check that the pistons of the cab locks can

move in and out freely.
Note:
A defective cab tilting mechanism is often the
result of contaminated oil.
K1 01 659
© 200346 3-1
3.2 INSPECTION AND ADJUSTMENT, PRESSURE LIMITING VALVE OF CAB

TILTING PUMP
} Always use a pressure gauge for

inspection and adjustment of the
pressure limiting valve. Too high a
pressure may damage the tilting
mechanism and give rise to
extremely dangerous situations.
Checking pressure limiting valve of cab tilting

pump
1. Remove the pipes from the pump and plug
the connection (D) on the pump with a A
dummy nipple.
2. Connect a pressure gauge with a range of no

less than 600 bar to connection (B).
3. Bleed the pressure gauge hose.
4. Check the oil level in the pump.
6 Note:
Check the oil level. Never fill the oil reservoir
when the cab is tilted. C
B
5. Put the two-way valve of the cab tilting pump D
in the "tilt forward" position. Operate the
pump. If the measured pressure does not
match the specified pressure, see "Technical
data", the pressure limiting valve must be
adjusted.
Note:
The pressure will fall slowly the moment K1 01 640
pumping is stopped; this is normal. A fast
pressure drop would indicate a defective
two-way valve.
6. Remove the pressure gauge and dummy

nipples and connect the pipes.
} Too high a pressure may cause the

end stop to be pushed out of the
lifting cylinder, causing the cab to tilt
forward off the chassis.
Note:
The pressure relief valve is located in the plunger
of the cab tilting pump and can be adjusted via
the filler opening (A).
3-2 © 200346
Adjusting pressure limiting valve of cab tilting

pump
1. Plug connection (D) on the pump with a
dummy nipple. A
2. Connect a pressure gauge with a range of no

less than 600 bar to connection (B).
3. Remove filler plug (A) and fill the reservoir

with the specified hydraulic fluid, see "Fluids
and lubricants" specification.
Note:
Never fill the reservoir when the cab is tilted.
4. Bleed the pressure gauge hose. Put the C

lifting cylinder cock into the "tilt forward"
B
position. Operate the pump. If the pressure is D
less than the specified pressure (bar), the
pressure relief valve should be adjusted.
(Remember that the pressure will drop
somewhat as soon as you stop pumping.)
5. Remove filler plug (A) and use a suitable

screwdriver to set the pressure relief valve in
the plunger to the specified pressure see K1 01 640 6
"Technical data".
6. Remove the pressure gauge and dummy

nipple. Connect the pipes.
© 200346 3-3
3-4 © 200346

4.1 REMOVAL AND INSTALLATION, CAB TILTING PUMP
Removing cab tilting pump

1. Disconnect the pipes and collect the oil in a
container.

remove the pump. Collect any remaining oil 1
from the pump in a container.
3. Thoroughly clean the threaded holes if the

nipples have been or will be removed from
the pump housing, and make sure that any
Teflon tape is removed.
Installing cab tilting pump

1. Install the pump with the attachment
bolts (1).
2. Connect the pipes. C
6
A = pressure pipe (thick pipe, M14) B
B = return pipe (thin pipe, M12)
C = not used A
K1 01 641
Note:
Use Teflon tape to install the nipples in the pump
housing. Note: Do not apply Teflon tape to the
first turn of the nipples. This will prevent the
system from being soiled with Teflon tape.
3. For filling and bleeding the system, see

chapter "Draining and filling".
K1 01 502
© 200346 4-1
4.2 REMOVAL AND INSTALLATION, LIFTING CYLINDER
}
Note:
Do not remove the lifting cylinder
while the cab is in the tilted position.
Mark the piping before removing it.
Removing lifting cylinder

1. If necessary, remove the cable gutter.
2. Disconnect the pipes from the lifting cylinder

and collect the oil in a container. Plug off the
pipes and connections.
3. Remove the compressor pipe.
4. Remove the attachment bolt (1) and

washer (2) and take the lifting cylinder from
the axle journal.
5. Remove the attachment nut (3) and
6 attachment bolt (4), which attach the lifting

cylinder to the cab.
6. Remove the lifting cylinder and remove the

plastic rings (5).
5
5
2 1
K1 00 710
K1 00 711
4-2 © 200346
Installing lifting cylinder

1. Fit the plastic rings (5) on both sides of the
lifting cylinder, with the flat sides in the
recesses.
2. Fit the lifting cylinder to the axle journal and

fit the washer (2) and attachment bolt (1).
5
2 1
K1 00 710
3. Use the attachment bolt (4) and attachment

nut (3) to attach the lifting cylinder to the cab.
Do not yet tighten the attachment bolt (4) to
"Technical data".
6
4
K1 00 711
© 200346 4-3
4. Connect the pipes to the lifting cylinder.

A= pressure pipe
B = cab locks
C = return pipe
Note: A M14 B
Use Teflon tape to install the nipples in the
pump housing. Note: Do not apply Teflon
tape to the first turn of the nipples. This will
prevent the system from being soiled with M12
Teflon tape.
5. Tilt the cab forwards.

C
6. Fit the compressor pipe.
7. If necessary, install the cable gutter.
6 K1 00 712
K1 01 502
8. Secure the attachment bolt (1).
5
2 1
K1 00 710
4-4 © 200346
9. Tighten the attachment bolt (4) to the

11. For filling and bleeding the system, see

chapter "Draining and filling".
K1 00 711
© 200346 4-5
4.3 REMOVAL AND INSTALLATION, CAB TILTING PUMP SEALS
Note:
- Use a repair kit to replace the seals.
- Disassembling any other parts of the tilting
pump than those described in this chapter is
not permitted. A defective cab tilting
mechanism is often the result of incorrect
disassembly and/or assembly of the cab
tilting pump.
- Clean the outside of the cab tilting pump.
- Work in a clean environment.
Removing cab tilting pump seals

1. Remove the cab tilting pump.
2. Loosen the 4 Torx screws used to attach the

reservoir to the pump housing. Collect the oil
in a container.
K100136
3. Remove the pump housing from the

reservoir and remove the gasket.
4. Remove the filter and the magnet from the

pump housing.
K100137
4-6 © 200346
5. Secure the pump housing in a vice according

to the adjacent figure and tap the pin out of
the holder and the lever axle.
K1 01 499
6. Remove the holder and the lever axle.

Remove the O-ring from the lever axle.
7. Clean the reservoir, the filter, the magnet

and the contact surfaces of the gasket.
Installing cab tilting pump seals 6

1. Fit a new O-ring to the lever axle.
K100139
© 200346 4-7
2. Fit the holder to the lever axle. Tap the pin

into its holder and the lever axle. Secure the
pin as shown in the adjacent figure.
3. Fit the filter and the magnet to the pump

housing.
K1 01 498
4. Fit the reservoir with a new gasket onto the

pump housing using the 4 Torx bolts.
5. Install the cab tilting pump.
K100137
4-8 © 200346
4.4 REMOVAL AND INSTALLATION, CAB TILTING PUMP TWO-WAY VALVE
Note:
- Use a repair kit to replace the two-way valve.
- Disassembling any other parts of the tilting
pump than those described in this chapter is
not permitted. A defective cab tilting
mechanism is often the result of incorrect
disassembly and/or assembly of the cab
tilting pump.
- Clean the outside of the cab tilting pump.
- Work in a clean environment.
Removing cab tilting pump two-way valve

1. Remove the cab tilting pump.
2. Tap the notched pin out of the two-way valve

and remove the steel ring. Remove the O-
ring from the steel ring.
K1 01 340
3. Secure the pump housing in a vice as shown

in the adjacent figure and carefully tap the
two-way valve with the sealing plug out of the
housing. Note: Mark the position of the two-
way valve in the pump housing so that the
new two-way valve can be mounted in the
right position.
K1 01 496
© 200346 4-9
4. Take the pump housing from the vice and

remove the inlet ball.
K1 01 497
5. Remove the O-ring and the Teflon ring from

the pump housing.
Installing cab tilting pump two-way valve
Note:
- When the two-way valve is installed, observe
the correct position of the openings in k100144
relation to the connections.
6 - After assembly of the two-way valve, the

pressure limiting valve must be checked/
adjusted. See "Inspection and adjustment".
1. Fit the new inlet ball into the pump housing.
2. Apply a little oil to the O-rings of the new two-

way valve only.
3. Fit the two-way valve and the sealing plug in

the housing. Note: Make sure the openings
in the two-way valve and the connections in
the pump housing are well positioned.
4. Fit the new O-ring and the Teflon ring in the

pump housing.
4-10 © 200346
5. Fit the new O-ring in the steel ring. Fit the

steel ring onto the two-way valve and tap the
new notched pin into the two-way valve.
K1 01 340
© 200346 4-11
4-12 © 200346
ΧΦ65/75/85 series Disassembly and assembly
5. DISASSEMBLY AND ASSEMBLY

5.1 DISASSEMBLY AND ASSEMBLY, LIFTING CYLINDER
A defective lifting cylinder is often caused by

leaking oil sealing rings or a damaged piston rod.
To be able to repair the lifting cylinder, the entire
piston rod must be removed and the oil seals
must be replaced. The cab tilting pump is
required to take out the piston rod.
Reconditioning of a lifting cylinder requires not
only the use of the reconditioning kit, but also the
reuse of a number of components.
Use a separate cab tilting pump to pump the
piston in and out.
Disassembling lifting cylinder

1. Remove the dust cap.
2. Take the dirt scraper out of the lifting

cylinder.
K100148
© 200346 5-1
Disassembly and assembly ΧΦ65/75/85 series
3. Connect the lifting cylinder to the pump and

pump the piston rod outward to approx. 10
mm from the end.
6
K100120
4. Tap the upper bearing of the piston rod 5 to

10 mm back. Make sure that the piston rod is
not damaged in the process.
k100149
5-2 © 200346
5. Remove the upper circlip from the cylinder

and pump the piston rod fully out.
K100150
6. Remove the circlip from the piston rod and

remove the piston from the rod.
6
K100151
7. Remove the stop ring and the upper bearing.
K100152
© 200346 5-3
8. Remove the non-return valve from the

cylinder using a 17-mm hexagonal socket.
Thoroughly clean all parts.
9. Check the piston rod and the upper part of

the cylinder for scratches and damage. If
necessary, replace the entire cylinder.
K1 01 344
5-4 © 200346
Assembling lifting cylinder
Note:
The components marked in the figure form part of
the reconditioning kit (13).
1. Fit the sealing ring (9) in the new dirt scraper

housing (11) and fit the "O"-ring (10) into the
outer groove, see situation A.
2. Fit the sealing ring (8) into the new brass

upper bearing (7) and fit the "O"-ring (6) into
the outer groove, see situation B.
3. Slide the dirt scraper housing (11) over the

piston rod. B C A
1
2
4. Slide the circlip (12) over the piston rod. 3
4
5. Slide the new brass upper bearing (B) over 5
the piston rod, as shown. 6
7
6. Slide the stop ring (5) over the piston rod, 8
ensuring that the tapered side fits into the 9
upper bearing. 10
11 6
7. Fit the circlip (4), possibly using an axle 13 12
spring clip pliers (outer circlip pliers), into the A
K1 01 661
piston rod groove.
8. Slide the existing piston (3) over the piston

rod until it touches the stop.
9. Fit the circlip (1) onto the piston rod, using an

axle spring clip pliers (outer circlip pliers).
10. Position the cylinder upright in a vice. Press

the piston rod into the cylinder. Tap the brass
upper bearing approx. 5 mm into the cylinder
(past the circlip groove) with a punch.
11. Fit the circlip (12) into the cylinder. Pull the
piston out fully to check whether the circlip is
properly seated in the groove. This also puts
the upper bearing in its final position.
12. Turn the cylinder upside down and press the

piston into the cylinder using the cab tilting
pump. Add another twenty pump strokes
when the piston has been fully pressed into
the cylinder to bleed the cylinder.
13. Press the piston out of the cylinder and

pressurise the cylinder. Inspect the latter for
leakage.
© 200346 5-5
14. Tap the dirt scraper housing (A) evenly into

the cylinder using a plastic or copper
hammer.
15. Fit the dust cover.
16. Attach the lifting cylinder underneath the cab

and check its operation.
5-6 © 200346
ΧΦ65/75/85 series Draining and filling
6. DRAINING AND FILLING

6.1 FILLING AND BLEEDING, TILTING MECHANISM
Note:
- Check whether the lifting components have
been fitted correctly and whether the
connected piping is secure enough.
- Do not add oil to the pump reservoir when
the cab is tilted. Add oil to the reservoir only
when the cab has been completely tilted
back.
- Check the cab tilting pump, the lifting
cylinder, pipes and connections for any
leakage.
Filling tilting mechanism

1. Clean the area surrounding the filler plug.
Remove the filler plug.
2. Put the pump plunger in bottom position by

moving the pump actuating rod fully down.
6
3. Top up the reservoir with the specified oil,
see specification manual "Fluids and
lubricants", to the top of the pump plunger.
Note:
The cab must be tilted completely back into
place.
Bleeding tilting mechanism

1. Place a tray beneath the pump to collect the
oil.
2. Start with approx. 30 full pump strokes while

leaving the cab tilting pump in the reverse
tilting position. If necessary, top up the
reservoir with oil.
3. Tilt the cab fully forward (cab tilting pump in

the tilting position). Continue pumping and
keep the system pressurised. Check all the
connections for leaks.
4. Tilt the cab back. If necessary, top up the

reservoir with oil.
Note:
If the lifting cylinder has been overhauled or
renewed, the cab must be tilted twice to
obtain full bleeding.
5. Fit the filler plug.
© 200346 6-1
Draining and filling ΧΦ65/75/85 series
Refilling tilting mechanism

1. Carefully loosen the filler plug 3 to 4 turns
and wait until the overpressure, if any, has
left the reservoir.
2. Remove the filler plug.
3. Turn the cab tilting pump into the tilting

position and start pumping until this is clearly
getting heavier.
4. Put the pump plunger in bottom position by

moving the pump actuating rod fully down.
5. Top up the reservoir with the specified oil,

see specification manual "Fluids and
lubricants", to the top of the pump plunger.
6. Fit the filler plug and set the cab tilting pump
into the reverse tilting position.
6-2 © 200346
1 SEATS
CONTENTS
7 Seats
Page Date

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200346
2.3 Serial/type plate of seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200346
2.4 System description, air-sprung seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200346
2.5 Overview drawing, high luxury model ISRI 6800 . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . 200346
2.6 Overview drawing, luxury model ISRI 6800. . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . 200346
2.7 Overview drawing, standard model ISRI 6800 . . . . . . . . . . . . . . . . . . . . . 2-10 . . . . 200346

3.1 Inspecting seat belt operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

4.1 Removal and installation, seat assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346
4.2 Removal and installation, seat slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200346
4.3 Removal and installation, seat squab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200346
4.4 Removal and installation, seat squab guide . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200346
4.5 Removal and installation, rubber dust boot . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200346
4.6 Removal and installation, cover panel on control side. . . . . . . . . . . . . . . . 4-5 . . . . . 200346
4.7 Removal and installation, side cover panel . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200346
4.8 Removal and installation, front cover panel. . . . . . . . . . . . . . . . . . . . . . . .
4.9 Removal and installation, seat belt guide panel . . . . . . . . . . . . . . . . . . . .
4-6 . . . . .
4-7 . . . . .
200346
200346 7
4.10 Removal and installation, backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . 200346
4.11 Removal and installation, arm rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . 200346
4.12 Removal and installation, seat belt mechanism. . . . . . . . . . . . . . . . . . . . . 4-10 . . . . 200346
4.13 Removal and installation, seat belt lock . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . 200346
4.14 Removal and installation, air reservoirs for pneumatic lumbar support . . . 4-12 . . . . 200346
4.15 Removal and installation, heating elements . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . 200346
4.16 Removal and installation, switch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . 200346
4.17 Removal and installation, height control valve . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . 200346
4.18 Removal and installation, height adjustment valve . . . . . . . . . . . . . . . . . . 4-15 . . . . 200346
4.19 Removal and installation, entry/exit aid handle . . . . . . . . . . . . . . . . . . . . . 4-16 . . . . 200346
4.20 Removal and installation, vertical damping adjuster . . . . . . . . . . . . . . . . . 4-17 . . . . 200346
4.21 Removal and installation, seat tilting handle . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . 200346
4.22 Removal and installation, height adjustment handle . . . . . . . . . . . . . . . . . 4-19 . . . . 200346
4.23 Removal and installation, fixed seat height adjustment handle . . . . . . . . . 4-20 . . . . 200346
4.24 Removal and installation, back rest adjuster . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . 200346
4.25 Removal and installation, operating valve for pneumatic lumbar support . 4-23 . . . . 200346
4.26 Removal and installation, air bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . 200346
4.27 Removal and installation, adjustment cylinder. . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . 200346
4.28 Removal and installation, control unit of the height control valve . . . . . . . 4-26 . . . . 200346
4.29 Removal and installation, vertical damper . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 . . . . 200346
4.30 Removal and installation, Bowden cable for fixed seat gas damper . . . . . 4-28 . . . . 200346
4.31 Removal and installation, fixed seat gas damper . . . . . . . . . . . . . . . . . . . 4-28 . . . . 200346
4.32 Removal and installation, seat squab cover . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . 200346
4.33 Removal and installation, back rest cover . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . 200346
© 200346 1
SEATS 1
2 © 200346
1 SEATS
- Replace the seat belt if the belt is worn or

damaged.
- If the seat belts have been highly stressed
during a collision, the entire mechanism
must be replaced, even if no damage can be
observed.
- Always check the seat attachments for any
fractures or ruptures after a collision.
- After a collision, always check whether the
seat attachment bolts have been subjected
to excessive stress. If in doubt, replace them.
- Do not use abrasive cleaning agents to clean
the seat belts; these may damage the seat
belt material.
© 200346 1-1
SEATS 1
1-2 © 200346
1 SEATS
2. GENERAL
2.1 GENERAL
- Seat repairs must be carried out by trained

technicians only.
- The illustrations in this manual usually
represent the left-hand seat or the left-hand
side. For the right-hand seat or right-hand
side, repairs are carried out in a similar way.
- After each repair, a functional test must be
carried out; in the case of pneumatic repairs,
also carry out an air-tightness test.
- Do not lean on the seat if the back rest has
been fully folded forwards.
- The routes of the air pipes and cables must
be restored and their connections must be
restored to the original positions.
- Also keep to the proper colour position when
installing the air pipes.
- Air pipes and cables must not be kinked.
- In the case of transport and storage, ensure
that the seat is placed on its longitudinal
slides. Air pipes must not be kinked in this 7
case.
© 200346 2-1
SEATS 1
2.2 OPERATION
Legend
A. Back rest adjustment handle
B. Switch for seat heating
C. Operating valve for lumbar support
D. Seat height adjustment control
E. Seat angle adjustment control
F. Vertical damping adjustment control
G. Operating valve for entry/exit aid
H. Seat position adjustment bracket
I. Seat squab adjustment handle
7 B
C
D
E
F
G
I H
K1 01 658
2-2 © 200346
1 SEATS
2.3 SERIAL/TYPE PLATE OF SEAT
A
K100483
The serial number (A) and the DAF part number
of the seat are listed on the type plate, located at
the front of the seat underneath the dust boot.
The DAF part number is also located on the label
at the side of the seat.
© 200346 2-3
SEATS 1
2.4 SYSTEM DESCRIPTION, AIR-SPRUNG SEAT
16 17
3
G
B
E
P
8 4 18
7 5
6
C E 13
14 27
12 26 28
1 IPS IPS IPS

19 9
10
7
11
A
D
Rd H 25
Gr
Bl
Br K100482
Legend
A. Valve for entry/exit aid
B. Control unit of the height control valve
C. Switch valve
D. Height control valve
E. Height control valve
F. Adjustment cylinder
G. Air bellows
H. Valve for pneumatic lumbar support
Rd Red
Gr Grey
Bl Black
Br Brown
2-4 © 200346
1 SEATS
Colours and functions of the pneumatic

system air pipes
Cab air pressure supply
black cab air pressure supply to
- quick-release air valve A1
- valve H25 for pneumatic lumbar support
Pressure profile when operating entry/exit
aid, top button
red from pressure reduction for quick-release
valve A2 to
- control valve D10
- height control valve E14
Pressurising/depressurising the air bellows
brown from height control valve E12 to
- air bellows G18
Operation of entry/exit aid, bottom button
borwn from air bellows G18 to
- pressure release valve A19
Pressurising the air bellows during use
grey: from height control valve E13 to
- cab
Colours and functions of the height
adjustment air pipes
Seat up
brown: from control valve D9 to 7
- switch valve C5
- switch valve C8
- adjustment cylinder F16
Seat down
grey: from control valve D11 to
- switch valve C6
- switch valve C7
- adjustment cylinder F17
Seat up/down
black: from switch valve C4 to
- locking cylinder B3
© 200346 2-5
SEATS 1
2.5 OVERVIEW DRAWING, HIGH LUXURY MODEL ISRI 6800
81
80
40-43
60-63 67-70 47-50

75 44
51
65
7 55
46
45
13
17
10
6,8 9 17
29
25 26 16 52
23 14
15
5,7 21
11,12
22
27 20
24 19
18
K1 01 654
2-6 © 200346
1 SEATS
Item Description Note

5-8 Seat guides
9 Rubber dust boot with fastening material not shown
10 Guide for seat squab adjustment
11-13 Side cover panel
14 Front cover panel
15 Control of pneumatic lumbar support LWS = 1 or 2 switch buttons, IPS = 3 switch
buttons
16 Height control valve
17 Back rest adjustment mechanism Y-section (if any), not shown
18 Control of entry/exit aid
20 Seat angle control knob
21 Seat height control knob
22 Vertical damper
23 Pneumatic spring
24 Control unit of the height control valve
25 Adjustment cylinder
26
27
Switch valve
Height control valve
7
28 Connections/air pipes not shown
29 Back rest control knob
40-43 Back rest
44 Seat belt cover
45 Seat belt lock without contact switch
46 3-point seat belt
47-50 Back rest cover
51 Air reservoirs for pneumatic lumbar support
52 Switch for seat heating
60-63 Seat squab
65 Seat squab adjuster
67-70 Seat squab cover
80-81 Arm rests
© 200346 2-7
SEATS 1
2.6 OVERVIEW DRAWING, LUXURY MODEL ISRI 6800
40
60 67 47
44
65
46
45
7 13
17
26
10
6,8 17
9
27 29
14
5,7 21
11
20
K100485
2-8 © 200346
1 SEATS

5-8 Seat guides
9 Rubber dust boot with fastening material not shown
10 Guide for seat squab adjustment
11-13 Side cover panels
14 Front cover panels
20 Seat angle control knob
21 Seat height control knob
26 Gas spring with mounting material
27 Adjuster cable assembly
40 Back rest
44 Seat belt cover
47 Back rest cover
60 Seat squab 7
65 Seat squab adjuster
67 Seat squab cover
© 200346 2-9
SEATS 1
2.7 OVERVIEW DRAWING, STANDARD MODEL ISRI 6800
40,41
47,48
44
81
80
46
7
45 15,16
13 17
6,8
17
29
14
5,7
11
K100486
2-10 © 200346
1 SEATS

5-8 Seat guides
11-13 Side cover panel
14 Front cover panel
15-16 Seat squab cover
40-41 Back rest
44 Seat belt cover
47-48 Back rest cover
80-81 Arm rests
© 200346 2-11
SEATS 1
2-12 © 200346
1 SEATS

3.1 INSPECTING SEAT BELT OPERATION
- Give a short pull on the seat belt to test the

locking mechanism. During this test, the belt
must lock. It must not be possible to pull the
belt out any further after locking.
- Check the seat belts for wear.
© 200346 3-1
SEATS 1
3-2 © 200346
1 SEATS

4.1 REMOVAL AND INSTALLATION, SEAT ASSEMBLY
Removing seat assembly

1. Remove the air pipe between the cab floor
and the seat, at the rear of the seat, pressing
the side of the quick-release coupling and
pulling the pipe from the coupling.
2. Detach the seat heating connector (if

installed) between the cab floor and the seat,
at the rear of the seat.
3. Slide the seat backwards and remove the

K100412
front screws (1).
4. Slide the seat forwards and remove the rear

screws (2).
Installing seat assembly

1. Place the seat on the ground plate. Make
sure that the air pipes do not get pinched off.
Slide the seat backwards and tighten the
front screws (1).
2. Slide the seat forwards and tighten the back 2
3.
screws (2).
Connect the air pipe.

7
4. Install the seat heater connector (if 1
applicable).
K100487
5. Tighten the seat to the specified torque, see
"Technical data".
© 200346 4-1
SEATS 1
4.2 REMOVAL AND INSTALLATION, SEAT SLIDE
Removing seat slide

1. Remove the entire seat.
2. Remove the 4 attachment screws (1).

1
3. Bend back the bent pin (2) on either side and
disassemble the bracket.
Installing seat slide

1. Install the bracket and bend the pin (2).
2. Fit the 4 attachment screws (1).
3. Install the entire seat.

2
K100488
4-2 © 200346
1 SEATS
4.3 REMOVAL AND INSTALLATION, SEAT SQUAB
Removing seat squab

1. Slide the seat squab in the frontmost position
(only for models with seat squab
adjustment).
2. Remove the electric wiring from models with

heated seats.
3. Push the control lever (1) up with a

screwdriver (insert the screwdriver between
frame -X- and the lever). 1
4. Pull the seat squab forwards and up. 3
Installing seat squab
1. Slide the seat squab approx. 10 mm into the 2
guides at the back.
2. When doing so, press the seat squab at the

front down into the guides.
3. Slide the seat squab in the frontmost guides X

until the lever (A) engages with a click.
4. After assembly, check whether the adjuster

engages in the locking cam (2) in all
openings of the runner (1). If necessary,
align the runner to the left or the right. A
7
K100489
© 200346 4-3
SEATS 1
4.4 REMOVAL AND INSTALLATION, SEAT SQUAB GUIDE
Removing seat squab guide

1. Remove the seat squab.
1
2. Remove the screw (1) from the guide.
3. Remove the guide (2). 2
Installing seat squab guide

1. Install the guide (2).
2. Tighten the screw (1).
3. Fit the seat squab.
K100490
4.5 REMOVAL AND INSTALLATION, RUBBER DUST BOOT
Removing rubber dust boot

7 2. Remove the seat squab.

3
2
3. Remove the side cover on control side and
the opposite side.
4. Release the attachment caps (1) and clamps

(2) and (3).
5. Remove the seat belt mechanism and pull

the rubber dust boot over it.
6. Pull the rubber dust boot over the controls

and remove it via the bottom. 1
Installing rubber dust boot
1. Fit the rubber dust boot. K100491
2. Fit the seat belt mechanism.
3. Fasten the rubber dust boot with the

attachment caps (1) and clamps (2) and (3).
4. Fit the side covers.
6. Install the entire seat.
4-4 © 200346
1 SEATS
4.6 REMOVAL AND INSTALLATION, COVER PANEL ON CONTROL SIDE
Removing the cover panel on control side

(including control valve for pneumatic lumbar
support and seat heating switch)
2
2. Remove back rest adjuster button (1).
3. Remove the screws (2), (3) and (4).

3
4. Disconnect the plug of the seat heating
operating switch (6) behind the back rest.
5. Remove the air pipes from the operating 1

valve for the pneumatic lumbar support (5). 6
5
Installing cover panel on control side
1. Install the plug of the seat heating operating 3
switch (6).
4 3
K1 01 655
2. Connect the air pipes for the operating valve

for the pneumatic lumbar support (5).
3. Fit the screws (2), (3) and (4).
4. Fit the back rest adjuster button.
5. Fit the seat squab. 7
© 200346 4-5
SEATS 1
4.7 REMOVAL AND INSTALLATION, SIDE COVER PANEL
Removing side cover panel

2
2. Remove the screws (2), (3) and (1).
Installing side cover panel

1. Fit the screws (1), (2) and (3).

1
2 2
3
K100493
4.8 REMOVAL AND INSTALLATION, FRONT COVER PANEL
Removing front cover panel

7 2. Remove the screws (1) and (2).
3. Remove the front cover panel.
Installing front cover panel

1. Fit the front cover panel.
2. Fit the screws (1) and (2).

3
1 2
K1 01 656
4-6 © 200346
1 SEATS
4.9 REMOVAL AND INSTALLATION, SEAT BELT GUIDE PANEL
Removing seat belt guide panel

1. Remove the cover panel on control side.
2. Remove the bolt (1) from the seat belt

attachment plate (2) and unscrew the screws
(3) in the cover.
4
3. Pull the seat belt (2) through the opening (4).
3
Installing seat belt guide panel
1. Guide the seat belt (2) through the opening
(4).
2. Secure the seat belt attachment plate (2)

with the specified torque.
2
1
K100495
© 200346 4-7
SEATS 1
4.10 REMOVAL AND INSTALLATION, BACKREST
Removing back rest

2. Unscrew the screws (1) from the cover (2) 1

and remove screw (3) from the mounting
plate.
3 2
3. Remove the seat belt from the back rest.
4. Remove the electric plug connector (5) (if

fitted).
5. Remove the attachment screws (6) from the

back rest.
6
6. Fold the back rest down.
8
7. Click the back rest out of the side rails of the 5
frame.
4
8. Remove the back rest from the frame. 7
System with pneumatically adjusted lumbar
support
1. Remove the seat.
7 2. Remove the seat squab.
3. Unscrew the screws (1) from the cover (2)

and remove screw (3) from the mounting
plate.
K100496
4. Remove screw (8) from the seat belt roll and

screw (7) from the seat belt mounting
bracket.
5. Remove the belt.
6. Remove the rubber air hoses (4) (connection

is underneath the seat belt roll holder) and
the electric plug connector (5) (if applicable).
7. Remove the attachment screws (6) from the

back rest.
8. Fold the back rest down.
9. Click the back rest out of the side rails of the

frame.
10. Remove the back rest from the frame.
4-8 © 200346
1 SEATS
Installing back rest

1. Click the folded back rest in the side rails of
the frame.
2. Fix the back rest with attachment bolts (6),

tightening the bolts to the specified torque.
3. Connect the air hoses (4) and the seat

heating connector (5) (if fitted).
4. Fit the screw (3) in the mounting plate,

together with the belt.
5. Fit the cover (2).
6. Fit screw (8) of the seat belt roll and screw

(7) of the seat belt mounting bracket.
8. Fit the seat.
4.11 REMOVAL AND INSTALLATION, ARM REST
Removing arm rest

1. Remove the black covers.
7
2. Unscrew and remove the screws (1) from the
arm rest.
Installing arm rest

1. Fit the screws and install the black covers.
K100498
© 200346 4-9
SEATS 1
4.12 REMOVAL AND INSTALLATION, SEAT BELT MECHANISM
Removing seat belt mechanism

1. Remove the side cover panel on control side
without disconnecting the air hoses of the
control valve for the pneumatic lumbar
support or the seat heating. 1
2. Remove the cover (1).
3. Remove the screw (2) from the mounting

3
plate (3).
4. Remove the screw (4) from the seat belt roll. 2

5. Remove the screw (5) from the lower seat
belt mount.
Installing seat belt mechanism

1. Install the seat belt mounts and tighten them
to the specified tightening torque, see
"Technical data".
2. Fit the seat belt roll and secure it with the

specified torque.
4
3. Fit the cover (1).
7 4. Install the side cover panel on control side.
K100499
4-10 © 200346
1 SEATS
4.13 REMOVAL AND INSTALLATION, SEAT BELT LOCK
Removing seat belt lock

1. Remove the side cover panel opposite the
control side.
2. Remove the bolt (1).

1
Installing seat belt lock
1. Install the lock mechanism and tighten the
bolt to the specified tightening torque. See
"Technical data".
2. Fit the side cover panel.
K100500
© 200346 4-11
SEATS 1
4.14 REMOVAL AND INSTALLATION, AIR RESERVOIRS FOR PNEUMATIC

LUMBAR SUPPORT
Removing air reservoirs for pneumatic

lumbar support
1. Carefully remove part of the back rest cover
and slide it more than halfway upwards.
2. Remove the four screws (6) (depending on

model).
3. Carefully remove the shaped foam at the

bottom of the frame.
4. Remove the pipes (1) (located underneath

the seat belt roll holder).
5. Remove the two clips (2) and remove the air 6

reservoir(s) (3). 3 2
5
6. Remove the side air reservoirs (5). 4
Installing air reservoirs for pneumatic lumbar
support
1. Install the air reservoirs (3) and (5) and
1
secure them with the clips (2).
7 2. Connect the pipes.
3. Install the shaped foam.
4. Fit the four screws (6).
5. Fit the cover.
K100501
4-12 © 200346
1 SEATS
4.15 REMOVAL AND INSTALLATION, HEATING ELEMENTS
Removing seat squab heating element

2. Remove the connector (3) from the electric

wiring.
3. Remove the seat squab cover.
4. Carefully remove the heating element (1) 1

from the shaped foam (use a knife, if 2
necessary).
Removing back rest heating element

1. Pull the back rest cover up as far as the white
loop for the padding thread, without
removing the back rest cover. 3
2. Carefully remove the heating element (2)
from the shaped foam (use a knife, if
necessary).
Installing seat squab heating element

1. Install a new heating element (1) and secure
it with double-sided adhesive tape.
2. Connect the connector (3) of the heating

element (1). 7
3. Fit the cover. K100502
Installing back rest heating element

1. Install a new heating element (2) and secure
it with double-sided adhesive tape.
2. Connect the connector (3) of the heating

element (2).
3. Fit the cover.
© 200346 4-13
SEATS 1
4.16 REMOVAL AND INSTALLATION, SWITCH VALVE
Removing switch valve

2. Put the seat squab in the highest tilting

position.
3. Release the rubber bellows at the front of the

seat frame. 1
2
4. Remove the screw (2) from the switch valve.
5. Disconnect the air pipes from the switch

valve (1).
Installing switch valve

1. Connect the air pipes to the switch valve.
K100503
2. Put the seat squab in the highest tilting
position.
3. Install the switch valve.
4. Fit the rubber dust boot.
7
4.17 REMOVAL AND INSTALLATION, HEIGHT CONTROL VALVE
Removing height control valve

2. Remove the screws (2).
3. Disconnect the air pipes from the height 2 1

control valve (1).
Installing height control valve

1. Connect the air pipes of the height control
valve (1).
2. Secure the control valve with the screws (2).
K100504
4-14 © 200346
1 SEATS
4.18 REMOVAL AND INSTALLATION, HEIGHT ADJUSTMENT VALVE
Removing height adjustment valve

2
2. Place the seat in the highest tilting position.
4. Disconnect the air pipes from the valve. 1
5. Remove the valve (2).
Installing height adjustment valve

1. Connect the air pipes to the valve (2).
2. Secure the valve (2) with the screws (1).
3. Fit the seat squab. K100505
© 200346 4-15
SEATS 1
4.19 REMOVAL AND INSTALLATION, ENTRY/EXIT AID HANDLE
Removing entry/exit aid handle

2. Cut the air pipes of the entry/exit aid control

handle according to size X (X = 130 mm).
X
3. Remove the side cover panel (without
disconnecting the air pipes from the valves 2
or the seat heating).
4. Slightly loosen the screw (2).
5. Remove the screws (3) from the entry/exit

aid handle and remove the handle along the 1 3
upper side.
K100506
Installing entry/exit aid handle
1. To install a new handle, it must be
reconnected to the cut section X (repair kit
includes handle and sections of pipe and
connection pieces).
2. Attach the air pipes of the handle (1) to the

cut air pipes. Use the same length as that
which was cut during removal.
7 3. Fit the handle (1) and secure it with the

screws (3).
4. Tighten the screw (2).
4-16 © 200346
1 SEATS
4.20 REMOVAL AND INSTALLATION, VERTICAL DAMPING ADJUSTER
Removing vertical damping adjuster

3
2. Remove the side cover panel (without
disconnecting the air pipes from the valves
or the seat heating).

2
4. Remove the shock absorber cable (remove
the lock ring (2) in the lowest position of the
system, and kink the cable from its holder (6) 1
when the system is in the highest position).
Installing vertical damping adjuster

1. Install the combined cable and mounting
plate assembly (3) and the control handle K100507
through the opening in the rubber bellows
into the frame.
2. Secure the handle (2) with the screws (1).
4. Install the adjustment cable before the seat
5.
cushion is fitted.
Adjust the cable before fitting the seat squab.

7
© 200346 4-17
SEATS 1
4.21 REMOVAL AND INSTALLATION, SEAT TILTING HANDLE
Removing seat tilting handle

2. Remove the springs (1) and (4).
3. Remove the plastic connection piece (2) by

1
sliding it towards the back rest.
4. Remove the control button (3) by lifting it and

pulling it out.
4
X
2
3
K100508
Installing seat tilting handle

1. Fit the seat tilting handle (3).
2. Fit the plastic connection piece (2). Note the 1

position of the small slot (X) when fitting the
new connection piece (2).
7 3. Fit the springs (1) and (4).

4
X
2
3
K100508
4-18 © 200346
1 SEATS
4.22 REMOVAL AND INSTALLATION, HEIGHT ADJUSTMENT HANDLE
Removing height adjustment handle

2. If necessary, remove the side cover panel Y

(without disconnecting the air pipes from the
valves or the seat heating).
3
3. Remove the screw (1) and the plastic
connection piece (2).
1
4. Remove the upper plate (3) by pushing it out

at position Y and pulling it from the frame.
4
5. Remove the handle (4). 5 X
6. Remove the plastic connection piece (5).
2
Installing height adjustment handle K100509
1. Fit the plastic connection piece (5). Note the

position of the small slot (X) when installing
the new connection piece (5).
2. Fit the handle (4).
3. Install the plate (3).
4. If the side cover panel was removed, reinstall

it.
7
© 200346 4-19
SEATS 1
4.23 REMOVAL AND INSTALLATION, FIXED SEAT HEIGHT ADJUSTMENT

HANDLE
Removing height adjustment handle

2. If necessary, remove the side cover panel 1

(without disconnecting the air pipes from the
valves or the seat heating).
Y
3. Remove the screw (1) and the plastic
connection piece (2). 3
4. Remove the upper plate (3) by pushing it out
2
at position Y and pulling it from the frame.
5. Remove the handle (4).

4
5
6. Remove the plastic connection piece (5).
X
Installing height adjustment handle K100512
1. Fit the plastic connection piece (5). Note the
position of the small slot (X) when installing
the new connection piece (5).
2. Fit the handle (4).
7 3. Install the plate (3).
4. If the side cover panel was removed, reinstall

it.
4-20 © 200346
1 SEATS
4.24 REMOVAL AND INSTALLATION, BACK REST ADJUSTER
Removing back rest adjuster without Y-

section
2. Remove the side cover panel without 4

disconnecting the pipes. 3
6 11
3. Fold the back rest forward until it stops.
5
4. Remove the screws (1) and (2) on control 8
side and on the opposite side.
10
5. Remove the lock rings (3) and (11).
1
6. Lift the spring (6) and pull the control plate (4) 9
from the axle, after which the wire (5) can be
removed. 7 2
7. Loosen the screw (7) of the back rest K100511
adjuster and remove it.
8. Push the tooth segment assembly from the

bracket (9) until the wire (10) can be
removed.
Installing back rest adjuster without Y-section

1. Fit the adjuster together with the wire (10) on 7
one side.
2. Fit the wire (10) into the tooth segment

assembly at the other side.
3. Insert the screw (7) into the back rest

adjuster.
4. Lift the spring (6) and fit the control plate (4)
onto the axle, after which the wire (5) can be
installed.
5. Connect the lock rings (3) and (11).
6. Insert the screws (1) and (2) on control side

and on the opposite side.
7. Fit the side cover panel and the seat squab.
© 200346 4-21
SEATS 1
Removing back rest adjuster with Y-section

2. Remove the back rest. 4

3
3. Remove the side cover panel without 6
disconnecting the pipes.
5
4. Remove the screws (1) and (2) on control 11
side and on the opposite side.
10
5. Remove the lock rings (3) and (11).
8
6. Lift the spring (6) and pull the control plate (4) 1
9
from the axle, after which the wire (5) can be
removed. 7 2
7. Loosen the screw (7) of the back rest K101366
adjuster and remove it.
8. Push the tooth segment assembly from the

bracket (9) until the wire (10) can be
removed.
Installing back rest adjuster with Y-section

1. Fit the adjuster together with the wire (10) on
one side.
7 2. Fit the wire (10) into the tooth segment

assembly at the other side.
3. Insert the screw (7) into the back rest

adjuster.
4. Lift the spring (6) and fit the control plate (4)
onto the axle, after which the wire (5) can be
installed.
5. Connect the lock rings (3) and (11).
6. Insert the screws (1) and (2) on control side

and on the opposite side.
7. Fit the side cover panel and the seat squab.
4-22 © 200346
1 SEATS
4.25 REMOVAL AND INSTALLATION, OPERATING VALVE FOR PNEUMATIC

LUMBAR SUPPORT
Removing operating valve for pneumatic

lumbar support
2. Remove the side cover panel on control side

without disconnecting the pipes. 2
3. Remove the air pipes from the operating
valve for the pneumatic lumbar support (1).
4. Use a screwdriver to lift the operating valve

for the pneumatic lumbar support (1) from
the cover (2) (the valve may be damaged 4
slightly in the process).
1
Installing operating valve for pneumatic 3
lumbar support
1. Fit the operating valve for the pneumatic K1 01 657
lumbar support. When fitting, position the
new valve in such a way that the top (3) can
be hooked in and then be pushed down into
the side cover.
2. Connect the air pipes for the operating valve

for the pneumatic lumbar support (1).
7
3. Install the side cover panel on control side.
© 200346 4-23
SEATS 1
4.26 REMOVAL AND INSTALLATION, AIR BELLOWS
Removing air bellows

4
3
1
3. Remove the clamping strip (1) (by cutting it).
4. Disconnect the air pipe (2) from the manifold

(3). 6 5
5. Unscrew the screws (4) and (5) to be able to
remove the air bellows including the air pipe.
Installing air bellows

1. Install the air bellows (6). In doing so, make
sure that the air bellows are not twisted. If
this is nevertheless the case, loosen screw 2
(4) a few turns and apply spring action to the
K100513
system under pressure; then tighten screw
(4) again while the air bellows are still under
pressure.
2. Tie the pipes together with a clamping strip.
7 4. Install the entire seat.
4-24 © 200346
1 SEATS
4.27 REMOVAL AND INSTALLATION, ADJUSTMENT CYLINDER
Removing adjustment cylinder

4
2. Lock the seat in its highest position.
8
3. Disconnect the air pipes (1) and (3) of the
adjustment cylinder.
12
4. Remove the retainer pin (4). 6
5
5. Remove the screw (5).
21
3
6. Push the metal plates that hold the cylinder
apart and remove the adjustment cylinder.
Installing adjustment cylinder

1. Push the metal plates that hold the cylinder
K100514
apart and insert the adjustment cylinder (2).
2. Install the retainer pin (4).
3. Connect the air pipes (1) and (3) to the

adjustment cylinder.
4. Tighten the screw (5) slightly during
5.
installation.
Release the lock and operate the height

7
adjustment button (upwards). Check
whether the cylinder (2) moves freely. If not,
loosen screw (5) slightly.
© 200346 4-25
SEATS 1
4.28 REMOVAL AND INSTALLATION, CONTROL UNIT OF THE HEIGHT CONTROL

VALVE
Removing control unit of height control valve

1. Remove the seat squab and remove the
rubber dust boot at the front. 4
2. Lock the system in the highest position.
3. Disconnect the air pipe (1) from the 8 10

11
cylinder (2).
9
4. Remove the lock ring (3) and pin (4). 5
5. Loosen the screw (5) slightly and push the 6
holder (6) of the control discs (7) a little apart. 2
This makes it possible to pull the control 12
discs from the adjustment cylinder (8). The
3
guide plate (9) must remain attached to the 7
1
pin (10). Push the ball (11) back onto the pin
(10) if it has come loose. K100515
Installing control unit of height control valve

1. Tighten the screw (5) slightly during
installation.
2. Operate the height adjuster (upwards) and

7 check whether the cylinder moves freely. If
not, loosen screw (5) slightly.
4-26 © 200346
1 SEATS
4.29 REMOVAL AND INSTALLATION, VERTICAL DAMPER
Removing vertical damper

2. Slide the entire seat forward.

6 5
3. Remove the locking ring (2) when the seat is
in its lowest position.
1
4. Remove the locking ring (1). 2
5. Lock the seat in its highest position.
7
6. Remove the rubber dust boot at the front and 4
remove the locking ring (3).
Installing vertical damper 3

1. Fit the damper and use the locking ring (3) to K100516
secure it at the bottom.
2. Release the lock.
3. Install the locking ring (1).
4. Place the seat in the frontmost and lowest

position and install the locking ring (2).
5. Before installing the seat squab, set the

damping cable (5) in such a way as to
7
achieve the stiffest damping when the
control handle is in the top position. To make
this adjustment, first release the lock nut (7).
Tighten lock nut (7) after completion of the
adjustment.
© 200346 4-27
SEATS 1
4.30 REMOVAL AND INSTALLATION, BOWDEN CABLE FOR FIXED SEAT GAS
DAMPER
Removing Bowden cable for fixed seat gas

damper
2. Remove the stops (1) and (2).
3. Remove the Bowden cable by taking it from 1

the attachment points.
Installing Bowden cable for fixed seat gas 2

damper
1. After fitting the new Bowden cable, check the
height adjustment. If necessary, adjust the
Bowden cable setting by turning the screws
for the Bowden cable away from or towards
one another.
2. Then tighten the Bowden cable using the K100517

check nut.
4.31 REMOVAL AND INSTALLATION, FIXED SEAT GAS DAMPER

7 Removing fixed seat gas damper
5
2. Place the seat in its lowest position.
3. Remove the stop (1) and Bowden cable (2)

(making sure not to operate the button).
1
3
4. Release nuts (3) and (4). 2
5. Pull the chair upwards, so that the gas spring 4
ejects from its holder.
Installing fixed seat gas damper

1. When installing a new gas spring, tighten the
check nut (5) (in the same position as the
previous gas spring). K100518
2. After fitting, check the height adjustment

and, if necessary, modify the Bowden cable
adjustment.
4-28 © 200346
1 SEATS
4.32 REMOVAL AND INSTALLATION, SEAT SQUAB COVER
At the positions marked with an X, the covers are

attached to the shaped foam with Velcro fastener.
Removing seat squab cover

A
2. Remove the clamps from the groove around
the bottom of the seat.
3. Remove the seat squab cover from the

groove around the bottom of the seat. 4
X
X 2
K100497
4. Carefully remove the cover little by little from

the shaped foam. At the same time, hold the
Velcro fastener in the shaped foam (pushing
it down) to prevent it from being torn loose.
Installing seat squab cover

1. Fit the seat squab cover in the groove around
the bottom of the seat; make sure that the
Velcro is in the right place.
2. Fix the seat squab cover with clamps in the

groove around the bottom of the seat.
K100519
© 200346 4-29
SEATS 1
4.33 REMOVAL AND INSTALLATION, BACK REST COVER
Removing back rest cover

1. Remove the seat belt guide panel.
2. Remove the cover by unhooking it from the

section at the bottom.
K100520
4-30 © 200346
1 SEATS
3. Carefully remove the cover little by little from

the shaped foam. At the same time, hold the
Velcro fastener in the shaped foam (pushing
it down) to prevent it from being torn loose.
Installing back rest cover

1. Fit the cover in such a way that the Velcro
fastener is in the correct position, and secure
the cover in the profile at the bottom.
K100521
K100522
© 200346 4-31
SEATS 1
4-32 © 200346
1 ACCESSORIES
CONTENTS
8 Accessories
Page Date


2.1 Adjusting roof spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

3.1 Removal and installation, roof spoiler (basic) . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346
3.2 Removal and installation, roof spoiler (aerodynamic) . . . . . . . . . . . . . . . . 3-2 . . . . . 200346
3.3 Removal and installation, fender assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200346
3.4 Removal and installation, roof spoiler extension pieces combined with
fenders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200346
3.5 Removal and installation, corner spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200346
3.6 Removal and installation, sun visor assembly . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200346
3.7 Removal and installation, spotlights complete with bracket. . . . . . . . . . . . 3-8 . . . . . 200346
3.8 Removal and installation, air horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . 200346
3.9 Removal and installation, rotating beacon. . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . 200346
3.10 Removal and installation, combi-light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200346
3.11 Removal and installation, 2nd bunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . 200346
© 200346 1
ACCESSORIES 1
2 © 200346
1 ACCESSORIES
General
mechanism. The pump is located on co-driver
underneath the cab.

© 200346 1-1
ACCESSORIES 1
1-2 © 200346
1 ACCESSORIES

2.1 ADJUSTING ROOF SPOILER
Note:
Correct adjustment of the roof spoiler is essential
to minimise fuel consumption.
1. Place the vehicle on a level and horizontal

surface. Make sure that in the case of a
1 /2 X
tractor/semi-trailer combination the tractor is
straight in front of the semi-trailer. P
X
2. Determine the centreline of the vehicle and
put a slat on the superstructure roof
protruding into the cab direction.
3. Put another slat (as a tangent) onto the outer

roof spoiler edge (P) pointing into the
direction of the superstructure.
4. Both slats should cross at half the distance

(∂ X) between the roof spoiler edge and the
start of the superstructure.
The roof spoiler height can be adjusted using
adjusting mechanism (B). For the roof spoiler
adjusting range see "Technical data".
K1 01 357
P
B
1
/2 X
8
P
X
K1 01 356
K1 01 355
© 200346 2-1
ACCESSORIES 1
2-2 © 200346
1 ACCESSORIES

3.1 REMOVAL AND INSTALLATION, ROOF SPOILER (BASIC)
Removing roof spoiler (basic)

1. Remove the four attachment nuts from the
cab roof attachment frame.
2. Take the roof spoiler from the cab roof.
Installing roof spoiler (basic)

1. Position the roof spoiler with attachment
frame onto the studs on the cab roof.
2. Fit the four attachment nuts of the

attachment frame.
3. Check the setting of the roof spoiler, see

chapter 'Inspection and adjustment".
© 200346 3-1
ACCESSORIES 1
3.2 REMOVAL AND INSTALLATION, ROOF SPOILER (AERODYNAMIC)
Removing roof spoiler (aerodynamic)

1. Remove the four attachment nuts from the
cab roof attachment frame.
2. Take the roof spoiler from the cab roof.
3. Remove the attachment bolts from the roof

spoiler side sections and remove the side
sections from the cab roof.
Installing roof spoiler (aerodynamic)

1. Fit the roof spoiler side sections on the cab
roof, using the attachment bolts.
2. Position the roof spoiler with attachment

frame onto the studs on the cab roof.
3. Fit the four attachment nuts of the

attachment frame.
4. Check the setting of the roof spoiler, see

chapter 'Inspection and adjustment".
3-2 © 200346
1 ACCESSORIES
3.3 REMOVAL AND INSTALLATION, FENDER ASSEMBLY
Note:
Take care not to damage the paint. Repair any
damaged paint using the right type of paint.
Removing fender assembly (cab without roof

spoiler)
1. Remove the attachment bolts and remove
the fender (A) from the cab.
Installing fender assembly (cab without roof

spoiler)
1. Fit the fender (A) using the attachment bolts.
K1 01 359
© 200346 3-3
ACCESSORIES 1
3.4 REMOVAL AND INSTALLATION, ROOF SPOILER EXTENSION PIECES

COMBINED WITH FENDERS
Note:
Take care not to damage the paint. Repair any
damaged paint using the right type of paint.
Removing roof spoiler extension pieces

combined with fenders
1. Remove the attachment bolts from the upper
fender (A) and remove the fender from the
roof spoiler.
2. Remove the attachment bolts from the A

middle fender (B) and remove the fender
from the roof spoiler.
3. Remove the attachment bolts from the lower

fender (C) and remove the fender from the
cab.
Installing roof spoiler extension pieces

B
combined with fenders
1. Fit the lower fender (C) to the cab, using the
attachment bolts.
2. Fit the middle fender (B) to the cab, using the

attachment bolts. C
3. Fit the upper fender (A) to the cab, using the
8
attachment bolts.
K1 01 361
3-4 © 200346
1 ACCESSORIES
Removing roof spoiler extension pieces

combined with fenders (cab with raised roof)
1. Remove the attachment bolts from the upper
fender (A) and remove the fender from the
roof spoiler.
2. Remove the attachment bolts from the lower

fender (B) and remove the fender from the A
cab.
Installing roof spoiler extension pieces

combined with fenders (cab with raised roof)
1. Fit the lower fender (B) to the cab, using the
attachment bolts.
B
2. Fit the upper fender (A) to the cab, using the
attachment bolts.
8
K1 01 360
© 200346 3-5
ACCESSORIES 1
3.5 REMOVAL AND INSTALLATION, CORNER SPOILER
Removing corner spoiler

1. Open the grille and remove the corner
piece (1).
2. Remove the attachment screws (2) and

remove the corner spoiler (3) from the corner
piece.
Installing corner piece 1

1. Fit the corner spoiler (3) to the corner
piece (1)
2
2. Fit the corner piece (1) and close the grille.
K1 01 415
3-6 © 200346
1 ACCESSORIES
3.6 REMOVAL AND INSTALLATION, SUN VISOR ASSEMBLY
Removing sun visor assembly, day/sleeper

cab
1. If fitted, remove the spotlights.

marker lights.

brackets and remove the sun visor complete
with brackets from the cab roof.
Installing sun visor assembly, day/sleeper

cab
1. To fit the sun visor stress-free, loosen the
attachment bolts fastening the plastic hood
to the brackets a few strokes.
2. Fit the sun visor complete with brackets to

the cab roof and fit the attachment bolts with
the plastic washers.
3. Tighten the attachment bolts fastening the

plastic hood to the brackets.
4. Fit the attachment bolts of the marker lights.
5. If present, fit the spotlights.
Removing sun visor assembly (cab with

raised roof)
1. If fitted, remove the spotlights.
8
brackets and remove the sun visor complete
with brackets from the cab.
Installing sun visor assembly (cab with raised

roof)
1. To fit the sun visor stress-free, loosen the
attachment bolts fastening the plastic hood
to the brackets a few strokes.
2. Fit the sun visor complete with brackets to

the cab and fit the attachment bolts with the
plastic washers.
3. Tighten the attachment bolts fastening the

plastic hood to the brackets.
4. If present, fit the spotlights.
© 200346 3-7
ACCESSORIES 1
3.7 REMOVAL AND INSTALLATION, SPOTLIGHTS COMPLETE WITH BRACKET
Removing spotlights complete with bracket

1. Detach the connector behind the spotlight
bracket.

bracket and remove the bracket complete
with spotlights from the cab roof.
Installing spotlights complete with bracket

1. Fit the bracket with spotlights to the cab and
fit the attachment bolts with the plastic
washers.
3. Check that the cable duct through the cab

roof is water-tight. If necessary, seal the
passage again.
3-8 © 200346
1 ACCESSORIES
3.8 REMOVAL AND INSTALLATION, AIR HORN
Removing air horn on roof spoiler

horn and remove the air horn from the roof
spoiler.
Note:
If, after removal of the attachment bolts, the air
horn cannot be removed from the spoiler, the air
horn has been retrofitted as an accessory. In this
case, detach the air pipe on the inside of the
spoiler.
Installing air horn on roof spoiler

1. Fit the air horn to the roof spoiler using
attachment bolts.
Removing air horn on roof

horn and remove the air horn from the roof.
Note:
If, after removal of the attachment bolts, the air
horn cannot be removed from the roof, the air
horn has been retrofitted as an accessory. In this
case, remove the headlining to disconnect the air
pipe.
Installing air horn on roof

1. Fit the air horn to the roof using attachment
bolts.
8
© 200346 3-9
ACCESSORIES 1
3.9 REMOVAL AND INSTALLATION, ROTATING BEACON
Removing rotating beacon

1. Remove the glass (1) of the rotating beacon
by pressing the locking clip at the bottom of
the glass and turning the glass
counterclockwise out of the lamp socket (2).
1
2. Loosen the connector.
3. Remove the three attachment bolts (3) and

remove the lamp socket from the roof.
Installing rotating beacon 2

1. Fit the lamp socket (2) to the roof and tighten
the attachment bolts (3). 3
3. Turn the glass (1) of the rotating beacon

clockwise onto the lamp socket (2). Continue
turning the glass until the locking clip 'clicks'
into the lock.
K1 01 414
3-10 © 200346
1 ACCESSORIES
3.10 REMOVAL AND INSTALLATION, COMBI-LIGHT
Removing combi-light
1. Remove the combi-light connector.
2. Remove the attachment screw (1) and take

the combi-light out of the bumper.
Installing combi-light
1. Fit the combi-light with attachment screw (1)
into the bumper.
2. Fit the combi-light connector. 1
K1 01 358
© 200346 3-11
ACCESSORIES 1
3.11 REMOVAL AND INSTALLATION, 2nd BUNK
Removing 2nd bunk, sleeper cab

1. Remove the mattress and the bunk shelf
from the bunk frame.
2. Remove the attachment bolts of the clamp

belt from the cab roof.
3. Remove the attachment bolts of the bunk

hinges from the cab rear wall and remove the
bunk.
Installing 2nd bunk, sleeper cab

1. Install the bunk and tighten the attachment
bolts of the bunk hinges to the cab rear wall.
2. Fit the attachment bracket of the clamp belt

in the cab roof using the attachment bolts.
3. Fit the bunk shelf and the mattress in the

bunk frame.
Removing 2nd bunk (cab with raised roof)

1. Remove the mattress and the undermattress
from the bunk frame.
2. Remove the attachment bolts of the clamp

belt from the cab roof.
3. Remove the sealing plugs and the

8 attachment bolts of the bunk supports from
the cab rear wall and remove the bunk from
the cab.
Installing 2nd bunk (cab with raised roof)

1. Place the bunk in the cab and fit the
attachment bolts and sealing plugs of the
bunk supports in the cab rear wall.
2. Fit the attachment bracket of the clamp belt

in the cab roof using the attachment bolts.
3. Fit the mattress and the undermattress in the

bunk frame.
3-12 © 200346
1 PREWAX TREATMENT
CONTENTS
10 Prewax treatmen t
Page Date

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346
2.2 Notes on re-treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200346
2.3 Treatment of the cab front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200346
2.4 Treatment of the doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200346
2.5 Treatment of the cab bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200346
10
© 200346 1
PREWAX TREATMENT 1
10
2 © 200346
1 PREWAX TREATMENT


precautions. The internal
mechanism of the lifting cylinder
may have been damaged to such an
extent that the cylinder is no longer
locked by the internal stop collar. In
that case there is a danger of the cab
no longer being held back and falling
forward to the ground.

Ensure that there is sufficient ventilation during

spraying and ML treatment.
10
© 200346 1-1
PREWAX TREATMENT 1
10
1-2 © 200346
1 PREWAX TREATMENT
2. GENERAL
2.1 GENERAL
Introduction
PREWAX is a transparent, odourless, non-toxic
mixture of various types of wax and corrosion-
inhibiting chemicals which is vapour-sprayed into
all corrosion-sensitive areas.
It penetrates all seams and adheres to all
surfaces where it combines electrochemically
with the metal.
PREWAX does not drip, so there is no fouling of
the cab and floor. It can be sprayed without
difficulty into all cavities if the DAF equipment is
used. The equipment does not need to be
cleaned.
10
© 200346 2-1
PREWAX TREATMENT 1
2.2 NOTES ON RE-TREATMENT
- Thoroughly stir the PREWAX before use.

- For optimal treatment, the temperature of
both the cab and the PREWAX must be
20|C.
- All holes required for re-treatment are
already present in the cab.
- Treat cavities with a minimum pressure of 6
bar.
- After treatment of seams and hinges, reduce
the air pressure to 3 bar (ideal pressure).
- Make sure to re-install the ML plugs after
treatment.
- Store the flexible spray pipe by hanging it in
vertical position.
- Ensure that the area is properly ventilated
during treatment.
- Use the ultraviolet light to check whether the
PREWAX has been applied properly.
10
2-2 © 200346
1 PREWAX TREATMENT
2.3 TREATMENT OF THE CAB FRONT
K100002
Treat the front of the cab through the existing
openings.
10
© 200346 2-3
PREWAX TREATMENT 1
2.4 TREATMENT OF THE DOORS
K100005
Remove the door upholstery and treat the door as
indicated in the illustration.
10
2-4 © 200346
1 PREWAX TREATMENT
2.5 TREATMENT OF THE CAB BOTTOM
K1 01 060
Treat the stepwell box girders through the
existing openings.
Note:
Cover the lifting cylinder piston rod.
10
© 200346 2-5
PREWAX TREATMENT 1
10
2-6 © 200346

Group 1 - Cab

Uploaded by

Group 1 - Cab

Uploaded by

1 STRUCTURE

2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

3. CAB TILTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

4. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346

5. ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346

1. INTERNAL AND EXTERNAL CAB COMPONENTS

Main dimensions and weights

Permissible cab weights, day and sleeper cab

Permissible cab weights, high sleeper:

Cab side members H

Recommended dimension between measuring points on the same side.

Recommended dimension between measuring points on opposite sides.

Recommended dimension between measuring points on opposite sides.

Setting times for windscreen adhesive 0

A relative humidity of less than 50% delays

Products applied for bonded windscreens

High sleeper cab

Products for gluing high sleeper cab

Windscreen wiper motor

Products for gluing anti-whistle weatherstrip

Setting time 12 hours

Adjustment dimensions of door lock rods

Adjustment dimensions of mirrors without

Size Normal (mm) Normal adjustment angle

Adjustment dimensions of mirrors with dead

Size Normal (mm) Normal adjustment angle

Dimensions of compulsory field of vision

Mirror size 1 size 2 size 3 size 4 size 5

1.2 TIGHTENING TORQUES

The tightening torques specified in this section

Windscreen wiper motor

(1) Use Loctite 243 to secure

Engine brake switch

(1) Always replace the attachment bolt and nut

Adjusting the coil spring elements:

Rear (size B) 272 ≥ 5 mm

The sizes given above are from the top centre to

Spring distance of the coil spring elements:

Adjusting the air suspension elements:

Rear (size B) 272 ≥ 5 mm

The sizes given above are from the top centre to

Spring distance of the air suspension

The cab height can be adjusted at the front.

2.2 TIGHTENING TORQUES

The tightening torques specified in this section

A M8 attachment bolt for tilt assist mechanism/

Rear cab suspension

A M14 attachment bolt for top of spring

3. CAB TILTING MECHANISM

Cab tilting pump

3.2 TIGHTENING TORQUES

3.3 FILLING CAPACITIES

Cab tilting pump

Roof spoiler setting range [mm]

1. CAB HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346

3. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

SYMPTOM: CAB TEMPERATURE TOO HIGH 1

SYMPTOM: INSUFFICIENT LATERAL DAMPING

SYMPTOM: AIR LEAKAGE

2.2 FAULT-FINDING TABLE, CAB TILTING MECHANISM

SYMPTOM: TILTING CYLINDER FAILS TO RESPOND

1 Possible cause Remedy

SYMPTOM: PUMP ROD REBOUNDS

SYMPTOM: PUMP ONLY FUNCTIONS IN THE LAST PART OF THE STROKE

SYMPTOM: PUMP OPERATES WITH DIFFICULTY, CYLINDER DOES NOT RESPOND

SYMPTOM: PUMP FAILS TO GENERATE PRESSURE

SYMPTOM: CAB LOCK CANNOT BE OPENED

SYMPTOM: SEAT FAILS TO RISE 1

SYMPTOM: SEAT MOVES UP AND DOWN INDEPENDENTLY (LOADED)

SYMPTOM: SEAT HEIGHT CANNOT BE ADJUSTED FOR HEIGHT

SYMPTOM: SEAT MOVES TO TOP-MOST POSITION AND IS NOT SPRUNG

SYMPTOM: BLOWS OFF CONTINUOUSLY AND IS PERMANENTLY IN TOP POSITION

1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346

3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346