Instructions on use of the cabin repair kit, type AC 11.0-50 (6367)PTSI.634241.350 R.
1. Dismantling the inside linings of the cabin platform [1]. – dismantling the seat (driver and
passenger)
- Remove safety seat belts
- Remove cabin lighting
- Dismantle search light framing
- Remove the decorative lining - 2 pcs. (unscrew 4 bolts, М8 and remove 2 plastic lugs in
the centre)
- Remove the hatch/sunroof cover (unscrew 10 screws)
- Remove the upper/top cover/shelf (unscrew 4 bolts М6 - 2 at centre and 1 each on the
left and right)
- Remove the front rack lining (left, right - unscrew 2 screws М6)
- Remove the top rack lining, which is attached to the sheath (unscrew the screws) remove sheath from ceiling
1
-
Remove all sheath fastening clips from the cabin platform
Drill in rivets in the aluminium lining with a double-cabin (drill bit 5 mm)
Dismantle the lining of the rear wall, side openings
2. Dismantle (cut, drill through the weld points), the regular horizontal doorway reinforcement [2]
on both sides of the cabin. UShM-125, drill, drill bit Ø5mm. During work conduct, ensure that
the electrical cables are protected from damage.
2
3. In its place, weld the upper part door opening reinforcement [3] and then weld the reinforcement
[4] at the corner of the cabin floor at join (on both sides)
2 pcs.(left, right
)
3
2 pcs.
4
2
Left side
3
2
4
4
5
3
4
3
4 Weld the roof reinforcement [5] on both sides (2 pcs. left, 2 pcs. right) at places with the
standard lateral roof reinforcement, on the rear areas of the cabin platform, thus connecting
the roof with the doorway. Upon completion of work, clean,degrease and prime
.
5
4 pcs.
5. Mounting of Cab frame reinforcement.
- Mount the frame reinforcement under the cab [6] with dimension 395±20 from the
bracket
-
-
To the front leaf spring and 125 from the longeron upper rack (it might be necessary to
make modification to the hub frame in the cabin [9] relocate the hub attachment plate to
the rear overhang), fix in 2 M16x70 bolts in the standard frame holes, and align
parts [6.1] and [6.2], screw on the inserted bolts, maintaining the size-125, from the
upper flange of the side member/longeron (left and right sides)
-
mount the following bolts М16х70 (part [6.1], [6.2]) and fix nuts М16 (left and right
sides)
-
mount part [6.4], fix in bolts M16х70 and fix nut M16
mount part [6.3], fix in bolts М16х70 and fix nut М16
carry out the nut tightening procedure, observing the sequence: parts [6.1] and [6.2], part
[6.4], part [6.3]
On the joined parts [6.1] and [6.2] weld, clean, prime, paint.
6
6.4
6.1
Bolt М16х70 - 24 pcs.
- 48 pcs.
Nut 16
- 24 pcs.
Nut М16
6.2
6.3
9
6.1
7
6.2
8
6
6.
-
-
cabin bracket rubber cushion on front part of cabin [7] attach to the chassis frame
Observing the size 30±10 mm from the front leaf springs brackets, place in two holes
(standard holes in the chassis frame), left and right sides.
Following the markings on the bracket, drill two holes Ø13 mm.
Mount the brackets (left, right sides) and tighten bolt М12, washer, nut.
On the front section of the cabin, smear glue, type Bostik 30600956 600ml ISR 7008AP
Simson Silicone Direct Glazing Adhesive – Black and secure the plate [8] opposite
brackets [7], left and right sides.
Mount the cushion [7.1] to the bracket [7] and then adjust the height of nut [10] relative
to the lowered cabin such that there is contact between the cushion [7.1] with plate [8]
and lock with nut М24
7
7.1
8
10
10
7
8
6
8
7
7 - at the front part section of the cabin, disassemble the grey radiator protection mounting
bracket [11], left and right sides
-
Instead, mount plates [12.1] and [12.2] (left, right) and fasten (standard bolts)
-
Insert pipe [12.3] into the plate holes [12.1]; [12.2] and apply heat, on welded areas,
clean and paint
Attachment points
11
12
12.1
12.3
12.2
13
Attachment points
8. Reinforcement of front section of the cabin platform
-
Reinforce the cabin platform front section attachment point [14] to the reinforcement
frame at the front section (at bumper), through a connecting bolt [15]
-
Unscrew bolts [14.1] (4 pcs.), bolts [14.2] (2 pcs.) mount bracket [15] align holes, insert
standard bolts in
holes [14.1], [14.2] and additionally mount bolt in hole [14.3], clamp connecting bolt .
14.2
15
14
15
14.1
14.3
14.2
14
14.1
14.3
15
9. Replacing the standard cabin lock beam
- dismantle the standard cabin lock beam [16]
- dismantle the standard plate for installation of the cabin lock [17]
- dismantle the cabin lock [18] and cut the locking mechanism [18.1] from the beam [16]
- instead of part [16], mount the upgraded cabin lock beam [19] (the cut out [19.1] should
be positioned on the right side along the direction of travel) and fasten using standard
bolts.
- mount the two plates [20.1], [20.2] under the cabin lock on the beam [19] (plate [20.2] is
fixed from the cab side, plate [20.1] is mounted from the superstructure side), fasten
using bolts, washers, nuts.
- Cut the plate which connects to the cabin lock [18] with the locking mechanism [18.1],
maintaining a dimension of 100 mm from the edge of the car lock.
- mount the cabin lock [18] to the plates [20.1], [20.2] and fix it with standard bolts.
- Insert the plate of the locking mechanism [18.1] through the grooves [19.2] and on the
edge of the beam
- [19] weld the locking mechanism [18.1] by connecting to the cabin lock plate [18] with
the locking mechanism plate [18.1] using an insert (plate) by welding, (length of the
insert (plate) to be determined in-situ).
- to replace the dismantled plate [17], install the plate to mount the lock [21]. What is the
purpose of doing the following: to attach the plate [21], to mark the holes, to drill holes Ф12
mm, to mount the plate and fix it (M10x40 bolt, M10x60 bolt, washer, nut). Install the
rubber bushings [21.1] after unscrewing the two pins [21.2]
17
19.2
19
18
18.1
16
19.1
20.2
21
21.1
20.1
21.2
18
22
100 мм
18.1
19.2
22
18
21
20.1
19.1
18.1
19
24
23
24
6
10. Weld the reinforcement [23] whilst observing the 42 mm dimension to the cushion support
bracket [24].
23
24