DAF 95 XF, XE Technical Data

1 CONTENTS
95XF series
TECHNICAL DATA
0
DIAGNOSTICS
1
INTERNAL CAB COMPONENTS
2
CAB HEATING
3
EXTERNAL CAB COMPONENTS
4
CAB SUSPENSION
5
CAB TILTING GEAR
6
SEATS
7
ACCESSORIES
8
9
PREWAX TREATMENT
10
ᓻ 200345
1 TECHNICAL DATA
95XF series Contents
CONTENTS
Page Date
0
1. INTERNAL AND EXTERNAL CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200345
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200345
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 . . . 200345
2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200345
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200345
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . 200345
3. CAB TILTING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200345
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200345
3.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200345
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200345
4. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200345
4.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200345
5. ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200345
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200345
ᓻ 200345 1
TECHNICAL DATA 1
Contents 95XF series
2 ᓻ 200345
1 TECHNICAL DATA
95XF series Internal and external cab components
1. INTERNAL AND EXTERNAL CAB COMPONENTS

1.1 GENERAL
0
1 2
K100442
Legend
1. Comfort Cab (type designation XL)
2. Space Cab (type designation XH)
3. Super Space Cab (type designation XC)
ᓻ 200345 1-1
TECHNICAL DATA 1
Internal and external cab components 95XF series
Main dimensions
Tilting angle 58.5_
0 Cab width
Cab length
2490 mm
2250 mm
Cab height (unloaded, tyre size 315/80R22.5):
XL 3225 mm
XH 3525 mm
XC 3850 mm
With open roof hatch height + 60 mm
Doors
Material galvanised sheet steel
Opening angle of doors 80_
Steering column
Tilting angle 15_
Height adjustment 85 mm
1-2 ᓻ 200345
1 TECHNICAL DATA
Recommended cab dimensions
K100825
Recommended dimension between measuring Recommended dimension between

points on the same cab side. measuring points on opposite cab sides.
F - F’ 1472 mm G-G 2260 mm
F’ - H 1509 mm G-F 2351 mm
G-K 1700 mm G-K 2801 mm
K-H 1018 mm F-H 2681 mm
F’ - G 725 mm F-F 2210 mm
A-B 790 mm
A’ - N 1935 mm
B’ - P 2096 mm
ᓻ 200345 1-3
TECHNICAL DATA 1
K100391
Recommended dimensions at the cab front

I-I 2230 mm
J-J 2275 mm
1-4 ᓻ 200345
1 TECHNICAL DATA
K100392
L-L 1025 mm
R-R 1025 mm
L-R 2239 mm
ᓻ 200345 1-5
TECHNICAL DATA 1
K100393
Recommended dimensions on cab floor

L-M 2061 mm
S-T 1554 mm
1-6 ᓻ 200345
1 TECHNICAL DATA
K100826
O-O 2350 mm
ᓻ 200345 1-7
TECHNICAL DATA 1
Glues and other application compounds for

synthetic/rubber/polyester components
0 Application compounds for rubber and synthetic components

Product name Properties Application DAF number
Dow Working time within 15 min. Silicone mastic for sealing the 0693628
Corning 752 floor parts (connector and
Maximum drying time 24 steering column feed--through)
hours Minimum bead thickness 4
mm
Loctite 401 Caution: drying time within a Superfast adhesive for gluing 1246863
few seconds fixed door window rubber to
window pillar
Curing time 12 hours
Glues and other application compounds for gluing the Super Space Cab roof
Sikaflex Working time within 15 min. Glue (drip channel) for gluing 1286578
252 white the polyester roof
Curing time 2 days (48 hours)
Sikaflex Working time within 15 min. Glue (cab front) for gluing the 1286577
260 black polyester roof
Curing time 2 days (48 hours)
Sika primer Minimum drying time 15 min. Primer for polyester/synthetic 1240547
SP 209N components
Maximum drying time 24
hours
Sika cleaner Minimum drying time 5 min. Cleaning agent for 1240548
SC 205 polyester/synthetic
components
Sika Remover Glue remover for removing 1241019
SR 208 glue that has not yet cured
Scotch-Brite Abrasive for 1387921
Very Fine sanding/roughening the
(red) polyester/synthetic
components to be glued
1-8 ᓻ 200345
1 TECHNICAL DATA
Glues and other application compounds for gluing the Super Space Cab plastic sun
0
visor/plastic roof window
Sikaflex Working time within 15 min. Glue/sealant for gluing/sealing 1286577
260 black the plastic sun visor/plastic
Curing time 2 days (48 hours) roof window
Sika primer Minimum drying time 15 min. Primer for polyester/synthetic 1240547
SP 209N components
Maximum drying time 24
hours
Sika cleaner Minimum drying time 5 min. Cleaning agent for 1240548
SC 205 polyester/synthetic
components
Sika remover Glue remover for removing 1241019
SR 208 glue that has not yet cured
Scotch-Brite Abrasive for 1387921
Very Fine sanding/roughening the
(red) polyester/synthetic
components to be glued
ᓻ 200345 1-9
TECHNICAL DATA 1
Adjustment dimensions of door locking

mechanism rods
0 Note:
Dimensions in mm, measured from ball joint
centre--to--centre or from ball joint centre to
extreme end of the rod.
554
599
637
90
79
K1 01 458
1-10 ᓻ 200345
1 TECHNICAL DATA
Adjustment dimensions of exterior mirrors

without dead angle exterior mirror
Model without integrated bracket 0
D E
C
A
B
B A
A
K1 01 524
Size Normal (mm) Normal adjustment angle

A(1) 966 32_
B(1) 1293 29_
C 20_
D(2) 1410
E 1450
(1) Relative to the cab floor

(2) Main mirror
ᓻ 200345 1-11
TECHNICAL DATA 1
Model with integrated bracket
D E
A
C
B
C A
B
K1 01 525

A 387 16_
B 147 66_
C 370 76_
D(1) 1387
E 1406
(1) Main mirror
1-12 ᓻ 200345
1 TECHNICAL DATA
Adjustment dimensions of exterior mirrors

with dead angle exterior mirror
Model with integrated bracket 0
E F
A
D
C B
D
C B A
K1 01 526

A 387 16_
B 84 56_
C 255 76_
D 640 76_
E(1) 1387
F 1406
(1) Main mirror
ᓻ 200345 1-13
TECHNICAL DATA 1
Dimensions of compulsory field of vision
0
D1
A
A2
D
A A3 C3
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 on co--driver’s 30 m 3.5 m 0.75 m 4m
side [C]
Main exterior mirror on driver’s side [D] 10 m 2.5 m
Note:
The field of vision dimensions of the dead angle
exterior mirror are not shown in the illustration
and the table because use of this mirror is not
required by law.
1-14 ᓻ 200345
1 TECHNICAL DATA
Headlights
Height adjustment - 1.0 %
Windscreen wiper
0
motor
Motor speed 1 35 rpm
Motor speed 2 50 rpm
Heater fan series resistor

- R1 4.2 ᐔ 10%
- R2 1.4 ᐔ 10%
- R3 2.2 ᐔ 10%
Fan setting:
- 1 R1+R2+R3
- 2 R2+R3
- 3 R3
- 4 no resistor
Heater control
Colour of control cables:
- Heater valve LHD red
RHD blue
- Defroster valve LHD green
RHD yellow
- Foot valve LHD black
RHD green
Doors
Adjustment dimensions:
- gap size (from front post, except for
corner piece) 8 ᐔ 2 mm
- maximum wedge shape of gap 2 mm
- transition between door-cab:
- inwards relative to front post 0 -1 mm
- outwards relative to rear post 0 -1 mm
ᓻ 200345 1-15
TECHNICAL DATA 1
1.2 TIGHTENING TORQUES
0 The tightening torques stated in this section are

different from the standard tightening torques
included in the overview of standard tightening
torques. Any other threaded connections that
are not specified must therefore be tightened to
the tightening torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed, unless stated otherwise.
Windscreen wiper unit

Motor shaft nut 38 Nm
Windscreen wiper arm nut 18 Nm
Windscreen wiper arm bracket lock nut M20 18 Nm
Threaded holes in bulkhead
windscreen wiper arm bracket silicone sealant
Clutch pedal
Sealant for end of clutch pedal spindle silicone sealant
Recessed locking bolt according to standard(1)
Steering column
Universal joint attachment bolts 54 Nm(2)
Steering wheel attachment nut 65 Nm
Door
Door limiter attachment nut M6 10 Nm
Hinge attachment bolts 30 Nm
Lock plate attachment bolts 18 Nm(1)
Striker plate (cab) 23 Nm
Window crank attachment screw according to standard(1)
Grille
Grille--side hinge attachment bolts 15 Nm
Threaded holes in bulkhead
Hinge on cab side silicone sealant
Exterior mirrors
Pavement mirror adjusting nut 7.0 - 8.1 Nm
Model with integrated arm:
attachment nut M8 for lower pivoting point of
D-shaped arm:
- driver’s side 22 Nm
- co--driver’s side 27 Nm
1-16 ᓻ 200345
1 TECHNICAL DATA
Front Underrun Protection leaf--sprung

model (without towing device)
Attachment bolt A
Attachment bolt B
170 ᐔ 15 Nm(1)
170 ᐔ 15 Nm(1)
0
(with towing device)
Attachment bolt A 170 ᐔ 15 Nm(1)
Attachment bolt B 260 Nm(1)
(1) Secure with Loctite 243

(2) Always replace the attachment bolt and nut
K100822
ᓻ 200345 1-17
TECHNICAL DATA 1
1-18 ᓻ 200345
1 TECHNICAL DATA
95XF series Cab suspension
2. CAB SUSPENSION
2.1 GENERAL
0
The F249 cab is mounted to the chassis at four
points with adjustable coil spring or air
suspension elements. These have integral
shock absorbers.
Adjustment dimensions of cab with coil
spring/air suspension elements
Size A ᐔ 5 mm 227.7 mm A
Size B ᐔ 5 mm 272.5 mm
Size A: distance between top of front

cross member and bottom of
stabiliser
Size B: distance from top of suspension
bracket to centre of cab
K100348
lock/suspension bolt
Note:
Measurements for unloaded cab and normal
system pressure
The coil spring elements can be adjusted in 4
steps of 3 mm.
Spring distance of coil spring and air
suspension elements:
Front approx. 80 mm (+40/-40)
Rear approx. 64 mm (+32/-32)
K100349
ᓻ 200345 2-1
TECHNICAL DATA 1
Cab suspension 95XF series
0 The tightening torques stated in this section are

2-2 ᓻ 200345
1 TECHNICAL DATA
Cab suspension
0
C B J
K
D
H
A
G
E
F
K100797
K100796
Position Description Tightening torque

A Rear bracket attachment bolt
M16 x 110 260 ᐔ 20 Nm + 90_ angular displacement
B Rear horizontal shock absorber
attachment bolt M14 x 65 170 ᐔ 15 Nm
C Rear horizontal shock absorber
attachment bolt M14 x 110 170 ᐔ 15 Nm
D Rear shock absorber attachment
bolt M14 x 65 170 ᐔ 15 Nm
E Self--locking nut M14 for front and
rear spring element 50 Nm
F Front right--hand side bracket
fastening bolt M16 x 50 260 ᐔ 20 Nm
G Front right--hand side bracket
H Front right--hand side bracket
J Vibration damper locating bolt
M18 x 145 360 ᐔ 30 Nm(1)
K Front left--hand side bracket
(1) Secure with Loctite 243
ᓻ 200345 2-3
TECHNICAL DATA 1
2-4 ᓻ 200345
1 TECHNICAL DATA
95XF series Cab tilting gear
3. CAB TILTING GEAR

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
Level check/filler plug pressure--relief valve 2.5 bar
The tightening torques stated in this section are

Lifting cylinder
Lifting cylinder cab support attachment bolts 260 Nm
Chassis support attachment bolt 60 Nm
Non--return valve seat 40 - 45 Nm
3.3 FILLING CAPACITIES
Cab tilting pump

Capacity of reservoir 625 cm3
ᓻ 200345 3-1
TECHNICAL DATA 1
Cab tilting gear 95XF series
3-2 ᓻ 200345
1 TECHNICAL DATA
95XF series Seats
4. SEATS
0
The tightening torques stated in this section are
Seats
Seat attachment bolts M8 20 - 25 Nm
Attachment of seat belt mechanism 7/16”
UNF-2B 30 - 40 Nm
ᓻ 200345 4-1
TECHNICAL DATA 1
Seats 95XF series
4-2 ᓻ 200345
1 TECHNICAL DATA
95XF series Accessories
5. ACCESSORIES
5.1 GENERAL
0
The roof spoiler height of the ’aerodynamic’ roof P
spoiler can be adjusted with the adjusting
mechanism (B).
B
Roof spoiler setting range [mm]
aerodynamic
Comfort Cab (XL) 630 - 810
Space Cab (XH) 370 - 515
Super Space Cab (XC) N/A K1 01 355
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.
ᓻ 200345 5-1
TECHNICAL DATA 1
Accessories 95XF series
5-2 ᓻ 200345
1 DIAGNOSTICS
CONTENTS
Page Date
1. CAB HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0209
1.1 Cab heating fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0209
2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0209
2.1 Fault-finding table, cab suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0209
1
2.2 Fault-finding table, cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0209
3. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
3.1 Fault-finding table, Isringhausen 6800 series . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
ᓻ 0209 1
DIAGNOSTICS 1
2 ᓻ 0209
1 DIAGNOSTICS
95XF series Cab heating
1. CAB HEATING
1.1 CAB HEATING FAULT-FINDING TABLE
COMPLAINT: CAB TEMPERATURE TOO HIGH

Possible cause Remedy 1
Heater valve cannot be fully closed. Check the setting of the heater valve.
ᓻ 0209 1-1
DIAGNOSTICS 1
Cab heating 95XF series
1-2 ᓻ 0209
1 DIAGNOSTICS
2. CAB SUSPENSION
2.1 FAULT-FINDING TABLE, CAB SUSPENSION
Air-sprung cab
COMPLAINT: SUSPENSION TOUCHES BUMP STOP 1

Possible cause Remedy
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.
COMPLAINT: INSUFFICIENT LATERAL DAMPING

Worn or damaged horizontal dampers at the Replace both dampers.
rear of the cab.
Worn or damaged silentblocks in front cab Replace both silentblocks.
suspension.
COMPLAINT: 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.
ᓻ 0209 2-1
DIAGNOSTICS 1
2.2 FAULT-FINDING TABLE, CAB TILTING MECHANISM
COMPLAINT: TILTING CYLINDER FAILS TO RESPOND

1 Damaged or broken pipe. Replace pipe or connection.

Pump reservoir empty. Top up reservoir and check for leaks.
Worn or damaged cylinder lubricating ring. Replace the cylinder or fit a reconditioning
set.
COMPLAINT: PUMP ROD REBOUNDS

Return stroke leakage. Replace the tilting pump.
COMPLAINT: 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.
COMPLAINT: 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 through 180°. Refit the
notched pin in the two-way valve.
2-2 ᓻ 0209
1 DIAGNOSTICS
COMPLAINT: PUMP FAILS TO GENERATE PRESSURE

Reservoir level too low. Top up the reservoir.
1
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 Fit a reconditioning kit.
valve.
Pressure release valve incorrectly set. Check the pressure release valve (using a
pressure gauge only) and adjust, if
necessary.
COMPLAINT: CAB LOCK CANNOT BE OPENED

Damaged or broken pipe. Replace pipe or connection.
Jammed piston in locking mechanism. Repair or replace the locking mechanism.
COMPLAINT: 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.
ᓻ 0209 2-3
DIAGNOSTICS 1
2-4 ᓻ 0209
1 DIAGNOSTICS
95XF series Seats
3. SEATS
3.1 FAULT-FINDING TABLE, ISRINGHAUSEN 6800 SERIES
COMPLAINT: SEAT FAILS TO RISE

Possible cause Remedy 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.
COMPLAINT: SEAT MOVES UP AND DOWN INDEPENDENTLY (UNLOADED)

Not a functioning fault, but excessive
resistance in the system itself.
COMPLAINT: 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 Loosen cylinder attachment screws and
the original position. tighten slightly (2 Nm).
ᓻ 0209 3-1
DIAGNOSTICS 1
Seats 95XF series
COMPLAINT: SEAT HEIGHT CANNOT BE ADJUSTED

Adjustment cylinder does not move. During upward operation of the height control
valve, check whether the pipe (16) blows off
1 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).
COMPLAINT: SEAT MOVES TO TOP-MOST POSITION AND IS NOT SPRUNG

Air connections not installed according to Correct the incorrect connection(s).
diagram.
COMPLAINT: BLOWS OFF CONTINUOUSLY AND IS PERMANENTLY IN TOP POSITION

Air connections not installed according to Correct the incorrect connection(s).
diagram.
COMPLAINT: SEAT FUNCTIONS BUT CANNOT MOVE DOWN

Kinks in air pipe. Check the air pipes for kinks.
3-2 ᓻ 0209
1 INTERNAL CAB COMPONENTS
CONTENTS
Page Date
1. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0209
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.1 Overview drawing, interior cab components . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.2 Overview drawing, steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0209
2.3 System description, steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0209
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Inspection, steering column setting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
......
......
0209
0209
2
3.2 Inspection, fastening of universal joint to steering box input shaft . . . . . . . . 3-1 ...... 0209
3.3 Adjustment, roller sun blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0209
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0209
4.1 Removal and installation, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0209
4.2 Removal and installation, instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0209
4.3 Removal and installation, radio panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0209
4.4 Removal and installation, lower central console storage compartment . . . . 4-3 ...... 0209
4.5 Removal and installation, upper central console storage compartment . . . 4-4 ...... 0209
4.6 Removal and installation, extendable table . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0209
4.7 Removal and installation, central console control panel . . . . . . . . . . . . . . . . 4-5 ...... 0209
4.8 Removal and installation, dashboard on co-driver’s side . . . . . . . . . . . . . . . . 4-6 ...... 0209
4.9 Removal and installation, pneumatic switch/pneumatic valve for
steering column setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . . 0209
4.10 Removal and installation, steering column panels . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . . 0209
4.11 Removal and installation, steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0209
4.12 Removal and installation, steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0209
4.13 Removal and installation, ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 . . . . . 0209
4.14 Removal and installation, floor plate on co-driver’s side . . . . . . . . . . . . . . . . 4-16 . . . . . 0209
4.15 Removal and installation, accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . . 0209
4.16 Removal and installation, brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0209
4.17 Removal and installation, clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0209
4.18 Removal and installation, engine brake switch . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0209
4.19 Removal and installation, parking brake switch/brake light switch . . . . . . . . 4-21 . . . . . 0209
4.20 Removal and installation, door panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 . . . . . 0209
4.21 Removal and installation, door locking mechanism . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0209
4.22 Removal and installation, manually operated window mechanism . . . . . . . . 4-27 . . . . . 0209
4.23 Removal and installation, electrically operated window mechanism . . . . . . 4-28 . . . . . 0209
4.24 Removal and installation, interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . . 0209
4.25 Removal and installation of roof console in Space Cab and Comfort Cab
to install accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . . 0209
4.26 Removal and installation of roof console components in Super Space Cab
to install accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 . . . . . 0209
ᓻ 0209 1
INTERNAL CAB COMPONENTS 1
2 ᓻ 0209
95XF series Safety instructions
1. SAFETY INSTRUCTIONS
You can stop the cab tilting forward
at any time by turning the tap 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 2
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.
ᓻ 0209 1-1
Safety instructions 95XF series
1-2 ᓻ 0209
95XF series General
2. GENERAL
2.1 OVERVIEW DRAWING, INTERIOR CAB COMPONENTS
2
2
4
5
6
8
K100476
Centre console
Legend
1. Rubber mat
2. Upper storage compartment
3. Lower panel
4. Extendable drawer
5. Control panel
6. Ashtray
7. Lower storage compartment
8. Parking brake panel
9. Parking brake valve frame
ᓻ 0209 2-1
General 95XF series
1
6
2 5
10
19
3 17
1
16 18
4
15
9 10
13 11
14
7
12
K100444
Side console on driver’s/co-driver’s side

Legend
1. Window panel 12. Lower panel on driver’s door side
2. Window vent 13. Lower panel central console side on
3. Instrument cover driver’s side
4. Dashboard on driver’s side 14. Instrument panel
5. Dashboard on co-driver’s side 15. Radio panel
6. Lower door post panel on co-driver’s side 16. Lower panel central console side on
7. Lower door post panel on driver’s side co-driver’s side
8. Defroster vent panel 17. Lower panel of central fuse box
9. Grommet for door ventilation 18. Central fuse box cover
10. Side vent 19. Lower panel co-driver’s door side
11. Lower panel of central console
2-2 ᓻ 0209
95XF series General
1 2
3
K100443
Ventilation/heating system air ducts

Legend
1. Front air duct on co-driver’s side
2. Rear air duct on co-driver’s side
3. Air duct for vents
4. Rear air duct on driver’s side
5. Front air duct on driver’s side
ᓻ 0209 2-3
General 95XF series
2 3
K100445
Dashboard attachment
Legend
1. Central fuse box attachment frame
2. Right-hand side instrument panel
attachment frame
3. Left-hand side instrument panel attachment
frame
4. Extendable table guide rail
5. Central console reinforcement profile
6. Central console attachment frame
7. Central console control panel attachment
frame
2-4 ᓻ 0209
95XF series General
2.2 OVERVIEW DRAWING, STEERING COLUMN
A B
A
2
G
C
F
C
E
H
D
K1 00 917
Legend
A. Steering column cover panels, top
B. Steering column switches
C. Attachment of steering column cover
panels, bottom
D. Steering column cover panels, bottom
E. Panel clamp
F. Steering shaft grommet
G. Steering column
ᓻ 0209 2-5
General 95XF series
2.3 SYSTEM DESCRIPTION, STEERING COLUMN
The height and the tilt angle of the steering

column can be adjusted manually. An 85mm A
difference in height can be achieved between
the lowest and highest positions by pulling the
steering wheel upwards. There is a 15_ angle
between the two extreme tilting positions.
B
A spring-loaded clamping mechanism fixes the
2 steering column in position. An air cylinder
located behind the steering column serves to
B
release the steering column pneumatically.
Once 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.
Such gradual bleeding will take place when the 1
switch is unloaded. 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
K100381
2-6 ᓻ 0209
95XF series Inspection and adjustment
3. INSPECTION AND ADJUSTMENT

3.1 INSPECTION, 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
3.
bottom of the switch.
Check whether the operating valve is bled
2
after the switch has been operated. Press
the convex side of the switch and wait a few
seconds until the adjustment mechanism is D000339
blocked again.
4. If this is not the case, check that no air pipe
is trapped. If not, replace the valve (switch).
3.2 INSPECTION, FASTENING OF UNIVERSAL JOINT TO STEERING BOX

INPUT SHAFT
Inspection, fastening of universal joint to

steering box input shaft
1. Check the universal joint for noticeable play.
If noticeable play is detected, the affected
part must be replaced.
2. Check whether there is any noticeable play
between the spline connection of the
universal joint and the steering box input
shaft. If noticeable play is detected, the
splines on the universal joint and those on
the input shaft need to be checked for wear.
If there is some wear, 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”.
K1 01 530
ᓻ 0209 3-1
Inspection and adjustment 95XF series
7
3.3 ADJUSTMENT, ROLLER SUN BLIND
Note:
There are two different roller sun blinds for the
vehicles of the 95XF series. Both models can be
distinguished, amongst other things, by the lip.
K1 01 443 K1 01 444
Model I Model II
Adjusting roller sun blind, model I

1. Remove the side cover with the operating 2
lever by pressing the locking pins on either 1
side of the sun blind and pulling out the
cover. Simultaneously press the operating
lever.
2. Pull out the spring rod (1) and let it loose,
enabling the roll-up mechanism to fully
expand.
K100816
3-2 ᓻ 0209
3. Tension the spring of the roll-up mechanism

by giving it three full turns (2) and then push
the spring rod inwards (without letting the
spring rod loose), to interlock the roll-up 2
mechanism.
2
K100817
K100818
4. Fit the side cover with the control lever.

Simultaneously press the operating lever.
5. Check that the roll-up mechanism is
working properly. The spring tension of the
roll-up mechanism may be increased or
reduced by turning the spring rod further
forward or backward.
ᓻ 0209 3-3
7
Adjusting roller sun blind, model II

Notes:
- The spring tension of the roll-up mechanism
must be adjusted on the other side than the
side where the operating lever is located.
- The attachment screws (4) of the side
cover may either be cross head screws or
torx screws.
2 1. Loosen the socket head screw (1) until the

guide bracket (2) with end stop (3) can be
1
taken out of the side cover.
Note:
Make sure that the side cover is pressed
against the roller sun blind when removing
the attachment screws. If the side cover is
taken too far from the roller sun blind, the
4
internal spring of the roll-up mechanism will
fully expand.
2. Remove the attachment screws (4) from
3
the side cover (if these are cross head
screws, remove them e.g. with a bent
screw driver). 2
K1 01 452
3. Take the side cover so far from the roller

sun blind that the side cover is able to turn.
Adjust the spring tension of the roll-up
mechanism.
4. Press the side cover fully against the roller
sun blind and fit the attachment screws (4).
5. Fit the guide bracket (2) with end stop (3) in
the side cover. Tighten the socket head
screw (1). Press the end stop (3) in the side
cover.
6. Check that the roll-up mechanism is
working properly. K1 01 453
3-4 ᓻ 0209
95XF 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
straight between the switch and the panel at
the side of the finger-sized depression (A),
until it touches the inside of the panel.
2. Remove the switch from its locked position
by carefully moving the feeler gauge in the 2
direction of the arrow (B).
3. Carefully remove the switch from the panel.
A
In doing so, ensure that the connector lock
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
ᓻ 0209 4-1
Removal and installation 95XF series
4.2 REMOVAL AND INSTALLATION, INSTRUMENT PANEL
Removing instrument panel

1. Remove the cover above the instrument
panel.
2
K100427
2. Remove the attachment bolts at the top of

the instrument panel.
K100428
3. Remove the two outer switches at the

bottom of the instrument panel.
4. Remove the attachment bolts beneath the
switches, after which you can pull the panel
forward. If the panel is to be removed, mark
the electrical and pneumatic connections
first.
Installing instrument panel
1. Connect up all the electrical and pneumatic
connections of the instrument panel.
2. Fit the panel. Be careful not to jam any
wires between the panel and the frame.
K100429
3. Re-fit the switches.

4. Fit the cover above the instrument panel.
4-2 ᓻ 0209
4.3 REMOVAL AND INSTALLATION, RADIO PANEL
Removing radio panel

1. Remove the attachment screws.
2. Slide the radio panel out of the instrument
panel.
3. If necessary, mark the location of the
connectors and remove them from the
4.
switches.
Remove the panel.
2
Installing radio panel
1. Fit the connectors.
2. Slide the radio panel behind the instrument
panel.
3. Fit the attachment screws. K100430
4.4 REMOVAL AND INSTALLATION, LOWER CENTRAL CONSOLE STORAGE

COMPARTMENT
Removing lower central console storage

compartment
1. Remove the rubber inlay and the
attachment screws from the lower storage
compartment.
2. Remove the electrical wiring harness from
the cigarette lighter and the accessories
port, after which you may remove the
storage compartment.
Installing lower central console storage
compartment K100332
1. Fit the lower storage compartment. Make
sure that the electrical wiring is underneath
the storage compartment.
2. Tighten the attachment screws and put the
rubber inlay in the storage compartment.
ᓻ 0209 4-3
4.5 REMOVAL AND INSTALLATION, UPPER CENTRAL CONSOLE STORAGE

COMPARTMENT
Removing upper central console storage

compartment
1. Remove the rubber inlay and the
attachment screws from the upper storage
compartment, after which the latter can be
removed.
2 Installing upper central console storage

compartment
1. Fit the upper storage compartment and
fasten it.
2. Put the rubber inlay in the storage
compartment.
K100337
4.6 REMOVAL AND INSTALLATION, EXTENDABLE TABLE
Removing the extendable table

1. Remove the upper central console storage
compartment.
2. Remove the extendable table by loosening
the attachment bolts on the back and front
(beneath the table) from the sliding rail.
Installing the extendable table
1. Fit the extendable table.
2. Fit the upper central console storage
compartment.
K100338
4-4 ᓻ 0209
4.7 REMOVAL AND INSTALLATION, CENTRAL CONSOLE CONTROL PANEL
Removing central console control panel

1. Remove the lower central console storage
compartment.
compartment.
3. Remove the extendable table.
4. Remove the ashtray. 2
5. Remove the attachment screws from the
central console control panel and take out
the panel. Mark the position of the electrical
connections.
Installing central console control panel
1. Fit the electrical connections of the central
console control panel and install the panel
on the central console.
2. Replace the ashtray.
4. Fit the lower central console storage
compartment.
5. Fit the upper central console storage K100339
compartment.
ᓻ 0209 4-5
4.8 REMOVAL AND INSTALLATION, DASHBOARD ON CO-DRIVER’S SIDE
Removing dashboard on co-driver’s side

1. Remove the floor mat.
2. Remove the lower door post panel.
3. Remove the floor pan on co-driver’s side.

4. Remove the panel clamps (using forked
2 tools). Remove the lower panel.
K100333
5. Remove the attachment screws and take off

the intermediate panel.
compartment.
7. Remove the lower central console storage
compartment.
K100334
8. Remove the vents along the windscreen.

9. Remove the attachment screws and take
the lower panel from the central console.
10. Remove the ashtray.
11. Remove the attachment screws and take
the side panel from the central console.
12. Remove the upper central console storage K100335
compartment.
13. Remove the extendable table.
14. Remove the central console control panel.
4-6 ᓻ 0209
15. Remove the attachment screws on top

(window edge) of the central cabinet panel.
K100341
2
central part of the central console.
K100473
17. Open the flap of the central cabinet and

remove the attachment screws on the side.
K100342
ᓻ 0209 4-7
18. Remove the attachment screw at the

bottom of the central cabinet panel which
secures the door air duct.
K100343
19. Remove the attachment screw which

connects the air vent supply pipe to the
panel.
K100345
20. Remove the attachment bolts on the bottom

(door post) of the panel.
21. Remove the central cabinet panel.
K100344
4-8 ᓻ 0209

the front air duct.
the rear air duct.
2
K100346
Installing dashboard panel on co-driver’s

side
1. Fit the air ducts.
2. Fit the central cabinet panel and secure the
air ducts. Make sure that the connections
between the air ducts are tight.
3. Install the door air duct. Make sure that the
rubber ring fits tightly.
4. Fit the vent duct for the windscreen.
5. Fit the side panel of the central console.
7. Fit the upper central console storage
compartment.
8. Fit the central console control panel. K100343
9. Fit the door post panel.

10. Install the lower panels and the floor pan.
11. Fit the lower panels of the central console.
12. Install the ashtray.
13. Connect the wiring of the lower storage
compartment.
14. Fit the lower storage compartment.
ᓻ 0209 4-9
4.9 REMOVAL AND INSTALLATION, PNEUMATIC SWITCH/PNEUMATIC VALVE

FOR STEERING COLUMN SETTING
Removing the pneumatic switch/pneumatic

valve for steering column setting
1. Remove the steering column panels.
2. Remove the bracket with the steering

column switch/valve, disconnect the air
2
pipes and push the switch/valve from the
bracket.
Installing the pneumatic switch/pneumatic
valve for steering column setting
1. Fit the air pipes to the switch/valve.
2. Press the switch/valve into the bracket and
fit the bracket to the steering column.
3. Install the steering column panels.
K100434
4-10 ᓻ 0209
4.10 REMOVAL AND INSTALLATION, STEERING COLUMN PANELS
Removing steering column panels

2. Using the steering column setting, move the
steering wheel to its highest possible
position.
3. Remove the two covers under the steering

wheel. The right-hand side of the upper
cover (1) (windscreen wiper side) must be 2
released by lifting and sliding it across the 1
left handle (direction indicator).
4. Remove the lower panels to the left and
right of the steering column cover (4).
5. Remove the steering column cover (4) by
disconnecting the attachment screws (2)
and the panel clamps (3) on the back.
Installing steering column panels
1. Re-place the cover around the steering
column and make sure that the steering
column setting is working properly after
doing so.
2. Remove the panels to the left and right of 2
the steering column cover.
3. Fit the two covers beneath the steering
wheel. Make sure that the rubber dust 3
covers on the handles are properly in place.
2
4. Place the floor mat.
4
K1 01 490
ᓻ 0209 4-11
4.11 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 4.
batteries.
Remove the steering wheel.
5. Remove the multi-function switches and the
ignition switch.
6. Remove the bracket holding the height
setting switch.
7. Disconnect the air pipes from the control
valve and plug the supply pipe.
8. Loosen one of the universal joints of the
steering shaft (which one depends on the
operation to be performed; either the
S7 00 166
universal joint beneath the steering wheel or
the universal joint on the steering box).
Before loosening, mark the position of the
universal joint versus the steering shaft.
9. Remove the attachment bolts at the bottom

of the steering column.
10. Remove the steering column.
K100799
4-12 ᓻ 0209
Installing steering column

1. Fit the universal joint on the splines of the
steering shaft or steering box. Line up the
groove (A) in the clutch with mark (B) on the
steering shaft or steering box.
Check that the universal joint is
correctly in place on the steering
shaft or steering box so that the
attachment bolt can be put in the
notch (C).
A B 2
2. Only fit a new attachment bolt with nut to
the universal joint. Tighten the bolt to the
specified tightening torque, see “Technical C
data”. K1 01 353
3. Connect the air pipes to the control valve.
4. Fit the bracket holding the height setting

switch.
5. Fit the ignition lock and multi-function
switches.
6. Install the steering column panels.
7. Fit the steering wheel.
K100434
ᓻ 0209 4-13
4.12 REMOVAL AND INSTALLATION, STEERING WHEEL
Note:
The special tools required to remove the
steering wheel cannot be obtained from DAF.
These tools should be manufactured by yourself
according to the drawing.
S7 00 065
Removing steering wheel

1. Place the steering gear in the central
position using the markings on the steering
box.
S7 00 166
4-14 ᓻ 0209
2. Remove the cover plate (1) from the

steering wheel (2).
1
3. Remove the steering wheel nut (3).
4. Fit the special tool, steering wheel puller 2
(A), to the steering wheel using its two outer
bolts. Turn the central bolt of the steering
wheel puller until the steering wheel is
released. 3
Installing steering wheel
1. Check whether the steering gear is still in
A
2
the central position using the markings on B
the steering box or the steering gear.
2. Fit the steering wheel (2) on the steering
shaft (4) so that the markings on the
steering wheel and the steering shaft (see
the arrows B) “align”.
B
3. Fit the attachment nut (3). Tighten the nut to
the specified tightening torque, see
“Technical data”
4
4. Fit the cover plate (1).
K1 01 144
4.13 REMOVAL AND INSTALLATION, IGNITION LOCK
Removing ignition lock A

1. Remove the caps (A) from the steering
column below the steering wheel.
2. Disconnect the connectors (behind the
dashboard). A
3. Drill off the head of the security bolt, use a

bit with the same diameter as the hole
where the head falls and remove the
ignition lock.
Installing ignition lock
1. Install the ignition lock.
2. Tighten the security bolts with such a torque
that the heads break off.
3. Fit the covers (A) around the steering K1 01 154
column.
ᓻ 0209 4-15
4.14 REMOVAL AND INSTALLATION, FLOOR PLATE ON CO-DRIVER’S SIDE
Removing floor plate on co-driver’s side

2. Remove the small attachment screw from

the foot board and take the latter out.
K100436
3. Remove the panel clamps (using a forked

tool) on the leg side of the floor pan.
K100333

the floor pan.
Installing the floor pan
1. Fit the floor pan.
2. Fit the foot board and the floor mat.
K100435
4-16 ᓻ 0209
4.15 REMOVAL AND INSTALLATION, ACCELERATOR PEDAL
Removing accelerator pedal

1. If applicable, remove the throttle cable from
the accelerator pedal.
3. Remove the dashboard panel from above
the accelerator pedal.
4. Disconnect the accelerator pedal connector,
if applicable.
2
5. Remove the attachment bolts (1).
6. Remove the accelerator pedal from the cab
floor.
Installing accelerator pedal
1. Check the gasket. Replace the gasket, if
damaged.
2. Fit the accelerator pedal with gasket on the
cab floor.
3. Insert the attachment bolts (1). Make sure
that the gasket is positioned just below the
pedal.
4. If present, fit the connector. 1
5. Fit the dashboard panel above the
accelerator pedal.
6. Place the floor mat.
7. If present, install the throttle cable to the
accelerator pedal.
K1 01 448
ᓻ 0209 4-17
4.16 REMOVAL AND INSTALLATION, BRAKE PEDAL
Removing brake pedal

1. Fully depress the brake pedal and remove 2
the circlip from the hinge pin (1).
2. Remove the hinge pin (1) with a punch in
the direction indicated.
3. Remove the brake pedal (2) and fittings.
2 Installing brake pedal
1. Fit the brake pedal and fittings.
1
2. Fit the hinge pin.

3. Fully depress the brake pedal and fit the
circlip to the hinge pin (1).
K1 01 528
4.17 REMOVAL AND INSTALLATION, CLUTCH PEDAL
Removing clutch pedal

1. Remove the dashboard panels to the left
and right of the steering column.
2. Remove the steering column panel.
3. Remove the spring from the clutch pedal.

4. Remove the attachment bolt that controls
the clutch cylinder.
K1 00 945
4-18 ᓻ 0209
5. Loosen the recessed locking bolt (1) on the

outside of the vehicle and push the clutch
pedal spindle to the left.
6. Remove the clutch pedal from the inside.
Installing clutch pedal
1. Put the clutch pedal in place.
2. Apply locking compound to the recessed 1
locking bolt (1), see “Technical data”.
3. Push the spindle to the right and tighten the
2
2
recessed locking bolt. Put silicone sealant
on the end of the clutch pedal spindle (2).
4. Fit the attachment bolt that controls the
clutch cylinder (take care with the ring).
5. Install the clutch pedal spring.
6. Fit the dashboard panels to the left and right
K1 01 065
of the steering column.
7. Fit the steering column panel.
8. Fit the storage compartment on the engine
tunnel.
ᓻ 0209 4-19
4.18 REMOVAL AND INSTALLATION, ENGINE BRAKE SWITCH
Removing engine brake switch

1. Remove the dashboard panel (1) above the
mounting plate (2) with engine brake
switch (3). 1
2. Remove the protection cover (4) from the
grab handle and the foot board (5).
4
2 3. Disconnect the mounting plate (2) with the
engine brake switch (3). 2
4. Loosen the connector. 3

5. Remove the lock nut from the engine brake
switch (3) and remove the engine brake
switch from the mounting plate (2).
Installing engine brake switch
1. Fit the engine brake switch (3) with lock nut
to the mounting plate (2).
3. Fit the mounting plate (2) with the engine 5
brake switch (3). Do not fit the central
attachment screw as yet.
K1 01 446
4. Fit the protection cover (4) from the grab
handle and the foot board (5).
5. Fit the dashboard panel (1) above the
mounting plate (2) with engine brake
switch (3).
4-20 ᓻ 0209
4.19 REMOVAL AND INSTALLATION, PARKING BRAKE SWITCH/BRAKE LIGHT

SWITCH
Removing parking brake switch

1. Position the parking brake in the parking
position.
2. Remove the radio panel.
3. Remove the heater pipe in front of the
parking brake switch.
2
4. Remove the plugs (1) of the parking brake
switch (2).
5. Remove the parking brake switch (2) from
the holder (5). 3
Installing parking brake switch
1. Fit the parking brake switch (2) in the 4
holder (5).
2. Fit the plugs (1).
3. Fit the heater pipe and the radio panel.
Removing brake light switch
2. Remove the heater pipe in front of the
parking brake switch.
5 2 1
3. Remove the plugs (3) of the parking brake K1 01 483
switch (4).
4. Remove the parking brake switch (4) from
the holder (5).
Installing the brake light switch
1. Fit the parking brake switch (4) in the
holder (5).
2. Fit the plugs (3).
3. Fit the heater pipe and the radio panel.
ᓻ 0209 4-21
4.20 REMOVAL AND INSTALLATION, DOOR PANEL
Removing door panel

1. If a manual window mechanism is fitted, 2
remove the cover (1) using a sharp 1
screwdriver.
2. If a manual window mechanism is fitted,
remove the attachment screw (2) and
remove the window crank.
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.
K100370
4. Remove the control panel for operating the

mirror and windows by lifting it carefully
from the panel with a small screwdriver.
Mark the connectors and disconnect them.
K100373
4-22 ᓻ 0209
5. 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.
2
K100371

panel.
K100374
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.
8. Remove the panel.
K100372
ᓻ 0209 4-23
Installing door panel

1. Fit the panel by pushing the spring clips into
the clamping sleeves. Make sure that the
upper edge of the panel fits tightly and that
the lock button and wiring of the control
panel fall through the openings.
2. Fit the control panel for operating the
mirror/windows.
2
3. Push the door knob on to the mechanism.
4. Slide the alignment plate for the door lock
into the panel.
5. Fit the attachment screws and secure the
panel.
6. If a manual window mechanism is fitted, fit
the window crank with the attachment
screw. Apply locking compound to the
attachment screw, see “Technical Data”.
Press the sealing cap in the window crank.
4-24 ᓻ 0209
4.21 REMOVAL AND INSTALLATION, DOOR LOCKING MECHANISM
Removing door locking mechanism

1. Remove the door panel.
2. Remove the foil (A) from the inside of the 6

door. 7
5
3. Remove the attachment screws (1), if
applicable. Disconnect the central door
locking by unhooking it from the control rod.
4 2
4. Remove the attachment bolt (2) and remove
the window guide from the door.
5. Remove the attachment bolts (3) of the lock
plate (4) and remove the lock plate.
6. Remove the attachment bolts (5 and 6) from
the unlocking handle. 3
7. Remove the door handle.
8. Remove the door lock (7) completely with
control rods through the opening on the
inside of the door. 2 1 A K1 01 455
Installing door locking mechanism

1. Check the length of the control rods and
adjust them, if necessary. See “Technical
data”.
2. Fit the door lock completely with control
rods through the opening on the inside of
the door.
3. Fit the door handle.
4. Fit the unlocking handle.
5. Fit the lock plate and tighten the attachment
bolts to the specified tightening torque,
see“Technical data”.
ᓻ 0209 4-25
6. Fit the window guide by first fitting the

fastening lip (1) of the window guide in the
recess (2) in the door. Now fit the 2
attachment bolt (3), but do not tighten it yet. 1
Slide up the window guide as far as
possible and tighten the attachment bolt (3).
7. If necessary, fit the locking mechanism of
the central door locking system.
2
Note:
The control rod of the central door locking
must be positioned behind the control rod of
the unlocking handle.
8. Fit new foil on the inside of the door.
9. Fit the door panel.
K1 01 504
4-26 ᓻ 0209
4.22 REMOVAL AND INSTALLATION, MANUALLY OPERATED WINDOW

MECHANISM
Removing manually operated window

mechanism
2. Remove the foil (A).
2
3. Lower the glass, remove the attachment
bolts (1) and raise the glass.
4. Remove the caps (5) and attachment bolts
(2), (3) and (4).
5. Remove the window mechanism out of the
door through the opening.
Installing manually operated window
mechanism
1. Fit the window mechanism in the door and
fit the attachment bolts (2), (3), (4) and the
caps (5).
3
2. Lower the glass and fit it to the window
mechanism using attachment bolts (1).
2
3. Raise the glass.
Close the glass almost completely. 4
Check whether the top edge of the glass is 2
parallel with the window frame. 5
Loosen the attachment bolts (1), if A
necessary.
K1 01 512
Adjust the glass to the correct position and
re-tighten the attachment bolts.
4. Fit the new foil (A).
ᓻ 0209 4-27
4.23 REMOVAL AND INSTALLATION, ELECTRICALLY OPERATED WINDOW

MECHANISM
Removing electrically operated window

mechanism
2. Remove the foil (A).
2
bolts (1) and raise the glass.
4. Detach the electric motor connector.
5. Remove the caps (5), attachment bolts (2)
and (4) and attachment nuts (3).
6. Remove the window mechanism out of the
door through the opening.
Installing electrically operated window
mechanism
1. Fit the window mechanism in the door and
fit the attachment bolts (2) and (4), the 2
attachment nuts (3) and the caps (5).
2. Connect the electric motor connector up. 3
3. Lower the glass and fit it to the window 4

mechanism using attachment bolts (1). 2
4. Operate the window switch and close the 5
A
glass almost completely.
Check whether the top edge of the glass is K1 01 513
parallel with the window frame.
Loosen the attachment bolts (1), if
necessary.
Adjust the glass to the correct position and
re-tighten the attachment bolts.
5. Fit the new foil (A).
4-28 ᓻ 0209
4.24 REMOVAL AND INSTALLATION, INTERIOR LIGHTING
Removing interior lighting 2 1

1. Remove the covers (1) and (2).
2. Use a long screwdriver to bend back the
lugs (B) of the lamp holder.
3. Take the lamp holder out of the headlining.
4. Unplug the connectors and remove the
lamp holder. 2
K1 01 447
Installation, interior lighting

1. Bend back the lugs (B) of the lamp holder.
2. Connect the connectors and fit the lamp
holder.
3. Fit the covers (1) and (2).
K1 00 617
ᓻ 0209 4-29
4.25 REMOVAL AND INSTALLATION OF ROOF CONSOLE IN SPACE CAB AND

COMFORT CAB TO INSTALL ACCESSORIES
Note:
The roof console of the F95XF Space Cab
and Comfort Cab is hinged to allow good A
access to the wiring behind it. The hinges (A)
include slotted holes (B) for the purpose of
2
adjusting the console in the longitudinal
direction of the vehicle. When opened the C
console can be pulled several centimetres
backwards due to these slotted holes. As a B
result of this the front edge has sufficient
space and will therefore not break.
Please ensure that no there are no loose
K100552
objects in the console that may fall out
during tilting.
Tilting roof console

1. Loosen the small guide rail socket head
screw and remove the guide rail from the
sun blind.
2. Support the console.
3. Slacken the 4 screws (C) in the upper edge.
4. Pull the console backwards as far as
possible (approx. 2 cm).
5. Tilt the console.
6. Make sure the console is not tilted too far.
This is to prevent the ends of the sun blind
mechanism from damaging the windscreen.
K100437
4-30 ᓻ 0209
Tilting back the roof console

1. Tilt the console back.
2. Push the console as far as possible A
forwards.
3. Tighten the 4 screws (C) in the upper edge.
This means that the self-locking nuts of the C
hinges (with B), may only be permanently
hand-tightened. These nuts will already B
2
have been hand-tightened in the factory.
If the console only has to be tilted then do
not change anything.
4. Install the sun blind guide rail and fasten the K100552
small socket head screw.
ᓻ 0209 4-31
4.26 REMOVAL AND INSTALLATION OF ROOF CONSOLE COMPONENTS IN

SUPER SPACE CAB TO INSTALL ACCESSORIES
Overview drawing
F
E
2
B
A
C
K100470
Legend
A 24 volt (40 A)-connector (for microwave,
TV, etc.).
B Passage tube
C 12 volt-connector for audio equipment (e.g.
CB transmitter)
D Cover plate for additional switches
Air duct for air horn
F Central roof console connector
Note:
Several facilities have been pre-installed in the
roof console to facilitate the installation of
accessories.
4-32 ᓻ 0209
Removing roof console components in

Super Space Cab to install accessories
Central storage cabinet
In the right-hand post (on co-driver’s side), the
central storage cabinet has been equipped with
a cable and connector (A) for high-capacity
accessories.
This cable is safeguarded by a 40A fuse in the
2
central fuse box.
Two installation openings, covered by plates,
have been provided in the central storage
cabinet on driver’s side for installation of
additional audio equipment, such as a CB
transmitter or a CD player. There is a 12 volt
connector (C) behind the lower plate.
Storage cabinet on driver’s side

An air pipe (E) is provided on the driver’s side
for the installation of an air horn.
To access this pipe, the bottom plate must be
removed from the cabinet. To do so, remove the
upholstery to expose the screws. This is also the
location of the central connector (F) for the roof
console.
Use double-sided tape to fasten the upholstery.
Storage cabinet on the co-driver’s side
Underneath the floor of the storage cabinet
there is a vacant passage (B) for the connection
of additional accessories. This passage runs
through the door post and ends under the
central fuse box.
Additional switches for accessories
To facilitate the installation of additional switches
in the roof console, spaces have been provided
K100471
behind the two cover plates on both the driver’s
and the co-driver’s side, in which switches will
fit.
1. Remove the floor from the storage cabinet
to enable installation of the switches.
2. Remove the two attachment nuts from the
inside.
ᓻ 0209 4-33
4-34 ᓻ 0209
1 CAB HEATING
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0209
2.1 System description of heater, heater control . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0209
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
3.1 Inspection and adjustment, heater valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0209
4.1 Removal and installation, interior filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0209
4.2 Removal and installation, heating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0209
4.3 Removal and installation, heater control panel . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Removal and installation, heater radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5 . . . . . .
4-7 . . . . . .
0209
0209 3
4.5 Removal and installation, heating unit electric motor . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 0209
4.6 Removal and installation, recirculation valve control motor . . . . . . . . . . . . . . 4-11 . . . . . 0209
4.7 Removal and installation, series resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0209
ᓻ 0209 1
CAB HEATING 1
2 ᓻ 0209
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.
ᓻ 0209 1-1
CAB HEATING 1
1-2 ᓻ 0209
1 CAB HEATING
95XF series General
2. GENERAL
2.1 SYSTEM DESCRIPTION OF HEATER, HEATER CONTROL
The heater is installed in the central console as

a complete unit.
The unit contains all control valves, control
handles and switches needed for ventilation and
heating.
There are two versions available for the F249:
- heating/ventilation system
3
- heating/ventilation system combined with
air conditioning.
The heater control consists of three rotary
knobs and two switches (one for the model
without air conditioning). The switches are fitted
on the radio panel.
Knob 1
Five-position switch to control fan speed.
1
K100395
Knob 2
Air distribution in the cab. A B
0 = 0-position
A = leg area
B = windscreen and leg area
C = windscreen (defroster) C
2
K1 01 126
Knob 3
Temperature control: offers a continuously
variable supply of hot air from 0 to 100%.
3
K100397
ᓻ 0209 2-1
CAB HEATING 1
General 95XF series
Switch 1
Recirculation valve control: the recirculation
valve can be used to partly shut off the air
supply from outside the cab; the air in the cab is
recirculated.
K1 01 463
Switch 2 (only for model with air conditioning)

Air conditioning control switch
3 K1 01 462
Air distribution
Optimal air distribution in the cab can be
achieved by means of knob 2 in combination
with the rotating and adjustable vents on the
central console and at the sides of the
dashboard.
After passing through an air filter, along the

recirculation valve, outside air enters the heater F
housing through opening A behind the grille. E
G
The recirculation valve is operated by an electric H
motor and a switch on the dashboard. The
D
inflowing air is then passed to the heater fan.
The first air distribution takes place in space B
between the fan and the radiator. Some of this
air bypasses the heater radiator and can be
passed directly to the cab D through the central
air vents C. The amount of air is controlled by C
rotating the dials on the air vents. A B
Opening the air vents in the central console will
cause less air to be passed to the heater
radiator. K1 00 993
The air being supplied will now be heated by the
heater radiator, depending on the position of the
heater valve. The second distribution will now
take place behind the heater radiator (through
valves 1 and 2), i.e. via the various air ducts
leading to the outlet openings beneath F (floor
area) and above the dashboard E (windscreen,
side windows and air vents).
2-2 ᓻ 0209
1 CAB HEATING

3.1 INSPECTION AND ADJUSTMENT, HEATER VALVE
Inspecting the heater valve

1
1. Remove the heater control panel.
2. Turn the temperature knob on the control
panel fully left (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).
2 K1 01 350
3. Turn the control knob fully right (warm) once

and fully left 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 1
be adjusted.
2
4. Fit the heater control panel.
K1 01 352
ᓻ 0209 3-1
CAB HEATING 1
Adjusting heater valve

1
1. Remove the heater control panel.
2. Turn the temperature knob on the control
panel fully left (cold). Remove the fastening
clip and press the bowden cable (1) against
the stop (2) and fit the fastening clip.
3 2 K1 01 350
3. Turn the temperature knob fully left (cold)

and then 10 mm right (warm).
10mm
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 right (warm) once

2
and fully left 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 ᓻ 0209
1 CAB HEATING

4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER
Removing interior filter

1. Open the grille.
2. Remove the attachment bolts (2) from the

fastening strip (1).
3. Remove the interior filter from the filter
housing by sliding the bottom of the filter
element outwards and downwards.
Installing interior filter
1. Place the top of the interior filter in the filter 3
housing and push the filter upwards. Note
the arrow (’airflow’) on the edge of the filter
element.
2. Fit the fastening strip with the attachment 1 2
screws. K1 01 469
3. Close the grille.
ᓻ 0209 4-1
CAB HEATING 1
4.2 REMOVAL AND INSTALLATION, HEATING UNIT
Removing the heating unit

1. Partially drain the coolant.
2. Remove the air conditioning liquid, if
applicable.
Note:
The air conditioning system may only be
opened and filled by a specialist.
Furthermore, many countries require official
certification to carry out such activities.
3 3. Remove the dashboard panels on

co-driver’s side and from the central
console.
4. Remove the ashtray and the ashtray holder
6. Remove the air ducts on driver’s side.
7. Remove the connector from the central

console control panel.
9. Unscrew the instrument panel until the
attachment screws on the inside can be
removed.
K100398
10. Remove the attachment screws at the top

and front of the central console, allowing the
panel to be lifted slightly.
K100405
4-2 ᓻ 0209
1 CAB HEATING
11. Remove the frame at the front of the central

console, including the vents. To that end,
slightly lift the dashboard panel enabling the
frame to be removed more easily.
12. Remove the frame at the top of the central
console. To that end, slightly lift the
dashboard panel enabling the frame to be
removed more easily.
3
K100404
13. Remove the attachment bolts of the heating

unit in the cab floor.
14. Remove the attachment bolts of the heating
unit at the front of the cab (underneath the
grille) To do so, remove the interior filter
housing.
15. Remove the coolant pipe at the front of the
cab (underneath the grille). Plug the
connections on the heater in such a way
that no coolant can leak from the heater
when it is removed.
K100406
16. Remove the connector on the side of the

central cabinet.
17. Remove the heating unit.
K100408
ᓻ 0209 4-3
CAB HEATING 1
Installing heating unit

Note:
Please ensure that the bowden cables are not
pinched off when the heating unit or dashboard
panels are installed. After installation, check the
operation of the heating unit.
1. Install the heating unit and connect the
hoses at the front of the cab.
2. Fasten the heating unit to the front of the
cab and the cab floor. Fit the interior filter
housing.
3 3. Connect the connector on the side of the

central cabinet.
4. Install the upper air duct on driver’s side.
5. Place the central console upper frame and
hand-tighten it (lift the dashboard panel on
driver’s side slightly to make installation
easier).
6. Install the central console front panel and
tighten both frame parts.
7. Connect the connector of the central
8. Fit the instrument panel, radio panel, control
panel, dashboard panels, ashtray and
ashtray holder.
9. Top up the cooling system.
10. If relevant, fill the air conditioning system.
4-4 ᓻ 0209
1 CAB HEATING
4.3 REMOVAL AND INSTALLATION, HEATER CONTROL PANEL
Removing control panel

1. Turn all control knobs fully to the left (0 and
cold respectively).

control panel.
Note:
If the heating unit is removed, remove the
attachment bolts from the control panel and
put the panel to one side. Do not disconnect
the control cables. 3
4. Remove the control panel from the frame
and turn it until the control cables can be 01 2 3
4
reached.
5. Remove the clips from the control cables.
6. Remove the control cables.
1
7. Disconnect all electrical connections. K1 01 457
8. Remove the control panel.
ᓻ 0209 4-5
CAB HEATING 1
Installing control panel

Note:
For the colours of the control cables for the
heater refer to “Technical data”.
1. Turn all control knobs fully to the left (0 and
cold respectively).
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
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
heater valve to the temperature control
lever, push the outer cable against the stop
and fix the clip.
5. Attach the other side of the control cable to
the heater valve, adjust the heater valve, K1 01 148
see chapter “Inspection and adjustment”
and attach the clip.
6. 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.
7. Reconnect all electrical connections.
8. Fit the control panel and the radio panel.
4-6 ᓻ 0209
1 CAB HEATING
4.4 REMOVAL AND INSTALLATION, HEATER RADIATOR
Removing heater radiator

2. Remove the lower air duct.
3. Remove the pipes on the heating unit.

Capture any escaping coolant.
K100401
4. Remove the pipe clamp.
K100399
ᓻ 0209 4-7
CAB HEATING 1
5. Remove the control panel.

6. Remove the attachment screws on the side
of the heater.
7. Remove the radiator by carefully pulling it
out of the heating unit.
Installing heating radiator
1. Place the radiator and carefully slide it into
the heating unit.
2. Fit new O-rings to the pipes and fit them.
K100401
3. Fit the pipe clamp.

4. Fit the lower air duct.
5. Install the control panel.
6. Fit the radio panel.
7. Top up the cooling system.
4-8 ᓻ 0209
1 CAB HEATING
4.5 REMOVAL AND INSTALLATION, HEATING UNIT ELECTRIC MOTOR
Removing the heating unit electric motor

1. Remove the dashboard panels on
console.
4. Install the lower air duct on driver’s side.
5. Remove the connector from the central
6.
console panel.
Remove the central console control panel.
3
K100398
7. Remove the attachment screws at the top

slightly lift the dashboard panel (driver’s
side) enabling the frame to be removed
more easily.
K100404
ᓻ 0209 4-9
CAB HEATING 1
9. Remove the clips at the front of the heater

and take the cover off.
3 K100402
10. Remove the motor by pulling it out of the

unit. Mark the connections.
K100403
Installing the heating unit electric motor

1. Install the electric motor in the unit and
connect all connectors.
2. Install the cover and fix it with the clips. In
doing so, make sure that the bowden cable
does not get pinched off.
3. Install the upper air duct on driver’s side.
4. Install the central console front panel and
fasten it.
5. Connect the connector of the central
6. Fit the radio panel, dashboard panels,
ashtray and ashtray holder.
4-10 ᓻ 0209
1 CAB HEATING
4.6 REMOVAL AND INSTALLATION, RECIRCULATION VALVE CONTROL

MOTOR
Removing recirculation valve control motor

1. Remove the heating unit.
valve control at the bottom of the heating
unit.
3. Remove the connector from the control
motor.
4. Remove the control motor.
Installing recirculation valve control motor
1. Install the control motor and fit the
3
connector.
2. Install the heating unit.
K100407
ᓻ 0209 4-11
CAB HEATING 1
4.7 REMOVAL AND INSTALLATION, SERIES RESISTOR
Removing series resistor

1. Remove the dashboard panels on
console.
4. Remove the lower air duct on driver’s side.
3 6. Remove the attachment screws at the top


slightly lift the dashboard panel (driver’s
side) enabling the frame to be removed
more easily.
K100404
8. Remove the clips at the front of the heater

and take the cover off.
K100402
4-12 ᓻ 0209
1 CAB HEATING
9. Remove the connectors from the series

resistor (1).
10. Using a screwdriver, push the retainer lips
to one side and slide the series resistor
including its support off the heater motor. 1
Installing series resistor 2

1. Press the series resistor (1) with the support
4
firmly into the retainer lips on the heater
motor.
3
2. Connect the connectors. Note the markings
or the wire numbers.
3.
4.
Fit the cover with the clips.
Fit the frame at the front of the central
1 3
console, including the vents. K1 01 096
5. Fit the attachment screws at the top and

front of the central console.
6. Fit the central console control panel.
7. Fit the lower air duct on driver’s side.
8. Fit the radio panel.
9. Fit the ashtray and the ashtray holder.
10. Fit the dashboard panels on co-driver’s side
and from the central console.
ᓻ 0209 4-13
CAB HEATING 1
4-14 ᓻ 0209
1 EXTERNAL CAB COMPONENTS
CONTENTS
Page Date
1. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200345
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .... 200345
2.1 Description of exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .... 200345
2.2 Description of windscreen wiper and washers . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 .... 200345
2.3 Functional description of headlight washing system . . . . . . . . . . . . . . . . . . . . 2-3 .... 200345
2.4 Description of headlight height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 .... 200345
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200345
3.1 Inspection and adjustment, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200345
3.2 Inspection and adjustment, exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 .... 200345
3.3 Inspection and adjustment, headlight washing system . . . . . . . . . . . . . . . . . 3-4 .... 200345
3.4 Inspection and adjustment, headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 .... 200345
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200345
4.1 Removal and installation, door extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Removal and installation, door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 . . . .
4-2 . . . .
200345
200345 4
4.3 Removal and installation, door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . 200345
4.4 Removal and installation, drop glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . 200345
4.5 Removal and installation, fixed door window . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . 200345
4.6 Removal and installation, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . 200345
4.7 Removal and installation, exterior mirrors complete with bracket . . . . . . . . . 4-10 . . . 200345
4.8 Removal and installation, exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . 200345
4.9 Removal and installation, exterior mirror glass . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . 200345
4.10 Removal and installation, bottom step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . 200345
4.11 Removal and installation, mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . 200345
4.12 Removal and installation, windscreen wiper panel . . . . . . . . . . . . . . . . . . . . . 4-21 . . . 200345
4.13 Removal and installation, windscreen wiper mechanism . . . . . . . . . . . . . . . . 4-23 . . . 200345
4.14 Removal and installation, windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . 4-26 . . . 200345
4.15 Removal and installation, windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . 200345
4.16 Removal and installation, corner piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . 200345
4.17 Removal and installation, headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . 200345
4.18 Removal and installation, headlight bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 . . . 200345
4.19 Removal and installation, headlight levelling control . . . . . . . . . . . . . . . . . . . . 4-34 . . . 200345
4.20 Removal and installation, cab grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 . . . 200345
4.21 Removal and installation, lower grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 . . . 200345
4.22 Removal and installation, steel bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 . . . 200345
4.23 Removal and installation, roof hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 . . . 200345
4.24 Removal and installation, Super Space Cab roof . . . . . . . . . . . . . . . . . . . . . . 4-39 . . . 200345
4.25 Removal and installation, Super Space Cab plastic sun visor . . . . . . . . . . . 4-42 . . . 200345
4.26 Removal and installation, Super Space Cab plastic sun visor . . . . . . . . . . . 4-46 . . . 200345
ᓻ 200345 1
EXTERNAL CAB COMPONENTS 1
2 ᓻ 200345
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 is to be carried out
underneath the cab.
at any time by turning the cock to
the reverse tilting position.
When working on a tilted cab (for

example when welding,
spray-painting or applying bitumen
4
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 it is damaged or if you are in doubt as to its
condition.
ᓻ 200345 1-1
1-2 ᓻ 200345
95XF series General
2. GENERAL
2.1 DESCRIPTION OF EXTERIOR MIRRORS
All exterior mirrors and exterior mirror brackets

installed on the 95XF series vehicles are
factory-set under average driving conditions.
After the superstructure has been constructed
on the vehicle, it is required by law that all
exterior mirrors and exterior mirror brackets
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 brackets as provided for in
the Directive, it is important to follow all
adjustment procedures closely.
4
Mirror classification
This section describes the different types of
vehicle 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 exterior mirror
(/blind angle exterior mirror)
”Category 5” - Close-up exterior mirror
Note: Category 1 (inside) 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’s side) are fitted to a
D-shaped bracket on the door. A dead angle
exterior mirror (on co-driver’s side only) can also
be fitted on the D-shaped bracket. 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.
ᓻ 200345 2-1
General 95XF series
The pavement mirror is attached to the upper

part of the door on a separate bracket.
The exterior mirror bracket returns to its original
position if it gets flapped back. On several
models there is an extra exterior mirror (apart
from a pavement mirror) on co-driver’s side
giving the driver a better view of the drawn
vehicle.
The heating for the exterior mirrors can be
switched on by a switch on the dashboard.
When the exterior mirror heating is turned on,
the warning lamp in the switch lights up.
The exterior mirrors can be divided into:
- non-heated exterior mirrors
- heated exterior mirrors (except for the
pavement mirror)
- electrically adjustable main exterior mirrors
4 (always heated).
Exterior mirror types
There are two different exterior mirrors for the
vehicles of the 95XF series:
K101229 K101230
Model without integrated bracket Model with integrated bracket
2-2 ᓻ 200345
95XF series General
2.2 DESCRIPTION OF WINDSCREEN WIPER AND WASHERS
There are three windscreen wipers on the

windscreen which are equipped with nozzle tips,
each of which has three sprayer nozzles.
The filler opening of the storage tank for the
windscreen washers and possibly the headlight
washers is located in the stepwell on driver’s
side.
2.3 FUNCTIONAL DESCRIPTION OF HEADLIGHT WASHING SYSTEM
95XF-series vehicles may be equipped with a

headlight washing system consisting of a
high-pressure pump and washers. The
high-pressure pump for this washing system
abuts the storage tank. The washers are
underneath the headlights. The headlight 4
washing system can be activated by operating
the windscreen wipe-wash system when the
lighting is switched on. When the wipe-wash
system has been operated with the lighting
switched on, the high-pressure pump starts to
build up pressure. As the pressure rises, the
telescopes are pushed out. Only when the
pressure has reached its maximum does a valve
at the top of the telescope open, after which the
liquid is sprayed at high pressure through the
nozzle tips onto the headlight glass. The
high-pressure pump stops after one second; the
washing cycle is complete. The built-in spring
now retracts the telescopes.
To begin another washing cycle, the windscreen
wipe-wash system must be re-activated.
2.4 DESCRIPTION OF HEADLIGHT HEIGHT ADJUSTMENT
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 knob is situated on the dashboard to the left
of the steering wheel.
The headlights are levelled by means of electric
motors located at the bottom of the headlight
unit.
ᓻ 200345 2-3
General 95XF series
2-4 ᓻ 200345

3.1 INSPECTION AND ADJUSTMENT, DOOR
Note:
To adjust the door using the door hinges, the
door panel must be removed.
1. Check that the size and wedged shape of
the gap between cab and door match the
specified gap size and wedged shape all
round, see ”Technical data”. If necessary,
adjust the door, with the door hinges. See
”Technical data” for the specified tightening
torque for the door hinge bolts.
2. Look and feel whether there is a smooth
transition between the door and corner
section and between the door and cab roof,
see ”Technical data”. If necessary, adjust 4
the door by moving the door hinges inwards
or outwards. See ”Technical data” for the
specified tightening torque for the door
hinge bolts.
K1 01 492
3. Check that the surface of the door handle

area continues smoothly into that of the cab
body. See ”Technical data”. If necessary,
adjust the door, using the striker plate (1).
Loosen the Torx screws (2) and (3) and 1
move the striker plate. See ”Technical data” 2
for the tightening torque for the Torx screws
(2). 3
K1 01 491
ᓻ 200345 3-1
3.2 INSPECTION AND ADJUSTMENT, EXTERIOR MIRRORS
Height/angle adjustment of exterior mirrors

without integrated bracket
Check whether the driver and passenger’s
exterior mirrors have been adjusted in
accordance with the values given 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 01 494
2. Unscrew the clamping bolts (1). This allows

the mirrors to move freely over the bracket.
3. Set the mirror to the proper height and
angle, see ”Technical data”.
4. Tighten the clamping bolts (1).
K1 01 493
3-2 ᓻ 200345
Height/angle adjustment of exterior mirrors

with integrated bracket
Check whether the driver and passenger’s
exterior mirrors have been adjusted in
accordance with the values given 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
K1 01 094
2. Unscrew the clamping bracket bolts (1).

This allows the mirrors to move freely over
the bracket.
4. Tighten the clamping bracket bolts (1). 1
K1 01 095
ᓻ 200345 3-3
Adjustment, 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”.
4
A B
K100236
3.3 INSPECTION AND ADJUSTMENT, HEADLIGHT WASHING SYSTEM
1. Using a felt pen, draw two adjustment

points from the centre on the headlight
glass. Determine the location of these
adjustment points using the drawing. The
outer adjustment point should always be
58 mm away from the headlight centreline.
The situation shown here applies to the
right-hand headlight glass. The mirror
image of this drawing applies to the
left-hand headlight glass.
3-4 ᓻ 200345
27 58
27
2
1
4
K100820
2. Pull the telescope out and fix it in the

extreme position.
3. Place the special tool (2)
(DAF no. 0694939) with the short bent side
in one of the nozzle tips and adjust by
turning it in such a manner that the long
side of the adjusting tool points to the
headlight glass.
4. Repeat this procedure for the other nozzle
tip.
Note:
The high-pressure pump of the headlight
washing system supplies a pressure of 2.5 bar.
The pipes from the pump to the washing system
are therefore armoured.
When replacing them, always make sure that
armoured pipes are fitted. From the
high-pressure pump there is one pipe to the
crosspiece. From the crosspiece there is one
pipe to the left-hand and one pipe to the
right-hand spray telescope. Both pipes must be
of the same length to ensure proper functioning
of the system.
ᓻ 200345 3-5
3.4 INSPECTION AND ADJUSTMENT, HEADLIGHTS
Inspection and adjustment, headlights
Note:
Use adjustment equipment to check and adjust
the headlights.
1. Place the unladen vehicle with the specified
tyre pressure on a flat and level surface.
2. Check in the cab that the control knob of the
headlight levelling is set to ”0”.
3. Check the headlight levelling. See
”Technical data” for the specified height
adjustment.
The specified height adjustment is also
4 shown on a sticker on the inside of the

corner section around the headlight.
4. If necessary, adjust the headlights:

- using adjusting screw 1 the headlight
can be adjusted vertically.
- using adjusting screw 2 the headlight
can be adjusted horizontally.
1
K1 01 481
3-6 ᓻ 200345

4.1 REMOVAL AND INSTALLATION, DOOR EXTENSION
Removing the door extension

1. Remove the three attachment bolts (A) on
the underside of the door upholstery. K
2. Remove the two attachment screws and the
attachment plate (D).
3. Remove the six attachment screws (B) and
take the extension off the door. F
4. If necessary, remove the side-impact bar (F)
by removing the two screws (G) and the A
plate (H).
F
4
Installing the door extension
1. If necessary, fit the side-impact bar (F).
Hand-tighten this bar using attachment
plate (H).
2. Slide the side-impact bar into the door D
opening. Make sure that the tip of the bar
aligns with the lip (K) in the door. Fit the
extension to the door by hand-tightening the
attachment screws.
H
3. Hand-tighten the three attachment bolts into B G
the interior upholstery.
4. Make sure the extension is properly aligned
with the upper part of the door. Then tighten
K100360
the connections firmly.
ᓻ 200345 4-1
4.2 REMOVAL AND INSTALLATION, DOOR HANDLE
Removing the door handle

2. Remove the attachment bolts on the inside
of the door. To do so, remove the door
seals.
4 K100421
3. Remove the door handle by turning it

downwards. At the same time, hold the
handle pressed in and the key turned
clockwise (lock). The rods can then be
taken from the door handle.
K100422
4-2 ᓻ 200345
Installing the door handle

1. Fit the door handle by first installing the
longest rod. Keep the door handle pressed.
Then install the shorter rod. Keep the key
turned clockwise (lock).
2. Fit the attachment bolts.
3. Fit the seals on the inside of the door.

4. Install the door panel.
K100423
4.3 REMOVAL AND INSTALLATION, DOOR LOCK
Removing the door lock A

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
handle.
Installing the 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 01 445
ᓻ 200345 4-3
4.4 REMOVAL AND INSTALLATION, DROP GLASS
Removing the drop glass

1. Remove the door panel and remove the foil
covering the inside of the door.
2. Remove the attachment bolt (3) of the

window guide and remove the window
guide. 2
1
K1 01 504

bolts (1) and lower the mechanism.
K1 01 089
4. Slide the glass down and remove the rubber

seals and squeegee strips.
4-4 ᓻ 200345
5. Carefully cut loose the glue in places where

the rubber of the fixed window is glued to
the window pillar.
K1 01 511
4
6. Remove the window pillar attachment bolts.
K1 01 515
7. Tilt the window pillar, slide up the glass and

tilt the glass out of the door, along the front
of the window pillar.
K1 01 514
ᓻ 200345 4-5
Installing the drop glass

1. Position the drop glass in the door.
2. Fit the window pillar.
3. Fit the window guide by first fitting the

fastening lip (1) of the window guide in the
recess (2) in the door. Now fit the 2
attachment bolt (3), but do not tighten it yet. 1
Slide up the window guide as far as
possible and tighten the attachment bolt (3).
K1 01 504
4. Fit the rubber seals and squeegee strips.

Make sure that the foil (against the inside of
the inner plate) is pressed against the inside
of the door by the lower squeegee strip. .
5. Secure the drop glass to the window

mechanism, using the attachment bolts (1).
6. Close the drop glass until nearly shut.
Check that the top edge of the window is
parallel to the window frame. If necessary,
loosen the attachment bolts (1) and adjust
the drop glass.
1
7. Fit new foil on the inside of the door.
8. Install the door panel.
K1 01 089
4-6 ᓻ 200345
9. Clean and degrease the window pillar and

the rubber in places where glue is to be
applied.
10. Apply the specified superfast adhesive to

the rubber, see ”Technical data”. Press the
rubber firmly to the window pillar.
Immediately remove the excess glue.
Caution: the specified superfast adhesive
dries within a few seconds.
11. Clean the glass (for example with DAF
window cleaning agent) and the parts of the
cab body which have become dirty during
installation of the window.
4
K1 01 511
ᓻ 200345 4-7
4.5 REMOVAL AND INSTALLATION, FIXED DOOR WINDOW
Removing the fixed door window

1. Remove the drop glass.
2. Remove the window pillar by pressing the
inner and outer door plates slightly apart in
the centre.
3. Remove the fixed door window by placing a

suction pad, special tool (DAF no. 0484800)
on the inside and outside and pulling the
window with rubber seal carefully out of the
frame (tilt, if necessary).
K1 01 527
Installing the fixed door window

1. Make sure that the window frame is smooth
and flat (no major irregularities).
2. Apply a lubricant to the outside of the
rubber seal.
3. Install the window using two suction pads,
special tool (DAF no.-0484800) in the door
frame. Tap the window properly and check
that the weatherstrip properly fits into the
door along the entire circumference.
4. Install the drop glass.
5. Clean the two windows (for example with
DAF window cleaning agent) and the parts
of the cab body which have become dirty
during installation of the windows.
4-8 ᓻ 200345
4.6 REMOVAL AND INSTALLATION, DOOR
Removing the door

1. Unplug the connectors of the door in the
A-pillar of the cab.
2. Remove the grommet (1) in the A-pillar.
3. Remove the circlip and pin of the door 3
check (2). Loosen the door check.
1
4. Suspend the door in slings.
Note: 2
Protect the door paint by fitting tape in the
places where the slings will touch the door.
5. Remove the hinge bolts (3) and take off the
door.
Installing the door 3 4
1. Suspend the door in the slings and position
it with the hinges in front of the attachment
holes. K1 01 501
Note:
Protect the door paint by fitting tape in the
places where the slings will touch the door.
2. Centre the attachment plate in the A-pillar
and fit all hinge bolts (3).
3. Fit the door check (2).
4. Feed the connectors through the A-pillar
and fit the grommet (1).
5. Connect the connectors in the A-pillar.
6. Close the door carefully and adjust it; see
chapter ”Inspection and adjustment”.
ᓻ 200345 4-9
4.7 REMOVAL AND INSTALLATION, EXTERIOR MIRRORS COMPLETE WITH

BRACKET
Model without integrated bracket
Removing exterior mirrors complete with

bracket
1. Remove the caps of the exterior mirror
bracket.
2. Remove the attachment bolts of the exterior
mirror bracket and take the exterior mirrors
complete with bracket and shim off the door.
3. Disconnect the exterior mirror heating and
mirror adjustment connectors. When
disconnecting the connectors make sure the
door wiring harness does not slip back
4 through the hole in the door. Should this
nevertheless happen and if you are unable
to reach the wiring harness through the
hole, disassemble the door upholstery and
guide the wiring harness through the
opening again.
Installing exterior mirrors complete with
bracket
1. Connect the exterior mirror connectors.
Note:
Apply silicone sealant (all round) to the
threaded holes for the attachment bolts of
the exterior mirror bracket. The purpose of
this is to prevent water from penetrating the
door.
2. Fit the exterior mirrors complete with
bracket and shim to the door.
3. Fit the caps.
4-10 ᓻ 200345
Removing exterior mirrors complete with

bracket
1. Remove the lower cover by pressing the top
and bottom sides (A) firmly. Tilt the cover
backwards (B), away from the D-shaped A
bracket. A
B
B A A
K1 01 226
4
2. Remove the connectors of the exterior
mirror heater and adjustment on the inside
of the door.
3. Remove the attachment bolts and remove
the exterior mirror complete with bracket.
Installing exterior mirrors complete with
bracket
Note:
Apply silicone sealant (all round) to the
threaded holes for the attachment bolts of
the exterior mirror bracket. The purpose of
this is to prevent water from penetrating the
door.
1. Install the exterior mirrors complete with
bracket and secure them using the
attachment bolts.
2. Fit the connectors to the inside of the door.
3. Fit the cover and press it firmly.
ᓻ 200345 4-11
Removing the pavement mirror complete

with bracket
1. Remove the attachment bolts (1) of the
pavement mirror and remove the mirror with
gasket.
Installing the pavement mirror complete with

bracket
1. Check the gasket. If damaged, replace the
gasket.
2. Put the pavement mirror with gasket in
place and secure it using the attachment
bolts (1).
4
1
K101 519
4-12 ᓻ 200345
4.8 REMOVAL AND INSTALLATION, EXTERIOR MIRRORS
Model without integrated bracket
Removing the main exterior mirror

1. Remove the cover at the back of the
exterior mirror.
2. Unplug the connector of the exterior mirror
adjustment and/or exterior mirror heating.
3. Remove the clamp bolts (1) and remove the
mirror from the bracket. 1
Installing the main exterior mirror

1. Fit the exterior mirror to the bracket and fit
the clamp bolts. Do not yet tighten the
clamp bolts.
2. Fit the connector of the exterior mirror
adjustment and/or exterior mirror heating.
4
1
3. Adjust the mirror height and angle, see
4. Tighten the clamp bolts.
5. Fit the cover (push into place).
Removing the wide-angle exterior mirror
exterior mirror. K1 01 493
2. Unplug the connector of the exterior mirror

heating.
3. Remove the clamp bolts (1) and remove the
mirror from the bracket.
K1 01 494
ᓻ 200345 4-13
Installing the wide-angle exterior mirror

1. Fit the exterior mirror to the bracket and fit
the clamp bolts. Do not yet tighten the
clamp bolts.
heating.
3. Adjust the mirror height and angle, see
4. Tighten the clamp bolts.
5. Fit the cover (push into place).
4-14 ᓻ 200345
Removing the main exterior mirror

exterior mirror. This cover can be loosened
2. Unplug the connectors of the exterior mirror
heating and/or exterior mirror adjustment.
3. Remove the clamping bracket bolts (1) and
remove the exterior mirror from the bracket.
Installing the main exterior mirror
1. Attach the exterior mirror to the bracket and
hand-tighten the clamping bracket bolts (1)
but do not tighten them firmly.
2. Fit the connectors of the exterior mirror 4
heating and/or exterior mirror adjustment.
angle, see chapter ”Inspection and
adjustment”.
4. Tighten the clamping bracket bolts (1).
5. Fit the cover (push into place). K1 01 094
Removing the wide-angle exterior

mirror/dead angle exterior mirror
exterior mirror. This cover can be loosened
2. Unplug the connector of the exterior mirror 1
heating.
3. Remove the clamping bracket bolts (1) from
the exterior mirror and remove the exterior 1
mirror from the bracket.
K1 01 095
ᓻ 200345 4-15
Installing the wide-angle exterior mirror/dead

angle exterior mirror
1. Attach the exterior mirror to the bracket and
hand-tighten the clamping bracket bolts (1)
but do not tighten them firmly.
heating. 1
4. Tighten the clamping bracket bolts (1). 1
5. Fit the cover of the exterior mirror (push into
place).
4
1
K1 01 095
4-16 ᓻ 200345
4.9 REMOVAL AND INSTALLATION, EXTERIOR MIRROR GLASS
Removing the main exterior mirror glass

1. Press in the mirror glass at the top (1).
2. Push the mirror glass upwards (2).
1 4
3. Press in the mirror glass at the bottom (3).
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). 2
3
Installing the main exterior mirror glass
1. Put the mirror glass in place.
2. Push the mirror glass from the top down 3
into the fixing. 1 2 4
3. Put the mirror in its required position. 4
Removing the wide-angle exterior mirror
glass/dead angle exterior mirror glass
1. Press in the mirror glass on the left-hand
side (1). K1 01 029
2. Push the glass sideways from right to

left (2).
3. Press in 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 the wide-angle exterior 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.
ᓻ 200345 4-17
Removing the pavement mirror glass

1. Remove the cap of the attachment nut at
the top.
2. Remove the attachment nut and remove the
mirror glass.
Installing the pavement mirror glass
1. Fit the mirror glass and set the proper
angle, see chapter ”Inspection and
adjustment”.
2. Tighten the attachment nut to the specified
torque, see “Technical data”.
3. Fit the cap of the attachment nut.
4-18 ᓻ 200345
4.10 REMOVAL AND INSTALLATION, BOTTOM STEP
Removing the bottom step

1. Remove the two attachment bolts in the
step recess.
2. Remove the two attachment bolts (A) at the

back of the stepwell.
4
K100369
3. Remove the eight attachment bolts at the

front of the anti-underrun bumper. The cross
bracket at the rear will also come loose.
A
K100368
Installing the bottom step

1. Fit the bracket against the front of the
anti-underrun bumper. At the same time fit
the cross bracket at the rear of the
anti-underrun bumper.
2. Fit the step recess and secure it with the
two attachment screws. Make sure that the
step recess fits snugly against the bumper.
K100367
ᓻ 200345 4-19
4.11 REMOVAL AND INSTALLATION, MUDGUARD
Removing the mudguard

1. Tilt the cab.
2. Unplug the stepwell lighting connector (A). 6

upper attachment of the windscreen washer
tank or attachment plate.
4. Remove the attachment bolts (2) and (3) in 2
the steps.
1
5. Remove the attachment bolts (4) and (5) on
the inside of the wheel arch.
6. Support the mudguard, remove the 3
4
attachment bolts (6) and take the mudguard
off the cab. 5
4
Installing the mudguard A
1. Install the mudguard using attachment bolts
(6).
2. Fit the attachment bolts (4) and (5) on the
K1 01 487
inside of the wheel arch.
3. Fit the attachment bolts (2) and (3) in the
steps.
4. Fit the attachment bolts (1) of the upper
attachment of the windscreen washer tank
or attachment plate.
5. Connect the connector (A).
6. Tilt the cab to the driving position.
4-20 ᓻ 200345
4.12 REMOVAL AND INSTALLATION, WINDSCREEN WIPER PANEL
Removing the windscreen wiper panel

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
4. Remove the cab grille.
5. Remove the two covers across the linkage
of the windscreen wiper system.
ends of the windscreen wiper panel (1). 1
11
7. Remove the cap (9) and remove the
attachment bolt (10). 10
9
8. Remove the covers (4), locknuts (3) and
washers (2).
8
9. Remove the caps (6) and the attachment 7
bolts (7) of the handles (8) and remove the
handles. 6
10. Take the windscreen wiper panel some
distance away from the cab and remove the
windscreen washer supply hose from the
manifold.
11. Slide the windscreen wiper panel over the
cab grille brackets and remove the 5
windscreen wiper panel from the cab. 4 3 2
K1 01 461
ᓻ 200345 4-21
Installing the windscreen wiper panel
Note:
Apply silicone sealant (all round) to all threaded
holes of the attachment bolts and screws, and to
the attachment bolts and screws fitted in the cab
front. The purpose of this is to prevent water
from penetrating the cab.
1. Fit the windscreen washer supply hose to

the manifold and fit the windscreen wiper
panel (1) to the cab. Make sure that the
windscreen washer hoses are not kinked
and do not get pinched off when installing
the windscreen wiper panel.
1
2. Fit the handles (8) with the attachment bolts 11
(7) and press the caps (6) into the handles.
10
4 3. Fit the washers (2), locknuts (3) and covers
(4). Tighten the locknuts (3) to the specified
9
torque. See “Technical data”. 8

4. Fit the attachment bolt (10) and cap (9). 7
5. Fit the attachment bolts (11) to the ends of 6

the windscreen wiper panel.
6. Fit the two covers across the linkage of the
windscreen wiper system.
7. Fit the cab grille.
8. Fit the windscreen wiper arms (windscreen 5
wipers in horizontal position) and the 4 3 2
windscreen wiper hoses. K1 01 461
9. Fit the attachment nuts (5) of the

windscreen wiper arms. Tighten the nuts to
”Technical data” and close the covers of the
4-22 ᓻ 200345
4.13 REMOVAL AND INSTALLATION, WINDSCREEN WIPER MECHANISM
Removing the windscreen wiper mechanism

Before 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 linkage.
- Use proper tools when disassembling the
old wiper linkage in order to avoid damaging
the seals.
- Use FINA Ceran grease when fitting a new
wiper linkage.
- When fitting a new linkage, never hit the
sealing covers of the linkage with a hammer
4
or other hard object. These covers are only
1 mm thick and might suffer damage in this
way.
- If the motor spindle shows evidence of axial
play, replace the motor. This play will cause
excessive wear to the wiper linkage.
Removing the windscreen wiper mechanism

1. Open the windscreen wiper arm covers.
2. Remove the attachment nuts of the
3. Remove the windscreen washer fluid hoses
and remove the windscreen wiper arms.
K1 00 654
ᓻ 200345 4-23
4. Remove the covers (1), locknuts (2) and 3

washers (3) of the windscreen wiper arm
spindles. 2
5. Remove the cab grille. 1
6. Remove the two covers across the wiper

linkage.
4
7. Turn the crank of the windscreen wiper
5
arms and remove the nut of the windscreen
wiper motor spindle.
8. Using a plastic hammer, carefully tap the
end of the windscreen wiper motor spindle
and take the crank off the motor spindle.
K1 01 464
brackets of the wiper linkage (5).
4 10. Remove the wiper linkage.

Installing the windscreen wiper mechanism
Note:
Apply silicone sealant (all round) to all threaded
holes of the attachment bolts and screws, and to
the attachment bolts and screws fitted in the cab
front. The purpose of this is to prevent water
from penetrating the cab.
1. Fit the wiper linkage and secure it with the
attachment bolts.
2. Fit the washers, locknuts and covers of the
windscreen wiper arm spindles. Tighten the
locknuts to the specified torque. See
”Technical data”.
3. Set the windscreen wiper motor in the
neutral position by switching it briefly on and
off, using the control switch.
4. Put the windscreen wiper linkage in the
neutral position and fit the crank with the
attachment nut to the windscreen wiper
motor spindle. Tighten the nut to the
specified tightening torque, see ”Technical
data”.
4-24 ᓻ 200345
5. Fit the windscreen wiper arms (windscreen

wipers in horizontal position) with the
attachment nut. Tighten the attachment nuts
to the specified torque. See ”Technical
data”.
6. Connect the windscreen washer hoses and
close the windscreen wiper arm covers.
7. Operate the windscreen wiper motor and
check the windscreen wiper mechanism for
proper operation.
8. Fit the two covers across the wiper linkage.
9. Fit the cab grille.
ᓻ 200345 4-25
4.14 REMOVAL AND INSTALLATION, WINDSCREEN WIPER MOTOR
Removing the windscreen wiper motor

1. Open the cab grille.
2. Remove the attachment nuts (1) and the

cover (2) over the windscreen wiper
2
mechanism, and remove the cover by
sliding it downwards.
3. Turn the crank of the windscreen wiper
linkage and remove the nut of the
windscreen wiper motor spindle.
1
K1 01 459
4 4. Remove the attachment bolts of the

windscreen wiper motor.
5. Using a plastic hammer, carefully tap the
end of the windscreen wiper motor spindle
and take the crank off the motor spindle.
6. In the cab, remove the dashboard panels to
the right of the steering column and the
panel underneath the radio panel.
Note:
For a RHD vehicle, remove the dashboard
panels to the left of the steering column.
K100211
7. Unplug the connectors (1) and (2) and

press the connectors out of the dashboard
attachment frame (3).
8. Unplug the windscreen wiper motor
connector.
9. Remove the windscreen wiper motor (4) by
lowering it between the dashboard
attachment frame and the engine tunnel.
1 2 3 4
K1 01 460
4-26 ᓻ 200345
Installing the windscreen wiper motor

1. Check the motor spindle for axial play. If so,
replace the motor. This play will cause
excessive wear to the wiper linkage.
2. Check the windscreen wiper motor sealing
rubber.
3. Install the windscreen wiper motor on the
inside of the bulkhead.
4. Connect the windscreen wiper motor
connector.
5. Fit the attachment bolts on the outside of
the cab.
6. Fit the connectors to the attachment frame
in the cab and connect the connectors.
7. Fit the dashboard panels to the right of the
steering column and the panel underneath
4
the radio panel.
8. Set the windscreen wiper motor in the
neutral position by switching it briefly on and
off, using the control switch.
9. Put the windscreen wiper arms in the
neutral position (windscreen wipers in
horizontal position).
10. Fit the crank of the windscreen wiper arms
to the windscreen wiper motor spindle and
fit the nut to the motor spindle. Tighten the
nut to the specified tightening torque, see
11. Operate the windscreen wiper motor and
check the operation of the windscreen wiper
mechanism and the position of the
12. Fit the cover over the windscreen wiper
mechanism.
13. Close the cab grille.
ᓻ 200345 4-27
4.15 REMOVAL AND INSTALLATION, WINDSCREEN
Removing the windscreen

1. Remove the windscreen wipers.
2. Push the glass (or its remnants) out of the
rubber seal.
3. Remove any loose glass particles out of the
rubber seal and clean the latter.
Note:
Wear safety goggles if you clean the rubber
seal with compressed air.
Installing the windscreen

1. Apply a thin bead of sealant in the groove of
the rubber seal into which the glass will be
4 placed and fit the rubber seal around the

windscreen.
2. Apply a filler strip around the rubber seal in
the groove where the rubber seal will be
around the cab profile.
3. Cover the rubber seal with liquid soap.
4. Place the rubber seal with glass in the
window frame of the cab.
5. Using the filler strip, pull the rubber seal
with glass over the cab profile. Press the
rubber seal firmly from the outside in the
place where the filler strip is pulled out of
;;;
the rubber seal.
K1 01 517
6. Apply a thin bead of sealing compound
between the rubber seal and the cab to
ensure a proper seal.
7. Clean the entire windscreen and the parts
of the cab body which have been fouled
during installation of the windscreen.
8. Fit the windscreen wipers.
4-28 ᓻ 200345
4.16 REMOVAL AND INSTALLATION, CORNER PIECE
Removing the corner piece

1. Open the grille and remove the two
attachment bolts (A).
2. Open the door. By leaving the door ajar, you
will be able to reach the three attachment
screws of the corner piece, which are
located on the inside of the front door post.
Installing the corner piece A
1. Fit the corner piece by tightening the two
attachment bolts at the front until they are
fingertight. Make sure that the spoiler still
has some play.
2. Fit the three attachment screws to the
3.
inside of the front door post.
Close the grille.
K100359 4
ᓻ 200345 4-29
4.17 REMOVAL AND INSTALLATION, HEADLIGHT
Removing the headlight

1. Remove the battery terminal.
2. Tilt the cab.
3. Remove the two attachment bolts on the

side of the plastic corner piece around the
headlight and the four attachment bolts on
the inside of the plastic corner piece around
the headlight.
4. Remove the corner piece around the
headlight by pulling it from behind the lower
grille.
5. Mark the position of the connectors on the
4 6.
headlight and unplug them.
Remove the rubber grommet and the
direction indicator plugs.
7. Remove the attachment screw at the rear of
the direction indicator. Unhook the direction
indicator from the headlight.
K1 01 480
8. Remove the four attachment bolts (1) and 1

remove the headlight from the bracket.
1
K1 01 482
4-30 ᓻ 200345
Installing the headlight

1. Install the headlight to the headlight bracket,
using attachment bolts.
2. Fit the direction indicator to the headlight
and headlight bracket, using the attachment
screw.
3. Connect the connectors to the headlight
and the plugs to the direction indicator. Fit
the rubber grommet to the direction
indicator.
4. Slide the corner piece around the headlight
behind the lower grille on the attachment
brackets.
5. Remove the four attachment bolts on the
inside of the plastic corner piece around the
headlight and the two attachment bolts on
the side of the plastic corner piece around 4
the headlight.
6. Tilt the cab back to the driving position.
7. Connect the battery terminal.
ᓻ 200345 4-31
4.18 REMOVAL AND INSTALLATION, HEADLIGHT BRACKET
Removing the headlight bracket

1. Remove the battery terminal.
2. Tilt the cab.
3. Remove the two attachment bolts on the

side of the plastic corner piece around the
the inside of the plastic corner piece around
the headlight.
4. Remove the corner piece around the
headlight by pulling it from behind the lower
grille.
5. Mark the position of the connectors on the
4 6.
headlight and unplug them.
Detach the headlight/wipe-wash washer
hose (plug the hose).
7. Cut loose the clamping strips securing all
wiring and wiring harnesses to the headlight
bracket.
K1 01 480
8. Remove the four headlight bracket

attachment bolts and remove the bracket,
including the headlight unit.
K100366
4-32 ᓻ 200345
Installing the headlight bracket

1. Fit the headlight bracket.
2. Fit the connectors. Secure the wiring and
wiring harnesses with clamping strips.
3. Fit the hose for the headlight/wipe-wash
washer.
4. Fit the plastic corner piece around the
headlight on the brackets behind the lower
grille.
5. Fasten the plastic corner piece around the
headlights, using the two attachment bolts
on the side of the corner piece around the
the inside of the corner piece around the
headlight.
6. Tilt the cab to the normal driving position. 4
7. Connect the battery terminals.
ᓻ 200345 4-33
4.19 REMOVAL AND INSTALLATION, HEADLIGHT LEVELLING CONTROL
Removing the headlight levelling control

1. Remove the headlight.
2. Turn (approximately 1/3 turn) the headlight
levelling (1) out of the white bracket (2) (left
headlight clockwise, right headlight
counterclockwise).
3. Carefully take the rubber grommet around
the adjusting spindle from the headlight
housing.
4
2 1
K1 01 489
4. Remove the adjusting spindle (1) by

pushing it out of the opening in the holder 2
(2).
5. Remove the headlight levelling control from
the headlight. 1
Installing the headlight levelling control
1. Install the headlight levelling control by
fitting the adjusting spindle in the holder.
2. Carefully push the rubber grommet in the
opening of the headlight housing. Make
sure that the edge of the rubber grommet
fits snugly in the opening all round. The
purpose of this is to prevent water from
penetrating the headlight.
3. Turn the headlight levelling control in the
white bracket.
4. Fit the headlight onto the headlight bracket.
5. Check the headlight levelling and adjust if K1 01 488
necessary. See ”Inspection and
adjustment”.
4-34 ᓻ 200345
4.20 REMOVAL AND INSTALLATION, CAB GRILLE
Removing the cab grille 1

1. Open the cab grille and support it.
2. Remove the upper gas damper attachment 2
(1) and remove the gas dampers from the
grille.
grille hinges.
4. Remove the cab grille.
Installing the cab grille
1. Fit the grille and tighten the attachment
bolts (2) of the hinges.
2. Support the grille in the open position and
install the upper gas damper attachment (1)
to the grille. If applicable, use new split pins.
4
3. Close the grille.
K1 01 516
ᓻ 200345 4-35
4.21 REMOVAL AND INSTALLATION, LOWER GRILLE
Removing the lower grille

1. Open the bottom step and push the rubber
attachment strip back through the opening.
2. Remove the attachment bolts.
3. Close the bottom step and remove the
lower grille by pulling it upwards from the
attachment points.
4
K100424
K100425
Installing the lower grille

1. Close the bottom step.
2. Install the lower grille. Make sure that the
steps have been folded in and that the grille
is securely fastened against the front by
means of the attachment clips.
3. Fit the attachment bolts.
4. Open the steps and pull the rubber
attachment strips through the gaps in the
steps.
4-36 ᓻ 200345
4.22 REMOVAL AND INSTALLATION, STEEL BUMPER
Removing the steel bumper

1. If fitted, remove the combination lamps or
the covers.
2. Remove the four attachment bolts (A) on
the inside of the combination lamp B
installation opening.
A
3. Remove the four attachment bolts (B) on
the front of the bumper.
4. Remove the bumper.
B
4
K100363
Installing the steel bumper

1. Fit the bumper and hand-tighten the two
socket-head screws on the front of the
bumper.
2. Fit the four attachment bolts to the inside of
the combination lamp installation opening.
3. Fit the two remaining attachment bolts.
4. Make sure that the bumper is properly
aligned with the other parts. Tighten the
bumper attachments.
5. If applicable, fit the combination lamps or
the covers.
ᓻ 200345 4-37
4.23 REMOVAL AND INSTALLATION, ROOF HATCH
Removing the roof hatch

1. Remove the cover panel (2) from the roof
hatch.
2. Remove the blind hatch (4).
3. Remove the screws (5) on the inside of the
cab and remove the roof hatch (6). 6
Installing the roof hatch
1. Install the roof hatch (6).
2. Install the blind hatch (4) using attachment
screws (3).
3. Install the cover panel (2) using attachment
screws (1).
4
5
4 3
2
1
K1 01 503
4-38 ᓻ 200345
4.24 REMOVAL AND INSTALLATION, SUPER SPACE CAB ROOF
When using cleaning agents,

primers, glue removers and glues,
be sure to follow the applicable
safety instructions.
Excess cleaning agent, primer, glue

remover and glue which has not set
must be disposed of as chemical
waste. Glue which has set is not
classified as chemical waste.
Removing the Super Space Cab roof

1. Remove the interior compartments and
interior upholstery.
2. Disconnect the electrical connections
(wiring harnesses). 4
3. Remove the electrical roof hatch.
4. Saw off the polyester roof, approximately 10
cm from the bottom, and remove the roof
from the cab.
5. Cut through the sealing compound between
this edge and the steel cab.
6. Break off the polyester edge from the steel
cab in pieces.
7. Cut away as much of the sealant remnants
as you can from the roof edge. A thin layer
may remain.
8. Check that there is no gel coating (polyester
top coat) on the inside of the roof edge.
9. Check that there is no finishing coat or
bitumen coating on the part to be glued.
ᓻ 200345 4-39
Pre-treatment of cab front, cab drip channel

and polyester roof
Note:
The cab front is understood to mean the edge
above the windscreen.
1. Clean the places to which glue is to be
applied with a clean, non-pilling cloth
moistened with the specified cleaning
agent, see ”Technical data”.
2. Lightly sand the surface of the cab front
and polyester roof to be glued with the
specified abrasive, see ”Technical data”.
3. Clean the sanded surface again with the
specified cleaning agent, see ”Technical
data”.
4 4. Allow the cleaned surface to dry for at least
10 minutes at room temperature.
5. Check that the surface to be glued is free of
abrasives and other impurities. If necessary,
repeat the cleaning operation.
6. Using a brush, apply a thin, covering layer
of the specified primer to the surface of the
cab drip channel and polyester roof to
be glued, in accordance with the supplier’s
instructions, see ”Technical data”.
7. Allow the primer layer to dry for at least 30
minutes but no more than 24 hours at room
temperature.
4-40 ᓻ 200345
Gluing the roof to the cab

See ”Technical data” for the type of glue to be
used for the cab drip channel and the cab front
when gluing the roof onto the cab.
Pay attention to the following when installing the
roof onto the cab:
- Depending on the space available, apply 2
triangular beads of glue to the neck of the
8 mm
pre-treated cab drip channel. The beads
should measure about 8x12 mm (wxh).
Give the spraying nozzle the shape shown
in the drawing.
- At approx. 10 mm from the top of the front 12 mm
piece, apply a triangular bead of glue
measuring 8x12 mm (wxh). After positioning K1 00 721
the roof, apply a finishing bead of glue to
the front of the cab.
Setting:
It will take 2 days (48 hours) before
4
the glue is entirely set. Until then
the vehicle must not be driven.
ᓻ 200345 4-41
4.25 REMOVAL AND INSTALLATION, SUPER SPACE CAB PLASTIC SUN VISOR


Surface condition of the polyester roof

The outside of the roof has a gel coating
(polyester top coat).
Do not apply a finishing coat to the gluing
4 surface!
Removing the plastic sun visor
1. Remove the plastic sun visor by carefully
cutting the sealant between the polyester
roof and the plastic sun visor.
2. Remove as much of the sealant remnants
as you can from the polyester roof edge.
Pre-treating the plastic sun visor
The pre-treatment described below guarantees
that the entire surface which will come into
contact with the glue will be covered with a
suitable layer of primer.
1. To prevent the sun visor from being fouled
with primer or glue and to prevent damage
due to sanding, tape up the edges of the
area of the sun visor to be glued with thin,
smooth, adhesive tape.
2. Those areas of the plastic sun visor which
are to be glued should be cleaned
beforehand with a non-pilling, clean, white
cloth moistened with the specified cleaning
agent, see ”Technical data” and then lightly
sanded with the specified abrasive, see
4-42 ᓻ 200345
3. The sanded surface should be cleaned

once again with the specified cleaning
agent, see ”Technical data” and allowed to
dry for a minimum of 10 minutes at room
temperature.
4. Check whether the surface is free of
abrasives and other impurities and repeat
the cleaning process if necessary.
5. Next, using a brush apply a single or at
most two thin covering layers of the
specified primer, in accordance with the
supplier’s instructions, see ”Technical data”.
Allow this layer to dry at room temperature
for at least 30 minutes but no longer than 24
hours. Instead of using a brush you may
also use a felt-tip canister with soft felt.
Pre-treating the polyester roof (gel-coated
side)
4
1. Tape up the edges of the area to be glued
with thin, smooth, adhesive tape. When
taping up the edges of the area to be glued,
keep in mind the drip channel to be applied
later.
2. Clean the places to which glue is to be
applied with a clean, non-pilling cloth
moistened with the specified cleaning
agent, see ”Technical data”.
3. Lightly sand the surface of the cab front
and polyester roof to be glued with the
4. Clean the sanded surface again with the
data”.
5. Allow the cleaned surface to dry for at least
10 minutes at room temperature.
6. Check that the surface to be glued is free of
abrasives and other impurities. If necessary,
repeat the cleaning operation.
7. Using a brush, apply a thin, covering layer
of the specified primer to the surface to be
glued, in accordance with the supplier’s
instructions, see ”Technical data”.
8. Allow the primer layer to dry for at least 30
minutes but no more than 24 hours at room
temperature.
ᓻ 200345 4-43
Gluing the plastic sun visor
ATTENTION:
- Because a film forms on the beads of glue
(something which has a very negative
impact on the quality of the glue), it should
take no longer than 10 minutes to apply the
beads, glue the surfaces together and fix
them.
- Apply the beads of glue no more than 8
hours after the pre-treatment with primer.
See ”Technical data” for the type of glue to be

used for gluing the plastic sun visor to the cab.
8 mm
Give the spraying nozzle the shape shown in the
drawing.
4 12 mm
K1 00 721
Apply 3 triangular beads of glue measuring 8x12

;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;
mm (wxh) between the vertical spacer ribs on
the polyester roof (4).
- 1 bead at approx. 10 mm (3) distance from 10 mm
the bottom of the roof (4),
;; 1
- 1 bead at approx. 10 mm (1) distance from
where the top of the sun visor (5) is to be =
located,
;;
- 1 bead in line with the middle (2) of the sun 8 mm 2

visor (5).
Note: =
Immediately after applying the beads of glue, fit
the sun visor and press it until the glued seam is
3+1 mm thick. The sun visor should be
;;
10 mm 3
supported in this position for at least 2 hours.
Immediately after gluing, remove any excess
glue with a plastic filling knife or spatula and
smoothen the surface.
4
12 mm
5
K1 01 486
4-44 ᓻ 200345
Setting
The glue should set for at least 2 hours at 20_C
and 65% relative humidity before any further
treatment takes place.
It will take 2 days (48 hours) before
Sealing the plastic sun visor 2

Apply sealant (3) in the seam between sun visor
;
;
;;;;;;;;;;;;;
(1) and polyester roof (2). The sealant (3) at the 3
;;;;;;
top should be finished off in the form of a drip
;
;
channel. 1
;
Seal with the specified sealant. See ”Technical
;
;
data”.
;
;
;;;
4
;
; ;
; ;
; ;;;
;;;
;
; ;
; ;
;
3
;
; ;
; ;
;
K1 01 485
ᓻ 200345 4-45
4.26 REMOVAL AND INSTALLATION, SUPER SPACE CAB PLASTIC SUN VISOR


Removing the plastic roof window

1. Remove the plastic roof window by carefully
cutting the sealant between the polyester
roof and the plastic roof window.
4 2. Remove as much of the glue remnants as
you can from the window seal. A thin layer
of glue may remain. If transparent primer
has been used instead of black primer, it
should be removed entirely.
Surface condition of the polyester roof

The outside of the roof has a gel coating
(polyester top coat).
Do not apply a finishing coat to the gluing
surface!
Pre-treating the polyester roof
with thin, smooth, adhesive tape.
2. Those polyester areas which are to be

glued should be cleaned beforehand with a
non-pilling, clean, white cloth moistened
with the specified cleaning agent, see
”Technical data” and then sanded with the
The sanded surface should be cleaned
agent and allowed to dry for a minimum of
10 minutes at room temperature. Check
whether the surface is free of abrasives and
other impurities and repeat the cleaning
process if necessary.
4-46 ᓻ 200345
3. Use a brush to apply a single (or at most 2)

thin, covering layer of the specified primer,
in accordance with the supplier’s
instructions, see ”Technical data”. Allow this
layer to dry for at least 30 minutes but no
more than 24 hours at room temperature.
When the roof is new
with thin, smooth, adhesive tape.
2. Clean the area to be glued with a clean,
non-pilling cloth moistened with the
data”.
3. Then lightly sand the area to be glued with
the specified abrasive, see “Technical data”.
4. Clean the area to be glued once again with
a clean, non-pilling cloth moistened with the 4
data”. Allow the cleaned surface to dry for at
least 10 minutes at room temperature.
5. In places where there is no primer layer,
use a brush to apply a single (or at most 2)
thin, covering layer of the specified primer in
accordance with the supplier’s instructions,
see ”Technical data”. Allow this layer to dry
for at least 30 minutes but no more than 8
hours at room temperature.
ᓻ 200345 4-47
Pre-treating the plastic window when

re-using the window
Check the length and width of the window (when
re-using the window). The length should be no
more than 1860 mm and the width no more than
160 mm.
1. If the window has been used before,
remove as much of the glue remnants as
possible. A thin layer of glue may remain.
2. On the inside of the window, tape up the
edges of the area to be glued with thin,
smooth, adhesive tape.
3. Those window areas which are to be glued
should be cleaned beforehand with a
non-pilling, clean, white cloth moistened
with the specified cleaning agent, see
4 ”Technical data” and then sanded with the
The sanded surface should be cleaned
agent and allowed to dry for a minimum of
10 minutes at room temperature. Check
whether the surface is free of abrasives and
other impurities and repeat the cleaning
process if necessary.
4. Use a brush to apply a single thin, covering
layer of the specified primer, in accordance
with the supplier’s instructions, see
”Technical data”. Allow this layer to dry for
at least 30 minutes but no more than 24
hours at room temperature.
4-48 ᓻ 200345
Pre-treating the plastic window when

re-using the window
1. Clean the area to be glued with a clean,
non-pilling cloth moistened with the
data”.
2. Then lightly sand the area to be glued with
the specified abrasive, see “Technical data”.
3. Clean the area to be glued once again with
a clean, non-pilling cloth moistened with the
data”. Allow the cleaned surface to dry for at
least 10 minutes at room temperature.
4. Make sure the area to be glued is entirely
free from abrasives and other impurities (if
necessary, re-clean the area with the
data”).
4
5. Use a brush to apply a single thin, covering
layer of the specified primer , in accordance
with the supplier’s instructions. Allow this
layer to dry for at least 30 minutes but no
more than 24 hours at room temperature.
ᓻ 200345 4-49
Gluing the plastic window
ATTENTION:
- Because a film forms on the beads of glue
(something which has a very negative
impact on the quality of the glue), it should
take no longer than 10 minutes to apply the
beads, glue the surfaces together and fix
them.
- Apply the beads of glue no more than 8
hours after the pre-treatment with primer.
Note:
Open the vehicle windows in order to cushion
shock waves caused by closing the vehicle
doors. Avoid making the vehicle vibrate while
the glue is setting, as this could cause the
4
window to shift out of place.
1. Give the spraying nozzle the shape shown

in the drawing.
8 mm
12 mm
K1 00 721
2. Apply an 8x12 mm (wxh) bead of glue (see

illustration) in the neck of the window seal.
Use the specified glue for gluing the plastic
window, see ”Technical data”.
3. Fit the window into the frame and press it
into the bead of glue in such a way that the
window lines up evenly with the outside of
the polyester roof.
8mm
4. Immediately after fitting the window, fix it 12mm
into place with sturdy tape at a few points to
prevent it from shifting.
K100238
4-50 ᓻ 200345
5. Remove any excess glue with a plastic

spatula and smoothen the glued seam flat.
Glue remnants which are not yet dry can be
removed with the specified glue remover,
see ”Technical data”. Beads of glue which
have already set can only be removed
mechanically (cutting).
Note:
When using a glue remover, make sure this
does not come into contact with the area to
be glued, as this would seriously reduce the
quality of the glue bead.
Setting
The glue should set for at least 2 hours at 20_C
and 65% relative humidity before any further
treatment takes place.
Sealing the plastic window

Apply sealant (3) in the seam between window 2 4
(1) and polyester roof (2).
Seal with the specified sealant. See ”Technical 3
data”.
It will take 2 days (48 hours) before 1
K1 01 484
ᓻ 200345 4-51
4-52 ᓻ 200345
1 CAB SUSPENSION
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.1 Cab suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.2 Principle of air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0209
2.3 Sectional drawing of air suspension element . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0209
3.1 Inspection and adjustment, cab suspension with
coil spring elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
3.2 Inspection and adjustment, cab suspension with
air suspension elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0209
4.1 Removal and installation, stabiliser bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0209
4.2 Removal and installation, cab support silentblock . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . 0209
4.3 Removal and installation, stabiliser bar slide bearing bushes . . . . . . . . . . . . 4-5 . . . . . . 0209
4.4 Removal and installation, coil spring front suspension . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0209
4.5 Removal and installation, front air suspension . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 0209
4.6 Removal and installation, rear coil spring suspension . . . . . . . . . . . . . . . . . .
4.7 Removal and installation, rear air suspension . . . . . . . . . . . . . . . . . . . . . . . . .
4-11 . . . . .
4-12 . . . . .
0209
0209 5
4.8 Removal and installation, cab locking mechanism . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0209
4.9 Removal and installation, complete cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0209
ᓻ 0209 1
CAB SUSPENSION 1
2 ᓻ 0209
1 CAB SUSPENSION
General
cab fully forward if work must be carried out
underneath the cab.

5
Inspection after a collision

cab for cracks.
past its end stop.
ᓻ 0209 1-1
CAB SUSPENSION 1

After a collision, always check the lifting
cylinder for internal damage. Replace the lifting
cylinder if damaged or if in doubt.
1-2 ᓻ 0209
1 CAB SUSPENSION
95XF series General
2. GENERAL
2.1 CAB SUSPENSION
The F249 cab is attached to the chassis at four

different points. There are two types of cab
suspension:
- spring suspension
- air suspension.
Spring suspension
The cab is attached to the chassis with front and
rear coil spring elements. Depending on the type
of cab, this suspension may or may not be
adjustable. There is a stabiliser at the front.
Air suspension
The cab is attached to the chassis with front and
rear air suspension. The system is equipped
with height control valves and anti-dive valves.
The system has a stabiliser at the front.
At the back, the cab is also damped laterally by
two horizontal dampers.
5
ᓻ 0209 2-1
CAB SUSPENSION 1
General 95XF series
2.2 PRINCIPLE OF AIR SUSPENSION
The air suspension consists of an air bellows

with an internal shock absorber.
The system is fitted with height control valves
and an electropneumatic valve at the front which
is used to disable the height control.
8 1
10-11
5 2-3
9
4
6
5
7
K100441
2-2 ᓻ 0209
1 CAB SUSPENSION
95XF series General
Item Description Location Note

1 Height control valve Rear right-hand side of the cab
2 Cab suspension relay Central fuse box, cab
3 Relay Central fuse box, cab
4 Height control valve Non-driver side behind front grille
5 Spring element Left- and right-hand sides under cab front
6 Height control disable Front left behind bumper
valve
7 Air reservoir Front left underneath bumper Capacity
7 litres
8 Spring element Left- and right-hand sides under cab rear
9 Approximation switch In left-hand cab lock
10 Air reservoir Central rear of the cab Capacity
7 litres
5
11 Horizontal damper Left- and right-hand sides under cab rear
ᓻ 0209 2-3
CAB SUSPENSION 1
General 95XF series
1000
1010
E013
E030
1209 G036
30
87A
87
D722 D759 G297

1 1
P C020 C021
E511 G297
3475
2
2
5
A000 3
1104
4 5
4602
3412
4589
85
CTE 1 B294
G036
(13)
D758 2 1
2
86
F616
4
CWS
(A11)
M
K100812
Basic codes Description

B294 Valve at front, switching off cab suspension height control
D758 Diode to prevent feedback CWS
D759 Diode to prevent feedback to brake lights
D722 Diode to prevent feedback CTE
E030 Fuse, brake lights, 10A
E013 Fuse, horn, 10A
G036 Brake light relay
G297 Cab air suspension relay
F616 Cab locking sensor
E511 Brake light control switch
2-4 ᓻ 0209
1 CAB SUSPENSION
95XF series General
When the brakes are operated, valve B294 is

activated through relay G036, causing the
height control to block (connection between the
height control valve and the cab air suspension
is interrupted).
The height control is also blocked if relay G297
is activated. This situation occurs when the cab
is tilted (switch F616 is closed).
Pneumatic diagram of cab air suspension
A
7 ltr
5
B 294
B
7 ltr
1
K100382
ᓻ 0209 2-5
CAB SUSPENSION 1
General 95XF series
2.3 SECTIONAL DRAWING OF AIR SUSPENSION ELEMENT
1 Attachment eye
2 Rebound rubber
3 Piston rod
4
5
Flange seam seal
Sealing ring
1
6 Rod guides
2
3
4
5
6
K1 01 451
2-6 ᓻ 0209
1 CAB SUSPENSION

3.1 INSPECTION AND ADJUSTMENT, CAB SUSPENSION WITH COIL SPRING
ELEMENTS
Cab suspension with coil spring elements

If the cab has adjustable coil spring elements,
these have been factory set in the neutral
position. In the event of a higher cab weight
(more than 60 kg), for instance, because
accessories have been installed, or if there is
always a co-driver, this neutral position may be
different.
Note:
Ensure that the vehicle is standing on a level
and horizontal surface.
On vehicles with air suspension make sure that
the system is at maximum service pressure and
that the vehicle is at normal driving height.
If the cab floor is not parallel with the chassis,
the suspension must be adjusted.
Inspecting and adjusting front cab

5
suspension
1. Remove the lower grille.
2. Measure distance “A” at the front between
the bumper and the underside of the
stabiliser.
A
K100813
3. If necessary, adjust the spring elements by

turning the ring (1). For the setting value,
see “Technical Data”.
4. Install the lower grille. 1
K1 00 702
ᓻ 0209 3-1
CAB SUSPENSION 1
Inspecting and adjusting rear cab

suspension
1. Measure distance “B” at the rear between

the top of the bracket and the centre of the
upper attachment bolt.
K100814
2. If necessary, adjust the spring elements by

turning the ring (1). For the setting value,
see “Technical Data”.
1
K1 00 702
3-2 ᓻ 0209
1 CAB SUSPENSION
3.2 INSPECTION AND ADJUSTMENT, CAB SUSPENSION WITH AIR

SUSPENSION ELEMENTS
Inspecting and adjusting front cab

suspension
1. Bring the system up to maximum service
pressure.
Risk of being trapped when cab
suspension is vented.
A
2. Vent the cab suspension using the height
control valve.
3. Then allow the height control valve to raise
the cab to the proper height and measure
distance “A” between the top of the cross
beam and the bottom of the stabiliser. K100348
4. Correct the height by changing the length of

the control rod or by shifting the height
control valve (depending on the version).
For the setting value, see “Technical Data”.
5
Note:
The air bellows must be vented before each
new measurement. After this, the height control
valve will adjust to the set height.
ᓻ 0209 3-3
CAB SUSPENSION 1
Inspecting and adjusting rear cab

suspension
1. Bring the system up to maximum service
pressure.
Risk of being trapped when cab
suspension is vented.
2. Vent the cab suspension using the height

control valves.
3. Then allow the height control valve to raise
the cab to the proper height and measure
distance “B” between the top of the bracket
and the centre of the attachment bolt.
B
4. If this height must be adjusted, loosen the
attachment bolts of the height control valve.
After this, the height can be adjusted by
changing the position of the valve. For the
setting value, see “Technical Data”.
5 Note:
The air bellows must be vented before each
new measurement. After this, the height control
valve will adjust to the set height.
K100349
3-4 ᓻ 0209
1 CAB SUSPENSION

4.1 REMOVAL AND INSTALLATION, STABILISER BAR
When working on the cab

suspension provide extra supports
for the cab to avoid the risk of being
trapped.
Removing the stabiliser bar 7

8
1. Remove the cab grille, lower grille and 11
corner pieces. 8 7
2. Lift the cab at the front in such a way as to

make it possible to remove the cab bearing
pin.
6 1
3. Bleed the reservoirs (only applies to air 5 2
suspension elements).
4. Remove the pipes to allow grease
lubrication.
5. Remove the grease lubrication connection
nipple (1).
10 5
3 4
6. Using a drop stamp, remove the sealing
plug (2). (9)
K100821
7. Remove the locating bolt (3) from the

silentblock (4).
8. Remove the locking bolt at the front of the
stabiliser bar.
9. Remove the cab bearing pin (5) at the front.
10. Remove the stabiliser bar.
Installing the stabiliser bar
1. Install the stabiliser bar and insert the
locating bolt (3) through the silentblock.
2. Apply Loctite to the locating bolt and tighten
it to the specified tightening torque. See
ᓻ 0209 4-1
CAB SUSPENSION 1
3. Manufacture an assembly fork from thin

sheet metal (see figure) to facilitate the
installation of the cab suspension. 1
4. Bring the cab bracket, stabiliser bar and
suspension element together in such a way
as to be able to install the cab bearing pin.
While installing, ensure that the recess in
the bearing pin aligns with the opening in
the locking bolt.
A
5. Fit the locking bolt.
6. Fit the sealing plug using a plastic hammer.
7. Fit the grease lubrication connection nipple.
8. Connect the grease lubrication pipes. 2
9. Carefully tilt the cab back.
10. Fit the cab grille, lower grille and the corner
pieces around the headlights.
K100414
4-2 ᓻ 0209
1 CAB SUSPENSION
4.2 REMOVAL AND INSTALLATION, CAB SUPPORT SILENTBLOCK

trapped.
Removing cab support silentblock

2. Remove the cab support(s) of the chassis
3. Using the special tool (DAF no 1329401)
push the silentblock out of the support.
K100557
ᓻ 0209 4-3
CAB SUSPENSION 1
Installing cab support silentblock

1. Using the special tool (DAF no 1329401)
push the silentblock into of the support(s).
2. Fit the support to the chassis and tighten
the attachment bolts to the specified
tightening torque. See “Technical data”.
3. Fit the stabiliser bar.
K100558
4-4 ᓻ 0209
1 CAB SUSPENSION
4.3 REMOVAL AND INSTALLATION, STABILISER BAR SLIDE BEARING

BUSHES

trapped.
Removing the stabiliser bar slide bearing

bushes
2. Remove both slide bearing bushes (A) and
sealing rings (B) by tapping them out of the
stabiliser bar.
B
K100819
ᓻ 0209 4-5
CAB SUSPENSION 1
Installing the stabiliser bar slide bearing

bushes
1. Use the special tool (DAF no. 1240493) to
fit the slide bearing bushes and sealing
rings.
2. Fit the stabiliser bar.
K100415
4-6 ᓻ 0209
1 CAB SUSPENSION
4.4 REMOVAL AND INSTALLATION, COIL SPRING FRONT SUSPENSION

trapped.
Removing front spring suspension

1. Remove the cab grille, lower grille and
corner pieces.
pin.
3. Remove the pipe to allow grease
lubrication.
4. Remove the grease lubrication connection 7

8
nipple (1). 11
8 7
5. Using a drop stamp, remove the sealing
plug (2).
5
stabiliser bar. 1
6 2
5
7. Remove the cab bearing pin (5) at the front.
Make sure that the stabiliser bar cannot
rotate.
8. Detach the coil spring element at the
bottom. 10
9. Remove coil spring element. 3 4
(9)
K100416
ᓻ 0209 4-7
CAB SUSPENSION 1
Installing front spring suspension

1. Fit the coil spring element and tighten the
attachment nut at the bottom to the
specified tightening torque. See “Technical
data”.
2. Bring the cab bracket, stabiliser bar and coil
the locking bolt.
3. Fit the locking bolt for the cab bearing pin.
6. Connect the grease lubrication hose.
7. Carefully lower the cab.
5
4-8 ᓻ 0209
1 CAB SUSPENSION
4.5 REMOVAL AND INSTALLATION, FRONT AIR SUSPENSION

trapped.
Removing front air suspension

1. Bleed the air pressure system.
2. Remove the cab grille, lower grille and
corner pieces.
pin.
4. Remove the pipe to allow grease
lubrication.
5. Remove the grease lubrication connection

nipple (1). 7 8
6. Using a drop stamp, remove the sealing 8 7
11
5
plug (2).
stabiliser bar.
6 1
8. Remove the cab bearing pin (5) at the front. 5 2
Make sure that the stabiliser bar cannot
rotate.
12
9. Remove the air pipe from the air
suspension element (12).
10
10. Detach the air suspension element at the
bottom. 3 4
11. Remove the air suspension element (12). (9)
K1 01 529
ᓻ 0209 4-9
CAB SUSPENSION 1
Installing front air suspension

1. Fit the air suspension element and tighten
the attachment nut at the bottom to the
specified tightening torque. See “Technical
data”.
2. Bring the cab bracket, stabiliser bar and
the locking bolt.
3. Fit the locking bolt for the cab bearing pin.
6. Connect the grease lubrication hose.
7. Connect the air pipe to the air suspension
element.
5 8. Carefully lower the cab.

9. Pressurise the system.
4-10 ᓻ 0209
1 CAB SUSPENSION
4.6 REMOVAL AND INSTALLATION, REAR COIL SPRING SUSPENSION
Removing rear coil spring suspension

1. Tilt the cab.
2. Remove the coil spring element by

loosening the attachment bolt (A) a few
turns and loosening attachment bolt (B) and
attachment nut (C).
Installing rear coil spring suspension
1. Fit the coil spring element and hand-tighten
the attachment bolts and nut.
2. Tilt the cab back to the normal driving
position.
A
3. Tighten the attachment bolts and nut to the
specified tightening torque, see “Technical B
data-.
K1 01 450
ᓻ 0209 4-11
CAB SUSPENSION 1
4.7 REMOVAL AND INSTALLATION, REAR AIR SUSPENSION
Removing rear air suspension

1. Bleed the air pressure system.
2. Tilt the cab.
3. Disconnect the air pipe from the air
suspension element.
4. Remove the air suspension element by

loosening the attachment bolt (A) a few
turns and loosening attachment bolt (B) and
attachment nut (C).
Installing rear air suspension
1. Fit the air suspension element and
hand-tighten the attachment bolts and nut.
2. Connect the air pipe to the air suspension
element.
A
5
B
specified tightening torque, see “Technical
data-.
5. Pressurise the system.
K1 01 449
4-12 ᓻ 0209
1 CAB SUSPENSION
4.8 REMOVAL AND INSTALLATION, CAB LOCKING MECHANISM
Only use approved lifting

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

1. Tilt the cab until it is released from the cab
lock.
2. Support the cab by means of a hoist.
3. Switch the tilting pump to reverse tilting.
4. Remove the approximation switch

connector (C) at the right-hand side.
5. Remove the hydraulic line (D) and plug it.
Collect any oil flowing out of the system.
6.
7.
Remove the attachment bolts (A and B).
Remove the cab lock.
5
Installing cab lock mechanism
1. Install the cab lock and hand-tighten the
attachment bolts.
A
2. Connect the connector (C) and fit the B
hydraulic line (D).
D
3. Carefully tilt the cab back to the normal
driving position. When doing so, ensure that
the cab locks are open. C
data-.
5. Bleed the tilting mechanism.
K100420
ᓻ 0209 4-13
CAB SUSPENSION 1
4.9 REMOVAL AND INSTALLATION, COMPLETE CAB
Only use approved lifting

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

1. Disconnect the battery earth lead.
2. Open the cab grille.
Note:
Work on the air conditioning unit should only be
carried out by qualified personnel.
3. If present, drain the air conditioning unit.
4. Drain the clutch fluid.
5. Disconnect the clutch pipe.
5 6. Partially drain the coolant.

7. Remove the heater hoses at the connector
pipes.
8. Tilt the cab forwards.
9. Remove the lower grille and the two side
spoilers around the headlights.
10. Remove the steering column joint from the
steering box and tie it up.
11. Remove the throttle cable.
12. Disconnect the tachograph cable from the
gearbox and tie the cable to the cab.
13. Remove the engine noise insulation
underneath the cab and tilt the insulation
onto the engine.
14. Remove the connection blocks from the air
pipes and tie them to the cab.
15. In the case of a Hydraulic Gear Shift (HGS)
control, remove the pipes at the coupling
piece. Collect the oil and plug the pipes in
such a way as to prevent dirt from entering
them.
4-14 ᓻ 0209
1 CAB SUSPENSION
16. In the case of a Mechanical Gear Shift

(MGS) control, remove the attachment bolts
at the bottom of the rocker strip.
17. Remove the floor connectors and, if an
E-gas system has been fitted, the E-gas
connector.
18. Remove the connections and wiring of the
automatic grease lubrication system.
19. Remove the rear attachment bolts from the
cab hinges on the left-hand and right-hand
sides.
20. Place wooden blocks onto the rear cab
locks and tilt the cab back.
21. Remove the lifting cylinder at the bottom of
the cab.
22. Remove the door rubbers from the seal on
the left-hand and right-hand sides to install
5
the lifting yoke.
23. Install the lifting yoke (special tool
DAF no. 1329438) with filling.
24. Hang the cab in the lifting yoke in such a
way as to provide sufficient support for the
cab.
25. Remove the lower attachment points of the
front suspension.
26. Remove the front left and front right

attachment bolts (J) from the cab
silentblocks.
27. Hoist the cab from the chassis; while J
hoisting, check whether any cables/pipes
are still connected to the cab. Place the cab
onto a suitable cab stand or onto supports,
protecting the plastic substructure against
K
any damage.
K100417
ᓻ 0209 4-15
CAB SUSPENSION 1
Installing complete cab

1. Use the lifting beam to place the cab onto
the chassis.
2. Fit the front left and front right attachment

bolts (J) of the silentblocks.
3. Attach the spring elements at the bottom.
4. Remove the lifting yoke.
J
5. Attach the lifting cylinder to the cab and
tighten the attachment bolts temporarily to a K
tightening torque of 125 Nm.
6. Tilt the cab slightly forwards and remove the
wooden blocks on the cab locks. Tilt the cab
back again. H
7. Tighten the attachment bolts to the
data”. G
5
8. Tilt the cab forwards.
9. Tighten the upper attachment bolts of the F
lifting cylinder to the specified tightening
torque. See “Technical data”.
K100417
10. Fit the universal joint on the splines of the

steering shaft or steering box. Line up the
groove (A) in the clutch with mark (B) on the
steering shaft or steering box.
Check that the universal joint is
correctly in place on the steering
shaft or steering box so that the
attachment bolt can be put in the
notch (C).
11. Only fit a new attachment bolt with nut to B

the universal joint. Tighten the bolt to the
A
data”. C
K1 01 353
4-16 ᓻ 0209
1 CAB SUSPENSION
12. Position the air pipes and connect the

connector blocks.
13. Connect the clutch pipe.
14. Install the air conditioning pipes and secure
them using the attachment nuts.
15. Connect the cable and attach it to the
chassis.
16. Connect the heater hoses to the connector
pipes.
17. Connect the floor connectors and E-gas
connector.
18. In the case of a HGS shift control, connect
the pipes to the coupling piece. Ensure that
no dirt enters the pipes during assembly.
19. In the case of an MGS shift control, fit the

attachment bolts at the bottom of the rocker
5
strip and tighten them.
20. Install the engine noise insulation
underneath the cab.
22. Install the roof hatch rim and the roof hatch
glass.
23. Fit the door rubbers to the left and right.
24. Fill and bleed the clutch main cylinder.
25. Fill the cooling system.
26. Connect the battery. V300156
27. Let the engine idle and top up the cooling

system, if necessary.
28. If applicable, bleed the HGS switch control.
29. If applicable, fill the air conditioning system.
30. Check the lighting and all connections.
ᓻ 0209 4-17
CAB SUSPENSION 1
4-18 ᓻ 0209
1 CAB TILTING MECHANISM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.1 Operation, tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.2 Overview drawing, cab tilting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0209
2.3 Overview drawing, lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0209
3.1 Inspecting tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
3.2 Inspection and adjustment, pressure limiting valve of
cab tilting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . . 0209
4.1 Removal and installation, cab tilting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0209
4.2 Removal and installation, lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0209
4.3 Removal and installation, cab tilting pump seals . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0209
4.4 Removal and installation, two-way valve of cab tilting pump . . . . . . . . . . . . . 4-7 ...... 0209
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0209
5.1 Disassembly and assembly, lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0209
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0209
6.1 Draining, bleeding and refilling tilting mechanism . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0209
ᓻ 0209 1
CAB TILTING MECHANISM 1
2 ᓻ 0209
General
underneath the cab.

Inspection after a collision 6

cab for cracks.
past its end stop.

ᓻ 0209 1-1
Replacing the lifting cylinder:

After a collision, always check the lifting
cylinder for internal damage.
Replace the lifting cylinder if damaged or if in
doubt.
Always replace the cylinder if one of the
following points has occurred during a collision:
A. the cab has been pulled out of the cab
locks,
B. the cab locks have been deformed or
damaged,
C. the rear springs have been deformed or
damaged.
1-2 ᓻ 0209
95XF series General
2. GENERAL
2.1 OPERATION, TILTING MECHANISM
General
The F249 cab is equipped with a hydraulic tilting
mechanism. The pump is installed on co-driver’s
side.
The cab locks are automatically opened
hydraulically 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.
After a collision, always check the lifting cylinder
for internal damage.
Tilting the cab:
-
-
Make sure there are no people immediately
in front of the cab.
Make sure there is sufficient clearance
6
around the cab.
- Make sure there are no loose objects inside
the cab.
- Apply the parking brake.
- Move the gear lever to the neutral position
and turn off the engine.
- Close the doors.
- Turn the two-way valve of the cab tilting
pump fully to the right.
- Position the pipe in the pump and operate
the pump.
You can stop the cab tilting forward at any
time by turning the two-way valve to the
left.
- After tilting the cab back, check whether the A
warning lamp on the CWS display is
extinguished. If this lamp continues to burn, B
the cab is not properly locked.
D000393
ᓻ 0209 2-1
General 95XF series
Tilting the cab forward
3
A
4
1
2
5
7 8
6 6
K1 00 706
6 Turn the two-way valve (2) on the pump (1) to

the right (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 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 differential mechanism is based on the
effect of pressure on two different surfaces. 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.
2-2 ᓻ 0209
95XF series General
Tilting the cab back
B 4
1
2
5
7 8
6 6
K1 00 707
Turn the two-way valve (2) on the pump (1) to

the left (position B). The pressure which has
6
built up in the pump will be passed on to the
pressure side of the lifting cylinder (3) and will
simultaneously activate the non-return valve (5)
in the cylinder.
Each stroke of the pump opens the non-return
valve (5). When the non-return valve in the
lifting cylinder opens, oil can flow back into the
pump reservoir from the return side of the lifting
cylinder (3). The cab can therefore only be tilted
back when pressure has built up in the pump.
The pressure in the pump and the pipes drops
at the end of each pump stroke. The non-return
valve now closes. 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 cylinder piston is in the position
which allows a “leak-off” connection (4) between
the areas above and below the cylinder piston.
The warning lamp on the CWS panel will switch
off then.
ᓻ 0209 2-3
General 95XF series
2.2 OVERVIEW DRAWING, CAB TILTING PUMP
Note:
This drawing gives a general view and may
differ from the actual situation.
4 6 7 8 9
2
5
3
18 19
10
6 11
12
13
14
17 15
16
K1 01 500
Legend
1. Two-way valve 11. Magnet
2. O-ring 12. Filter
3. Teflon ring 13. Notched pin
4. Filler plug 14. Inlet ball
5. O-ring 15. O-ring
6. Pin 16. Ring
7. Holder 17. Torx bolt
8. Gasket 18. Lever
9. Reservoir 19. O-ring
10. Pump housing
2-4 ᓻ 0209
95XF series General
2.3 OVERVIEW DRAWING, LIFTING CYLINDER
Legend
1. Dirt scraper
2. Circlip
3. U-cup
4. Upper bearing
5. O-ring
6. Stop ring
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. Seal
17. Coupling
18. Coupling
19. Plastic ring
20. Plastic ring
K100127
ᓻ 0209 2-5
General 95XF series
2-6 ᓻ 0209

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.
Note:
A defective cab tilting mechanism is often the
result of contaminated oil.
ᓻ 0209 3-1
3.2 INSPECTION AND ADJUSTMENT, PRESSURE LIMITING VALVE OF CAB

TILTING PUMP
For inspection and adjustment of

the pressure limiting valve always
use a pressure gauge.
If the pressure is set too high, the

tilting mechanism may be
damaged, which can lead to very
dangerous situations.
Inspecting pressure limiting valve of cab 2

tilting pump
1. Remove the pipes from the pump and plug
the connections (A, B and C) on the pump
with a dummy nipple. A
2. Connect a pressure gauge with a range of
no less than 600 bar to connection (1). B
3. Bleed the pressure gauge hose.

4. Check the oil level in the pump.
C
Note: 1
6 Never check the oil level nor fill the oil
reservoir with the cab in tilted position.
5. Put the two-way valve of the cab tilting
pump in the “lowering” position.
Operate the pump. If the measured
pressure does not match the specified
pressure, see “Technical data”, the K1 01 468
pressure limiting valve must be adjusted.

Note:
The pressure will drop slowly as soon as
pumping is stopped; this is normal. A rapid
pressure drop indicates that the two-way
valve is defective.
6. Remove the pressure gauge and dummy
nipples and connect the piping.
3-2 ᓻ 0209
Adjusting pressure limiting valve of cab

tilting pump
If the set pressure is too high, the 2

end stop may be pressed out of the
lifting cylinder, which causes the
cab to tilt forwards off the chassis.
A
Note:
The pressure limiting valve is located in the B
plunger and can be adjusted via the filler
opening (2) in the cab tilting pump.
1. Remove the pipes from the pump and plug
the connections (A, B and C) on the pump C
with a dummy nipple. 1
2. Connect a pressure gauge with a range of
no less than 600 bar to connection (1).
3. Bleed the pressure gauge hose.
K1 01 468
Note:
Never check the oil level nor fill the oil
reservoir with the cab in tilted position.
5. Remove filler plug (2) and put the two-way 6
valve of the cab tilting pump in the
“lowering” position.
Operate the pump and, using an
appropriate screw driver, set the pressure
limiting valve in the plunger to the specified
pressure, see “Technical data”.
Note:
The pressure will drop slowly as soon as
pumping is stopped; this is normal. A rapid
pressure drop indicates that the two-way
valve is defective.
6. Remove the pressure gauge and dummy
nipples.
7. Connect the pipes.
ᓻ 0209 3-3
3-4 ᓻ 0209

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

1. Disconnect the pipes and collect the oil in a 3
container. 2
2. Remove attachment bolts (2), sealing rings
(3) and remove the pump. Collect any A
remaining oil from the pump in a container.
B
C
1
K1 01 456
Installing cab tilting pump
Note:
Use Teflon tape when fitting the pipes to the
nipples. Caution: Do not use the Teflon tape on
the first turn of the nipple thread. This is to 6
prevent contamination of the system with Teflon
tape.
1. Fit the pump, insert the sealing rings (3)
between the pump and the bracket, and fit
the attachment bolts (2).
- A = pressure pipe (thick pipe, M14)
- B = return pipe (thin pipe, M12)
- C = left-hand cab lock K1 01 502
3. For filling and bleeding the pump, see

“Draining and filling”.
ᓻ 0209 4-1
4.2 REMOVAL AND INSTALLATION, LIFTING CYLINDER
Do not remove the lifting cylinder

while the cab is in the tilted
position.
Removing lifting cylinder

1. Disconnect the pipes and collect the oil in a
container.
Plug off the pipes and connections.
2. Remove the attachment bolts of the
attachment bracket with which the lifting
cylinder is fastened to the top of the cab.
3. Remove the lower attachment bolt used to
attach the lifting cylinder to the chassis, and
remove the lifting cylinder.
;;;;;;
;;;;;;;;;;;;
;;;
4. Remove the attachment bracket (1) of the
lifting cylinder (4) by forcing the pin (2) out
of the bracket, using a press.
;;
6 1 2 3 4
K1 01 454
Installing lifting cylinder
Note:
Use Teflon tape when fitting the pipes to the
nipples. Caution: Do not use the Teflon tape on
the first turn of the nipple thread. This is to
prevent contamination of the system with Teflon
tape.
1. Apply grease to the attachment rings (3) in
the cylinder eye of the lifting cylinder (4).
Press the pin (2) into the attachment
bracket (1) through the cylinder eye of the
lifting cylinder.
Note:
Press the pin into the attachment bracket K1 01 502
until the conical ends of the pin protrude
fully on either side.
4-2 ᓻ 0209
2. Fasten the lifting cylinder to the cab using

the lower attachment bolt. Tighten the
attachment bolt to the specified tightening
3. Fit the attachment bolts of the attachment
bracket at the top of the lifting cylinder.
Tighten the attachment bolts to the
Data”.
5. For filling and bleeding the system, see
“Draining and filling”.
ᓻ 0209 4-3
4.3 REMOVAL AND INSTALLATION, CAB TILTING PUMP SEALS
Notes:
- Use a repair kit for replacing the seals.
- It is not allowed to disassemble the tilting
pump any further than described in this
chapter. A defective cab tilting mechanism
is often due to improper disassembly and/or
assembly of the cab tilting pump.
- Clean the cab tilting pump on the outside.
- Work in a clean environment.
Removing cab tilting pump seals
1. Remove the cab tilting pump.
2. Release the 4 Torx screws used to attach

the reservoir to the pump housing. Collect
the oil in a container.
K100136
3. Take the pump housing off the reservoir and

remove the gasket.
K100137
4-4 ᓻ 0209
4. Remove the filter and the magnet from the

pump housing.
5. Secure the pump housing in a vice as

shown in the opposite figure and carefully
tap the pin out of the holder and lever axle.
K1 01 499
6. Remove the holder and the lever axle.

Remove the O-ring from the lever axle.
K100139
7. Clean the reservoir, filter, magnet and

mating surfaces of the gasket.
ᓻ 0209 4-5
Installing cab tilting pump seals

1. Fit a new O-ring to the lever axle.
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 opposite figure.
K1 01 498
3. Fit the filter and the magnet to the pump

housing.
4. Fit the reservoir with a new gasket to the

6 pump housing, using the 4 Torx bolts.
K100137
5. Install the cab tilting pump.
4-6 ᓻ 0209
4.4 REMOVAL AND INSTALLATION, TWO-WAY VALVE OF CAB TILTING PUMP
Notes:
- Use a repair kit for replacing the two-way
valve.
- It is not allowed to disassemble the tilting
pump any further than described in this
chapter. A defective cab tilting mechanism
is often due to improper disassembly and/or
assembly of the cab tilting pump.
- Clean the cab tilting pump on the outside.
Removing two-way valve of cab tilting pump
1. Remove the cab tilting pump.
2. Tap the notched pin out of the two-way

valve and remove the steel ring. Take the
O-ring out of the steel ring.
K1 01 340
3. Secure the pump housing in a vice as

shown in the opposite figure and carefully
tap the two-way valve with the sealing plug
from the housing. Caution: mark the
position of the two-way valve in the pump
housing to ensure that the new two-way
valve is installed in the correct position.
K1 01 496
ᓻ 0209 4-7
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.
k100144
4-8 ᓻ 0209
Installing two-way valve of cab tilting pump

Notes:
- When the two-way valve is installed, make
sure the holes are correctly positioned
relative to the connections.
- When the two-way valve has been installed,
the pressure limiting valve must be
checked/adjusted. See “Inspection and
adjustment.
1. Fit the new O-ring and the Teflon ring in the
pump housing.
2. Fit the new inlet ball.
3. Lightly oil the new two-way valve. Fit the
new two-way valve and the sealing plug in
the housing. Make sure the holes in the
two-way valve and the connections in the
housing are well positioned.
4. Fit a new O-ring in the steel ring. Fit the

steel ring on the two-way valve and tap the
new notched pin into the two-way valve.
K1 01 340
ᓻ 0209 4-9
4-10 ᓻ 0209
95XF series Disassembly and assembly
5. DISASSEMBLY AND ASSEMBLY

5.1 DISASSEMBLY AND ASSEMBLY, LIFTING CYLINDER
Notes:
- To be able to repair the lifting cylinder,
remove the entire piston rod and replace
the oil seals.
- Reconditioning of a lifting cylinder requires
not only the use of the reconditioning kit,
but also a number of components have to
be reused.
- Before disassembly, clean the lifting
cylinder on the outside.
- A defective lifting cylinder is often caused
by leaking oil seals or a damaged piston
rod.
Never use compressed air to force
the piston rod into or out of the
lifting cylinder. This would involve
the risk of the piston moving into
or out of the lifting cylinder in an
uncontrolled manner.
Disassembling lifting cylinder 6

Note:
Use a separate cab tilting pump to pump the
piston in and out.
1. Take the dirt scraper out of the lifting

cylinder.
K100148
ᓻ 0209 5-1
Disassembly and assembly 95XF series
2. Connect the lifting cylinder to the cab tilting

pump.
K100120
6 Bleed the lifting cylinder to prevent

the piston rod from moving out of
the lifting cylinder in an
uncontrolled manner after the top
circlip has been removed from the
lifting cylinder.
3. Bleed the lifting cylinder by pumping out the

piston rod completely. Now turn the lifting
cylinder upside down (connections facing
upwards). Pump the piston rod 15
centimetres inwards. Now turn the lifting
cylinder round again.
4. Pump the piston rod out approximately
10 mm from the end.
5. 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 ᓻ 0209
6. Remove the upper circlip from the cylinder

and pump the piston rod carefully
completely out of the cylinder. Collect the
outflowing oil in a container.
K100150
7. Remove the circlip from the piston rod and

remove the piston and the O-ring
underneath.
6
K100151
8. Tap the stop ring slightly back and remove

the circlip underneath. Remove the stop
ring and the top bearing from the piston rod.
K100152
ᓻ 0209 5-3
9. Remove the non-return valve from the

cylinder using a 17mm hexagonal socket.
K1 01 344
10. Thoroughly clean all parts.

Note:
Check that the piston, piston rod and the
inside of the cylinder are neither scratched
nor damaged. If one of these parts is
damaged, replace the entire lifting cylinder.
5-4 ᓻ 0209
Assembling lifting cylinder
Note:
The components marked in the figure form part
of the reconditioning kit (6).
1. Position the lifting cylinder upright in a vice
(connections at the top).
2. Fit the non-return valve seat (B) together
with non-return valve (A) and ring (3) into
the cylinder.
Tighten seat (B) to the specified tightening
1
2 A*
3*
4
6* 5
B*
6
K1 01 345
Note:
The components marked in the figure form part
of the reconditioning kit (13).
3. Slide the new dirt scraper (A) over the
piston rod.
4. Slide the new circlip (12) over the piston
rod.
5. Slide the new brass upper bearing (B) over
the piston rod, as shown.
6. Slide the new stop ring (5) over the piston B C A
rod, ensuring that the tapered side fits into 1
the upper bearing. 2
3
7. Fit the new circlip (4), possibly using an 4
5
axle spring clip pliers (outer circlip pliers), 6
into the piston rod groove.
7
8. Fit the new O-ring (2). 8
9
10
11
13 12
A
K1 01 346
ᓻ 0209 5-5
9. Slide the piston (3) over the piston rod until

it touches the stop.
10. Fit the circlip (1) onto the piston rod, using
an axle spring clip pliers (outer circlip
pliers).
11. Tap the brass upper bearing approx. 5 mm
into the cylinder (past the circlip groove)
with a punch. The adhesive surfaces should
be degreased beforehand.
12. Press the piston rod into the cylinder.
B C A
13. Fit the circlip (12) into the cylinder. Pull the 1
piston rod fully out to check whether the 2
circlip is properly seated in the groove. This 3
4
also puts the upper bearing in its final 5
position. 6
14. Apply a thin film of oil to the piston rod and 7
the inside of the cylinder. 8
9
15. Turn the cylinder upside down and press 10
the piston rod into the cylinder using the 11
cab tilting pump. Add another twenty pump 13 12
strokes when the piston has been fully A
6
K1 01 346
pressed into the cylinder to bleed the
cylinder.
16. Press the piston rod out of the cylinder and
pressurise the cylinder. Inspect the latter for
leakage.
17. Tap the dirt scraper (11) evenly into the
cylinder using a plastic or copper hammer.
18. Attach the lifting cylinder underneath the
cab and check its operation.
5-6 ᓻ 0209
95XF series Draining and filling
6. DRAINING AND FILLING

6.1 DRAINING, BLEEDING AND REFILLING 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, lifting cylinder,
pipes and connections for any leakage.
Filling tilting mechanism
1. Remove the filler plug and put the pump
plunger into the lowest position by
completely moving downward the pump
actuating rod.
2. Top up the reservoir with oil, see
specification manual “Fluids and lubricants”,
to the top of the pump plunger.
Bleeding tilting mechanism
Note:
The cab must be tilted completely back into
6
place.
1. Start with approx. 30 full pump strokes while
leaving the two-way valve in the “lowering”
position. If necessary, top up the reservoir
with oil.
2. Fit the filler plug and tilt the cab fully forward
(two-way valve in the “lifting”) position.
Continue pumping and keep the system
pressurised. Check all the connections for
leaks.
3. Tilt the cab back. If necessary, top up the
reservoir with oil.
ᓻ 0209 6-1
Draining and filling 95XF 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 two-way valve into the “tilting”
position and start pumping until this is
clearly getting heavier.
4. Put the pump plunger into the lowest
position by completely moving downward
the pump actuating rod.
5. Top up the reservoir with oil, see
specification manual “Fluids and lubricants”,
to the top of the pump plunger.
6. Fit the filler plug and set the two-way valve
into the “lowering” position.
6-2 ᓻ 0209
1 SEATS
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0209
2.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0209
2.2 Serial/type plate of seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . 0209
2.3 System description, air-sprung seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . 0209
2.4 Overview drawing, high luxury model ISRI 6800 . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . 0209
2.5 Overview drawing, luxury model ISRI 6800 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . . 0209
2.6 Overview drawing, standard model ISRI 6800 . . . . . . . . . . . . . . . . . . . . . . . . 2-10 . . . . . 0209
3.1 Inspection, seat belt operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0209
4.1 Removal and installation, seat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0209
4.2 Removal and installation, seat slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0209
4.3 Removal and installation, seat squab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0209
4.4 Removal and installation, seat squab guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . 0209
4.5 Removal and installation, dust boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . 0209
4.6 Removal and installation, cover panel on control side . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0209
4.7 Removal and installation, side cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0209
4.8 Removal and installation, front cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 0209
4.9 Removal and installation, seat belt guide panel . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . . 0209
4.10 Removal and installation, backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0209
4.11 Removal and installation, arm rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . . 0209
4.12 Removal and installation, seat belt mechanism . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . . 0209
4.13 Removal and installation, seat belt lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 0209
4.14 Removal and installation, backrest air cushions (IPS system) . . . . . . . . . . .
4.15 Removal and installation, heating elements . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9 . . . . . .
4-10 . . . . .
0209
0209
7
4.16 Removal and installation, manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . . 0209
4.17 Removal and installation, height control valve . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . . 0209
4.18 Removal and installation, height adjustment valve . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0209
4.19 Removal and installation, rapid-lowering handle . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0209
4.20 Removal and installation, vertical damping adjuster . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0209
4.21 Removal and installation, seat tilting handle . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0209
4.22 Removal and installation, height adjustment handle . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0209
4.23 Removal and installation, fixed seat height adjustment handle . . . . . . . . . . 4-15 . . . . . 0209
4.24 Removal and installation, backrest adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 . . . . . 0209
4.25 Removal and installation, IPS valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0209
4.26 Removal and installation, air bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0209
4.27 Removal and installation, adjustment cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0209
4.28 Removal and installation, control unit of height control valve . . . . . . . . . . . . 4-20 . . . . . 0209
4.29 Removal and installation, vertical damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . . 0209
4.30 Removal and installation, Bowden cable for fixed seat gas damper . . . . . . 4-22 . . . . . 0209
4.31 Removal and installation, fixed seat gas damper . . . . . . . . . . . . . . . . . . . . . . 4-22 . . . . . 0209
4.32 Removal and installation, seat squab cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . . 0209
4.33 Removal and installation, backrest cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0209
ᓻ 0209 1
SEATS 1
2 ᓻ 0209
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 cracks after a collision.
- After a collision, always check whether
the seat slide and 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.
ᓻ 0209 1-1
SEATS 1
1-2 ᓻ 0209
1 SEATS
95XF series General
2. 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.
- It is necessary, however, to restore routing
of the air pipes and cables and their
connections 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
case.
- 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.
ᓻ 0209 2-1
SEATS 1
General 95XF series
2.1 OPERATION
Legend
A. Back rest adjuster
B. Operating buttons of IPS system
C. Height adjustment
D. Seat tilting adjuster
E. Vertical damping adjuster
F. Rapid-lowering handle
G. Seat position adjuster
H. Seat heating
I. Seat squab adjuster
7 C
D
E
F
I H G
K100350
2-2 ᓻ 0209
1 SEATS
95XF series General
2.2 SERIAL/TYPE PLATE OF SEAT
The serial number (A) and the DAF part number

of the seat are stated 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.
7
A
K100483
ᓻ 0209 2-3
SEATS 1
General 95XF series
2.3 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
11
A
D
7
Rd H 25
Gr
Bl
Br K100482
Legend
A. Rapid-lowering valve
B. Control unit of the level control valve
C. Switch valve
D. Height control valve
E. Level control valve
F. Adjustment cylinder
G. Air bellows
H. IPS (Integrated Pneumatic System)
Rd Red
Gr Grey
Bl Black
Br Brown
2-4 ᓻ 0209
1 SEATS
95XF series General
Colours and functions of the pneumatic

system air pipes
Cab air pressure supply

black Cab air supply to
- quick-release air valve A1
- IPS valve H25 (pneumatic
lumbar support valve)
Pressure reduction for quick-release valve

(top button)
red from pressure reduction for
quick-release valve A2 to
- control valve D10
- height control valve E14
Pressurising/depressurising the air

suspension
brown from height control valve E12 to
- air suspension G18
Quick-release valve, bottom button

brown from air suspension G18 to
- pressure relief valve A19
Pressurising the air suspension during

use
7
grey from height control valve E13 to
- cab
Colours and functions of the height

control air pipes
Seat up
brown from control valve D9 to
- switch valve C5
- switch valve C8
- adjustment cylinder F16
Seat down
grey from control valve D11 to
- “or”-element (switch valve) C6
- “or”-element (switch valve) C7
- adjustment cylinder F17
Seat up/down
black from “or”-element (switch valve)
C4 to
- locking cylinder B3
ᓻ 0209 2-5
SEATS 1
General 95XF series
2.4 OVERVIEW DRAWING, HIGH LUXURY MODEL ISRI 6800
81
80
40-43
60-63 67-70 47-50

44
75
51
65 55
46
7 45
13
17
10
6,8 9 17
29
25 26 16
23 14
15
52
5,7 21
11,12
22
27 20
24 19
18
K100484
2-6 ᓻ 0209
1 SEATS
95XF series General
Item Description Note

1-4 System covers items 5-29
5-8 Cousin guides
9 Rubber bellows with fastening material not shown
10 Guide for seat cushion adjustment (SKTE)
11-13 Side covers
14 Front cover
15 Pneumatic lumbar support assembly LWS = 1 or 2 switch buttons, IPS = 3
switch buttons
16 Height control valve
17 Back rest adjuster Y-section (if any) not shown
18 Quick-release valve assembly
20 Tilting control button
21 Height control knob
22 Shock absorber assembly
23 Air suspension assembly
24 Control disc assembly
25 Adjustment cylinder assembly
26 “Or”-element, complete
27 Level control valve assembly
28 Connections/air pipes not shown
29 Button (back) and switch buttons for LWS/IPS
40-43 Backrest assembly
44 Seat belt cover
45 Seat belt lock without contact switch
46 3-point seat belt
47-50
51
Backrest cover
Air reservoirs LWS/IPS
7
52 Seat heating switch
60-63 Seat cushion assembly
65 Seat cushion adjuster
67-70 Seat cushion cover
80-81 Arm rests
ᓻ 0209 2-7
SEATS 1
General 95XF series
2.5 OVERVIEW DRAWING, LUXURY MODEL ISRI 6800
40
60 67 47
44
65
46
45
13
17
7 26
10
6,8 17
9
27 29
14
5,7 21
11
20
K100485
2-8 ᓻ 0209
1 SEATS
95XF series General

5-8 Cousin guides
9 Rubber bellows with fastening material not shown
10 Guide for seat cushion adjustment (SKTE)
11-13 Side covers
14 Front cover
20 Tilting control button
21 Height control knob
26 Gas spring with mounting material
27 Adjuster cable assembly
29 Button (back)
40 Backrest assembly
44 Seat belt cover
47 Backrest cover
60 Seat cushion assembly
65 Seat cushion adjuster
67 Seat cushion cover
ᓻ 0209 2-9
SEATS 1
General 95XF series
2.6 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 ᓻ 0209
1 SEATS
95XF series General

5-8 Cousin guides
11-13 Side covers
14 Front cover
15-16 Seat cushion cover
29 Control button (back)
40-41 Backrest assembly
44 Seat belt cover
47-48 Backrest cover
80-81 Arm rests
ᓻ 0209 2-11
SEATS 1
General 95XF series
2-12 ᓻ 0209
1 SEATS

3.1 INSPECTION, SEAT BELT OPERATION
- Pull the belt quickly out of its retracting unit

to test the locking action. The belt must
lock. It must not be possible to pull the belt
out any further after locking.
- Check the seat belts for wear.
ᓻ 0209 3-1
SEATS 1
3-2 ᓻ 0209
1 SEATS

4.1 REMOVAL AND INSTALLATION, SEAT ASSEMBLY
Removing seat assembly

1. Remove the air pipes, pressing the side of
the quick-release coupling and pulling the
pipe from the coupling.
2. Remove the seat squab and remove the
seat heating connector (if applicable).
K100412
3. Slide the seat backwards and remove the

front screws (1).
4. Slide the seat forwards and remove the rear
screws (2).
2
Installing seat assembly
1. Place the seat on the ground plate. Make
sure that the air piping does not get pinched
off.
Slide the seat backwards and tighten the
1
front screws (1).
K100487
2. Slide the seat forwards and tighten the back
3.
screws (2).
Connect the air pipe.
7
4. Install the seat heating connector.
5. Tighten the seat to the specified tightening
torque, see “Technical data”
ᓻ 0209 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 pins (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
4.3 REMOVAL AND INSTALLATION, SEAT SQUAB
Removing seat squab

1. Slide the seat squab to the frontmost
position (only for models with seat squab
adjustment (SKTE)).
2. Remove the electric wiring from models with
heated seats.
7 3. Push the control lever (1) up with a

screwdriver (insert the screwdriver between 1
frame -X- and the lever).
3
4. Pull the seat cushion forwards and up.
Installing seat squab 2
1. Slide the seat cushion approx. 20 cm into
the guides at the back.
2. At the same time, push the front of the seat
cushion down and slide it in the front
guides, until the lever (A) clicks into X
position.
3. In the SKTE model, check after assembly
whether the adjuster engages in all
openings of the runner (1). If necessary,
push the runner to the left or the right.
A
K100489
4-2 ᓻ 0209
1 SEATS
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.
2
3. Remove the guide (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, DUST BOOT
Removing dust boot

1. Remove the entire seat. 3
3. Remove the side cover on control side and
the opposite side.
4. Release the attachment caps (1) and
clamps (2) and (3). 7
5. Remove the seat belt mechanism and pull
the rubber boot over it.
6. Pull the rubber boot over the controls and
remove them through the bottom. 1
Installing dust boot
K100491
1. Install the rubber bellows.
2. Fit the seat belt mechanism.
3. Fasten the boot with the attachment caps
(1) and clamps (2) and (3).
4. Fit the side covers.
ᓻ 0209 4-3
SEATS 1
4.6 REMOVAL AND INSTALLATION, COVER PANEL ON CONTROL SIDE
Removing cover panel on control side 2

(including LWS/IPS valve)
1. Remove the seat squab.
2. Remove backrest adjuster button (1). 3
3. Remove the screws (2), (3) and (1).
4. Remove the air pipes from the LWS/IPS 1
valve (5).
5
Installing cover panel on control side
1. Connect the air pipes of the LSW/IPS
valve (5). 4 3
3
K100492
2. Fit the screws (1), (2) and (3).
3. Fit the backrest adjuster button.
4.7 REMOVAL AND INSTALLATION, SIDE COVER PANEL
Removing side cover panel

2. Remove the screws (2), (3) and (1).
7 Installing side cover panel
1. Fit the screws (1), (2) and (3).
2. Fit the seat squab. 1
2 2
3
K100493
4-4 ᓻ 0209
1 SEATS
4.8 REMOVAL AND INSTALLATION, FRONT COVER PANEL
Removing front cover panel

2. Remove the screws (1) and (2).
3. Remove the plug connection at the back
from the side cover and remove the plug (3)
from the heater switch (4).
4. Remove the switch (4).
Installing front cover panel
1. Install the switch (4).
3
2. Connect the plug (3).
3. Fit the screws.
1 2
K100494
7
ᓻ 0209 4-5
SEATS 1
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 attachment bolt (1) from the
seat belt attachment plate (2) and remove
the screws (3) from the cover. 4
3. Pull the seat belt (2) through the 3

opening (4).
Installing seat belt guide panel
1. Guide the seat belt (2) through the
opening (4).
2. Tighten the seat belt mounting plate (2) to
2
1
7
K100495
4-6 ᓻ 0209
1 SEATS
4.10 REMOVAL AND INSTALLATION, BACKREST
Removing backrest
1
2. Remove the screws (1) from the cover (2)
and remove screw (3) from the mounting 3
plate. 2
3. Remove the rubber air hoses (4)

(connection is underneath the seat belt roll
holder) and the electric plug connector (5)
(if applicable).
4. Remove screw (6) and lift the backrest in
the closed position out from the side rails of 6
the frame.
8
IPS system
1. Remove the entire seat. 5
4
2. Remove the side cover on control side
(without disconnecting the air hoses from 7
the IPS valve).
3. Remove screw (7) from the seat belt
mounting bracket and screw (8) from the
seat belt roll.
4. Remove the rubber air hoses (4)
(connection is underneath the seat belt roll
holder) and the electric plug connector (5)
(if applicable).
K100496
7
Installing backrest
1. Install the backrest in the closed position
into the frame and secure it to the specified
2. Connect the air pipes (4) and the seat
heating connector (5) (if present).
3. Fit the seat belt roll holder and tighten it to
4. Fit the screw (3) in the mounting plate.
5. Fit the cover (2).
ᓻ 0209 4-7
SEATS 1
4.11 REMOVAL AND INSTALLATION, ARM REST
Removing arm rest

1. Remove the black covers.
2. Unscrew and remove the screws (1) from
the arm rest.
Installing arm rest
Fit the screws and install the black covers.
K100498
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
from the IPS valve). 1
2. Remove the cover (1).
7 3. Remove the screw (2) from the mounting

plate (3).
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
2. Fit the seat belt roll holder and tighten it to
“Technical data”. 4
3. Fit the cover (1).
4. Install the side cover panel on control side.
K100499
4-8 ᓻ 0209
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 attachment bolt (1). 1
Installing seat belt lock
1. Fit the locking mechanism and tighten the
attachment bolt to the specified tightening
2. Fit the side cover panel.
K100500
4.14 REMOVAL AND INSTALLATION, BACKREST AIR CUSHIONS (IPS SYSTEM)
Removing backrest air cushions (IPS

system)
1. Carefully remove part of the backrest cover
and slide it more than halfway upwards.
2. Remove the four screws (6) (IPS model
only).
7
3. Carefully remove the shaped foam at the
bottom of the frame.
4. Remove the pipes (1) (located underneath
the seat belt roll holder). 6
3 2
5. Remove the two clips (2) and remove the
air reservoir(s) (3). 5
4
6. Remove the side air reservoirs (5).
Installing backrest air cushions (IPS system)
1. Install the air reservoirs (3) and (5) and
1
secure them with the clips (2).
3. Install the shaped foam.
4. Fit the 4 screws (6).
5. Fit the upholstery.
K100501
ᓻ 0209 4-9
SEATS 1
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
2
from the shaped foam (use a knife, if
necessary).
Removing backrest heating element
1. Pull the backrest cover up as far as the
white loop for the padding thread, without
removing the backrest 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
K100502
Installing backrest 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).
4-10 ᓻ 0209
1 SEATS
4.16 REMOVAL AND INSTALLATION, MANIFOLD
Removing manifold
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 manifold.
5. Disconnect the air pipes from the
manifold (1).
Installing manifold
1. Connect the air pipes to the manifold.
K100503
2. Put the seat squab in the highest tilting
position.
3. Fit the manifold.
4. Install the rubber bellows.
4.17 REMOVAL AND INSTALLATION, HEIGHT CONTROL VALVE
Removing height control valve

2. Remove the screws (2).
2 1
3. Disconnect the air pipes from the height
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
ᓻ 0209 4-11
SEATS 1
4.18 REMOVAL AND INSTALLATION, HEIGHT ADJUSTMENT VALVE
Removing height adjustment valve

2. Place the seat in the highest tilting position.
3. Remove the screws (1).
1
4. Disconnect the air pipes from the valve.
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
4.19 REMOVAL AND INSTALLATION, RAPID-LOWERING HANDLE
Removing rapid-lowering handle

2. Cut the air pipes of the rapid-lowering X
control handle according to size X
(X = 130).
2
7 3.
4.
Remove the side cover on control side.
Slightly loosen the screw (2).
5. Remove the screws (3) from the
rapid-lowering handle and remove the
handle along the upper side.
1 3
Installing rapid-lowering handle K100506
Note:
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).
4-12 ᓻ 0209
1 SEATS
1. Attach the air pipes of the handle (1) to the

cut air pipes. Use the same length as that
which was cut during removal.
X
2. Fit the handle (1) and secure it with the
screws (3).
2
3. Tighten the screw (2).
4. Fit the side cover on control side.
1 3
K100506
4.20 REMOVAL AND INSTALLATION, VERTICAL DAMPING ADJUSTER
Removing vertical damping adjuster

2. Remove the side cover on control side
(without disconnecting the air pipes from the
valves).
3. Remove the screws (1). 2
4. Remove the shock absorber cable (remove
7
the lock ring (2) in the lowest position of the
system, and kink the cable from its holder 1
(6) when the system is in the highest
position).
Installing vertical damping adjuster
1. Install the combined cable and mounting K100507
plate assembly (3) and the control handle

through the opening in the rubber bellows
into the frame.
2. Secure the handle (2) with the screws (1).
3. Fit the side cover.
4. Install the adjustment cable (2.9.0) before
the seat cushion is fitted.
5. Adjust the cable before fitting the seat
squab; see “Installing the vertical damper”.
ᓻ 0209 4-13
SEATS 1
4.21 REMOVAL AND INSTALLATION, SEAT TILTING HANDLE
Removing seat tilting handle

2. Remove the springs (1) and (4). 1
3. Remove the plastic connection piece (2) by
sliding it towards the backrest.
4. Remove the control button (3) by lifting it
and pulling it out.
4
Installing seat tilting handle
1. Fit the seat tilting handle (3). X
2
2. Fit the plastic connection piece (2). Note the 3
position of the small slot (X) when fitting the
new connection piece (2). K100508
3. Fit the springs (1) and (4).

4.22 REMOVAL AND INSTALLATION, HEIGHT ADJUSTMENT HANDLE
Removing height adjustment handle

1. Remove the seat squab. Y
2. If necessary, remove the side covers
7 (without disconnecting the air pipes from the
valves). 3
3. Remove the screw (1) and the plastic 1
connection piece (2).
4. Remove the upper plate (3) by pushing it
out at position Y and pulling it from the 4
frame. 5 X
5. Remove the handle (4).
2
6. Remove the plastic connection piece (5).
K100509
4-14 ᓻ 0209
1 SEATS
Installing height adjustment handle

1. Fit the plastic connection piece (5). Note the Y
position of the small slot (X) when installing
the new connection piece (5).
2. Fit the handle (4). 3
3. Install the plate (3). 1
4. If necessary, install the side covers.
5. Fit the seat squab. 4
5 X
2
K100509
4.23 REMOVAL AND INSTALLATION, FIXED SEAT HEIGHT ADJUSTMENT

HANDLE
Removing height adjustment handle

2. Remove the side cover (without
disconnecting the pipes from the valve).
Y
3. Remove the stop (1), after which the
adjustment cable (2) can be lifted. 3
4. Remove the upper plate (3) by pushing it
out at position Y and pulling it from the
2 7
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).
3. Install the plate (3).
4. Install the adjustment cable and fit the
stop (1).
5. Fit the side cover.
ᓻ 0209 4-15
SEATS 1
4.24 REMOVAL AND INSTALLATION, BACKREST ADJUSTER
Removing backrest adjuster without

Y-section
3
2. Remove the side cover. 6 11
3. Fold the backrest 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 9
(4) from the axle, after which the rod (5) can
be removed. 7 2
7. Loosen the screw (7) of the backrest K100511
adjuster and remove it.
8. Push the tooth segment assembly from the
bracket (9) until the wire (10) can be
removed.
Installing backrest adjuster without Y-section
1. Fit the adjuster together with the wire (10)
on one side.
2. Fit the wire (10) into the tooth segment
7
assembly at the other side.
3. Insert the screw (7) into the backrest
adjuster.
4. Lift the spring (6) and fit the control plate (4)
onto the axle, after which the wire (5) can
be fitted.
5. Connect the lock rings (3) and (11).
6. Insert the screws (1) and (2) on control side
and on the opposite side.
4-16 ᓻ 0209
1 SEATS
Removing backrest adjuster with Y-section

4
3
2. Remove the lumbar support.
6
3. Remove the side cover.
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 1
(4) from the axle, after which the rod (5) can 9
be removed.
7 2
7. Loosen the screw (7) of the backrest
K101366
adjuster and remove it.
8. Loosen the check nut of the coupling piece
in the centre of the pull rod (10) and divide
the pull rod by loosening the coupling piece.
9. Push the tooth segment assembly from the
bracket (9) until the pull rod (10) can be
removed.
10. Remove the tooth segment (8) combination
together with the bracket (9) from the seat
in downward direction.
Installing backrest adjuster with Y-section
1. Fit the adjuster together with the pull rod
(10) on either side of the seat. 7
2. Fit the coupling piece of the pull rod (10)
together and tighten the check nut.
3. Insert the screw (7) into the backrest
adjuster.
4. Lift the spring (6) and fit the control plate (4)
onto the axle, after which the rod (5) can be
fitted.
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, the backrest and the seat
squab.
ᓻ 0209 4-17
SEATS 1
4.25 REMOVAL AND INSTALLATION, IPS VALVE
Removing IPS valve

2. Remove the side cover on control side. 2
3. Disconnect the air pipes from the IPS
valve (1).
4. Use a screwdriver to lift the IPS valve (1)
from the cover (2) (the valve may be
damaged slightly in the process).
3
Installing IPS valve 1
1. Fit the IPS valve. 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. K100510
2. Connect the air pipes to the IPS valve (1).

3. Install the side cover on control side.
4.26 REMOVAL AND INSTALLATION, AIR BELLOWS
Removing air bellows

4
7
1. Remove the entire seat.
1
3. Remove the clamping strip (1) (by
cutting it).
6 5
4. Disconnect the air pipe (2) from the
manifold (3).
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 2
sure that the air bellows is not twisted. If this K100513
is nevertheless the case, loosen screw (4) a
few turns and apply spring action to the
system under pressure; then tighten screw
(4) again while the air bellows is still under
pressure.
2. Tie the pipes together with a clamping strip.
4-18 ᓻ 0209
1 SEATS
4.27 REMOVAL AND INSTALLATION, ADJUSTMENT CYLINDER
Removing adjustment cylinder

2. Lock the seat in its highest position. 8
3. Disconnect the air pipes (1) and (3) from the
adjustment cylinder. 12
6
4. Remove the retainer pin (4). 5
21
5. Remove the screw (5).
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
installation.
5. Release the lock and operate the height
adjustment button (upwards). Check
whether the cylinder (2) moves freely. If not,
loosen screw (5) slightly.
7
ᓻ 0209 4-19
SEATS 1
4.28 REMOVAL AND INSTALLATION, CONTROL UNIT OF HEIGHT CONTROL

VALVE
Removing control unit of height control

valve 4
1. Remove the seat squab and remove the
dust boot at the front.
2. Lock the system in the highest position. 8 10
11
3. Disconnect the air pipe (1) from the 9
cylinder (2).
5
4. Remove the lock ring (3) and pin (4). 6
5. Loosen the screw (5) slightly and push the 2
holder (6) of the control discs (7) a little 12 3
apart. This makes it possible to pull the 7
control discs from the adjustment cylinder 1
(8). The guide plate (9) must remain K100515
attached to the pin (10). Push the ball (11)
back onto the pin (10) if it has come loose.
Installing control unit of height control valve
1. Tighten the screw (5) slightly during
installation.
2. Operate the height adjuster (upwards) and
check whether the cylinder moves freely. If
not, loosen screw (5) slightly.
4-20 ᓻ 0209
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
4
6. Remove the rubber dust boot at the front
and remove the locking ring (3).
Installing vertical damper 3
1. Fit the damper and use the locking ring (3) K100516
to 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
achieve the stiffest damping when the
control handle is in the top position.
To make this adjustment, first release the
check nut (7). Retighten check nut (7) after
7
adjustment.
ᓻ 0209 4-21
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).
1
3. Remove the Bowden cable by taking it from

the attachment points. 2
Installing Bowden cable for fixed seat gas
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 from or
towards one another. K100517
2. Then tighten the Bowden cable using the

check nut.
4.31 REMOVAL AND INSTALLATION, FIXED SEAT GAS DAMPER
Removing fixed seat gas damper 5

2. Place the seat in its lowest position.
7 3. Remove the stop (1) and Bowden cable (2)
1
(making sure not to operate the button). 3
2
4. Release attachment nuts (3) and (4).
5. Pull the chair upwards, ejecting the gas 4
spring 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.
4-22 ᓻ 0209
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
A
fastener.
Removing seat squab cover
4
X
X 2
K100497
7
ᓻ 0209 4-23
SEATS 1
2. Remove the clips from the groove around

the bottom and pull the cover from the
groove.
1
K100517
1
3
2
4
7
K100518
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 seat squab cover
1. Fit the cover in such a way that the Velcro
fastener is in the correct position, and use
the clips to secure the cover.
K100519
4-24 ᓻ 0209
1 SEATS
4.33 REMOVAL AND INSTALLATION, BACKREST COVER
Removing backrest cover

1. Remove the seat belt guide panel.
2. Remove the cover by unhooking it from the

section at the bottom.
K100520
ᓻ 0209 4-25
SEATS 1
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 backrest 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
4-26 ᓻ 0209
1 ACCESSORIES
CONTENTS
Page Date
2.1 Adjusting roof spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0209
2.2 Overview drawing, accessory holes pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0209
3.1 Removal and installation, roof spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0209
3.2 Removal and installation, rear air foils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0209
3.3 Removal and installation, side skirts and catwalk . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0209
3.4 Removal and installation, corner spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0209
3.5 Removal and installation, windscreen sun visor . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0209
3.6 Removal and installation, air dam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 0209
3.7 Removal and installation, combi-light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 0209
3.8 Removal and installation, roof spotlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ...... 0209
3.9 Removal and installation, air horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ...... 0209
3.10 Removal and installation, rotating beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 ...... 0209
ᓻ 0209 1
ACCESSORIES 1
2 ᓻ 0209
1 ACCESSORIES
General
underneath the cab.
ᓻ 0209 1-1
ACCESSORIES 1
1-2 ᓻ 0209
1 ACCESSORIES

2.1 ADJUSTING ROOF SPOILER
Note: 1 /2 X
Correct adjustment of the roof spoiler is
essential to minimise fuel consumption.
P
1. Place the vehicle on a level and horizontal X
surface. Make sure that in the case of a
tractor/semi-trailer combination the trailer is
straight in front of the semi-trailer.
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
(1/2 X) between the roof spoiler edge and
the start of the superstructure.
The roof spoiler height can be adjusted K1 01 357
using adjusting mechanism (B). For the roof

spoiler adjusting range see “Technical P
data”. B
1
/2 X
P
X
K1 01 356
K1 01 355
ᓻ 0209 2-1
ACCESSORIES 1
2.2 OVERVIEW DRAWING, ACCESSORY HOLES PATTERN
430
A A
E 140
200
D
1120
160
100 30
C C
195
443
A A
G BF
90
1110
220
57
33
H 33
600
K100474
XL CAB
Legend
A. Roof spoiler
B. Cable duct for rotating light*
C. Hose duct for air horn*
8 D. Cable duct for satellite aerial

E. Mounting position for mobile phone aerial
F. Radio aerial (standard)
G. Cable duct for CB aerial
H. Cable duct for roof spotlights*
* Reverse for RHD models
2-2 ᓻ 0209
1 ACCESSORIES
430
A A
E 140
200
D
1120
105
160
C
C
448
593
100
A A
G
B F
90
1110
220
H
32,5
40
600
K100475
XH CAB
Legend
A. Roof spoiler
B. Cable duct for rotating light*
C. Hose duct for air horn*
D. Cable duct for satellite aerial 8
E. Mounting position for mobile phone aerial
F. Radio aerial (standard)
G. Cable duct for CB aerial
H. Cable duct for roof spotlights*
* Reverse for RHD models
ᓻ 0209 2-3
ACCESSORIES 1
2-4 ᓻ 0209
1 ACCESSORIES

3.1 REMOVAL AND INSTALLATION, ROOF SPOILER
Removing roof spoiler (aerodynamic)

1. Remove the attachment nuts from the cab
roof attachment frame.
2. Take the complete roof spoiler from the cab
roof.
Installing roof spoiler (aerodynamic)
1. Fit the complete roof spoiler with the lower
frame on the studs in the cab roof.
2. Fit the attachment nuts of the lower frame
on the studs in the cab roof and tighten the
nuts to the specified tightening torque. See
Removing roof spoiler
1. Remove the attachment nuts of the roof
spoiler and the roof spoiler extension.
2. Take the complete roof spoiler with roof
spoiler extension from the cab roof.
Installing roof spoiler
1. Fit the entire roof spoiler with roof spoiler
extension on the cab roof.
2. Fit the attachment nuts of the roof spoiler
and roof spoiler extension and tighten the
nuts to the specified tightening torque. See
ᓻ 0209 3-1
ACCESSORIES 1
3.2 REMOVAL AND INSTALLATION, REAR AIR FOILS
Removing rear air foils 1

1. Remove the attachment bolt and nut of the
reinforcement (3) from the rear air foil
extension (2) to the upper rear air foil 2
bracket. 3
2. Remove the attachment bolts of the rear air
foils (4) and the lower extension pieces (5)
from the tapped holes at the cab rear.
3. Remove the rear air foils (4) together with 4
the lower extension pieces (5).
4. If necessary, remove the rear air foil
extension (2) by removing the clamping
brackets at the cab rear and any
5
attachment bolts on the roof spoiler.
5. If necessary, remove the roof spoiler
extension (1) of the ’aerodynamic’ roof K1 01 479
spoiler by removing the attachment bolts

and nuts.
Installing rear air foils
1. Using the attachment bolts, fit the rear air
foils (4) and the lower extension pieces (5)
to the cab rear and tighten the attachment
bolts to the specified tightening torque, see
2. If necessary, fit the rear air foil extension (2)
with the clamping brackets to the cab rear,
fit any attachment bolts and nuts to the roof
8 spoiler and tighten the attachment bolts and
nuts to the specified tightening torque, see
3. If necessary, fit the roof spoiler extension
(1) to the ’aerodynamic’ roof spoiler using
the attachment bolts and nuts and tighten
the attachment bolts and nuts to the
data”.
3-2 ᓻ 0209
1 ACCESSORIES
3.3 REMOVAL AND INSTALLATION, SIDE SKIRTS AND CATWALK
Removing side skirts and catwalk

1. Unhook the attachment brackets at the side
skirt top and open the side skirt.
2. Unplug the connectors of the side marker
lighting.
3. Unhook the check straps at the side skirt
top.
4. Tilt the side skirt completely open and
unhook the side skirt from the lower
attachment.
5. Unhook the catwalk plates lengthwise from
their attachment points.
6. Remove the attachment bolts of the front
catwalk plate and the remaining catwalk
plates widthwise.
7. Remove the front catwalk plate.
K1 01 478
8. Unhook the remaining catwalk plates from

the chassis members.
Installing side skirts and catwalk
1. Fit the front catwalk plate to the chassis.
2. Hook the catwalk plates widthwise
completely in the chassis members.
3. Fix the elements together, using the
attachment bolts.
4. Hook the catwalk plates lengthwise in 8
position.
5. Fit the side skirts on the lower attachment.
6. Hook the check straps firmly to the
attachment brackets.
7. Fit the connectors of the side marker
lighting.
8. Close the side skirts.
9. Adjust the attachment brackets.
ᓻ 0209 3-3
ACCESSORIES 1
3.4 REMOVAL AND INSTALLATION, CORNER SPOILER
Removing corner spoiler

1. Open the grille and door and remove the 1
attachment bolts of the corner piece (1).
2. Remove the corner piece (1) completely.
3. Remove the attachment bolts (2) and
remove the corner spoiler (3) from the
corner piece (1).
Installing corner spoiler 2
1. Fit the corner spoiler (3) to the corner
piece (1)
2. Fit the corner piece (1) completely and
close the grille and door.
K1 01 477
3.5 REMOVAL AND INSTALLATION, WINDSCREEN SUN VISOR
Removing windscreen sun visor

1. Remove the attachment bolts of the
mounting brackets from the tapped holes in
8
the cab.
2. Remove the sun visor from the cab.
Installing windscreen sun visor
1. To fit the sun visor stress-free, loosen the
attachment bolts fastening the plastic hood
to the brackets a few strokes.
2. Using the attachment bolts, fit the sun visor
complete with the attachment brackets to
the cab.
3. Tighten the attachment bolts fastening the
plastic hood to the brackets.
3-4 ᓻ 0209
1 ACCESSORIES
3.6 REMOVAL AND INSTALLATION, AIR DAM
Removing air dam

1. Unplug the connectors of the combi-light in
the air dam.
2. Remove the attachment nuts and bolts
fastening the suspension brackets to the
chassis.
3. Remove the attachment nuts and bolts of
the air dam at the cab bottom and remove
the air dam.
Installing air dam
1. Fit the air dam to the cab bottom, using the
suspension brackets and the attachment
bolts and nuts.
2. Fit the connectors of the combi-light in the
air dam.
3.7 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. 8
K1 01 520
ᓻ 0209 3-5
ACCESSORIES 1
3.8 REMOVAL AND INSTALLATION, ROOF SPOTLIGHTS
Removing roof spotlights

1. Unplug the connector to the roof spotlight,
coming from connector (291) to the left
behind the overhead boxes underneath the
bottom plate.
2. Remove the attachment bolts from the
bracket and remove the bracket complete
with roof spotlights from the cab roof.
Installing roof spotlights
1. Fit the bracket with roof spotlights to the
cab.
3. Check that the cable duct through the cab
roof is water-tight. If necessary, seal the
passage again.
3.9 REMOVAL AND INSTALLATION, AIR HORNS
Removing air horn on roof spoiler

1. Remove the attachment bolts from the air
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
8 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
2. Remove the attachment bolts from the air
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.
3-6 ᓻ 0209
1 ACCESSORIES
Installing air horn on roof

1. Fit the air horn to the roof using attachment
bolts.
3.10 REMOVAL AND INSTALLATION, ROTATING BEAM
Removing rotating beam

1. Remove the glass (1) of the rotating beam
by pressing the locking clip at the bottom of
the glass and turning the glass
counter-clockwise out of the lamp 1
socket (2).
2. Unplug the connector to the rotating beam,
coming from connector (291) to the left
behind the overhead boxes underneath the
bottom plate. 2
3. Remove the three attachment bolts (3) and
remove the lamp socket from the roof.
3
Installing rotating beam

1. Fit the lamp socket (2) to the roof and
tighten the attachment bolts (3).
3. Turn the glass (1) of the rotating beam K1 01 414
clockwise onto the lamp socket (2).
Continue turning the glass until the locking
clip “clicks” into the lock.
ᓻ 0209 3-7
ACCESSORIES 1
3-8 ᓻ 0209
1 PREWAX TREATMENT
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.1 Notes on re-treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0209
2.2 Treatment of the cab front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0209
2.3 Treatment of door post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0209
2.4 Treatment of the door sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0209
2.5 Treatment of the tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0209
2.6 Treatment of the back panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0209
2.7 Surface treatment of the roof hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0209
2.8 Treatment of the bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0209
10
ᓻ 0209 1
PREWAX TREATMENT 1
10
2 ᓻ 0209
1 PREWAX TREATMENT

past its end stop.

Ensure that there is sufficient ventilation during

spraying and ML treatment.
10
ᓻ 0209 1-1
PREWAX TREATMENT 1
10
1-2 ᓻ 0209
1 PREWAX TREATMENT
95XF series General
2. 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 into all cavities using the DAF PREWAX
kit (special tool, DAF no. 0689779) without
difficulty. The equipment does not need to be
cleaned.
2.1 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
vertically.
- Ensure that the area is properly ventilated
during treatment.
- Use the ultraviolet light to check that the
PREWAX has been applied correctly.
Symbols used
➔ Spray cavities using a pressure of
7 - 8 bar. 10
Treat surfaces using a pressure of
3 bar.
ᓻ 0209 2-1
PREWAX TREATMENT 1
General 95XF series
2.2 TREATMENT OF THE CAB FRONT
Treat the entire front behind the grille

cosmetically with a short spray pipe (special
tool). Treat the inside of the foremost front
beams through the existing holes (having
removed the ML plugs).
K100283
10
2-2 ᓻ 0209
1 PREWAX TREATMENT
95XF series General
2.3 TREATMENT OF DOOR POST
Treat the A post on both sides through the

existing holes, using the short and the flexible
spray pipe (special tool). Remove the ML plugs
before starting the treatment.
K100479
K100285
10
K100286
ᓻ 0209 2-3
PREWAX TREATMENT 1
General 95XF series
2.4 TREATMENT OF THE DOOR SILL
Treat the door sill via the bottom of the cab

(wheel arch) through the existing holes, using
the short and the flexible spray pipe (special
tool). Remove the ML plugs before starting the
treatment.
K100478
10
K100288
2-4 ᓻ 0209
1 PREWAX TREATMENT
95XF series General
2.5 TREATMENT OF THE TOOL BOX
Treat the hinges using the short spray pipe

(special tool) and a pressure of 3 bar. Treat the
inside using the short spray pipe (special tool)
and a pressure of 7-8 bar.
Treat the inside of the box door with the short
spray pipe (special tool).
First remove the bump caps from the door
(re-install them after completion of the
treatment).
K100477
2.6 TREATMENT OF THE BACK PANEL
Treat the back panel through the existing holes.

Pay extra attention to the extreme upper
corners, which are less accessible.
K100291
10
ᓻ 0209 2-5
PREWAX TREATMENT 1
General 95XF series
2.7 SURFACE TREATMENT OF THE ROOF HATCH
Reduce the pressure to 3 bar and treat all

seams and hinges, using the short and the
flexible spray pipe (special tool).
K100292
2.8 TREATMENT OF THE BOTTOM
Treat all longitudinal and transverse members

through the existing holes, using the flexible
spray pipe (special tool).
At the back of the transverse members, treat the
cab lock pin attachments using the short spray
pipe (special tool) (having reduced the pressure
to 3 bar).
K100293
10
2-6 ᓻ 0209

DAF 95 XF, XE Technical Data

Uploaded by

Copyright:

Available Formats

DAF 95 XF, XE Technical Data

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DAF 95 XF, XE Technical Data

Uploaded by

Copyright:

Available Formats

1 CONTENTS

1. INTERNAL AND EXTERNAL CAB COMPONENTS

Recommended cab dimensions

Recommended dimension between measuring Recommended dimension between

Recommended dimensions at the cab front

Recommended dimensions on cab floor

Glues and other application compounds for

0 Application compounds for rubber and synthetic components

Adjustment dimensions of door locking

Adjustment dimensions of exterior mirrors

Model without integrated bracket 0

Size Normal (mm) Normal adjustment angle

(1) Relative to the cab floor

Model with integrated bracket

Size Normal (mm) Normal adjustment angle

(1) Main mirror

Adjustment dimensions of exterior mirrors

Model with integrated bracket 0

Size Normal (mm) Normal adjustment angle

(1) Main mirror

Dimensions of compulsory field of vision

Mirror size 1 size 2 size 3 size 4 size 5

Heater fan series resistor

1.2 TIGHTENING TORQUES

0 The tightening torques stated in this section are

Windscreen wiper unit

Front Underrun Protection leaf--sprung

(1) Secure with Loctite 243

Size A: distance between top of front

2.2 TIGHTENING TORQUES

0 The tightening torques stated in this section are

Position Description Tightening torque

(1) Secure with Loctite 243

3. CAB TILTING GEAR

Cab tilting pump

3.2 TIGHTENING TORQUES

The tightening torques stated in this section are

3.3 FILLING CAPACITIES

Cab tilting pump

COMPLAINT: CAB TEMPERATURE TOO HIGH

COMPLAINT: SUSPENSION TOUCHES BUMP STOP 1

COMPLAINT: INSUFFICIENT LATERAL DAMPING

COMPLAINT: AIR LEAKAGE

2.2 FAULT-FINDING TABLE, CAB TILTING MECHANISM

COMPLAINT: TILTING CYLINDER FAILS TO RESPOND

1 Damaged or broken pipe. Replace pipe or connection.

COMPLAINT: PUMP ROD REBOUNDS

COMPLAINT: PUMP ONLY FUNCTIONS IN THE LAST PART OF THE STROKE

COMPLAINT: PUMP OPERATES WITH DIFFICULTY, CYLINDER DOES NOT RESPOND

COMPLAINT: PUMP FAILS TO GENERATE PRESSURE

COMPLAINT: CAB LOCK CANNOT BE OPENED

COMPLAINT: CAB CANNOT BE TILTED

COMPLAINT: SEAT FAILS TO RISE

COMPLAINT: SEAT MOVES UP AND DOWN INDEPENDENTLY (UNLOADED)

COMPLAINT: SEAT MOVES UP AND DOWN INDEPENDENTLY (LOADED)

COMPLAINT: SEAT HEIGHT CANNOT BE ADJUSTED

1 and during downward operation, whether the

COMPLAINT: SEAT MOVES TO TOP-MOST POSITION AND IS NOT SPRUNG

COMPLAINT: BLOWS OFF CONTINUOUSLY AND IS PERMANENTLY IN TOP POSITION