Service Bulletin: Subject

SERVICE
DJ003 (E)
See list with
BULLETIN
affected models
December 2015
SUBJECT: Overhead guard replacement
Affected Models: MR1.4-2.5, MR1.6N, MR1.6-2.0HD (D849)
Reason: Technical service information
Technical Description:
In the event that it becomes necessary to replace the overhead guard on the above-mentioned
models, we recommend to replace also all the bolts and nuts (that fix the OHG). Please refer to the
parts manual for the correct part number of the OHG.
Please follow below instructions for the correct procedure for the replacement of the OHG.
1. Remove the headrest, plastic covers (items 1 and 12 in the picture below), all the additional
items fitted on the OHG (i.e. flash beacon, work lights…) then remove all the fitting screws.
Picture 1: S/N until →D849T02693N Picture 2: S/N from D849T02694N→
INTERCHANGEABILITY: N/A
PARTS STOCK: Available from EPO Nijmegen, The Netherlands
EFFECTIVE SERIAL NUMBER: N/A
ORIGINAL DOCUMENT
Page 1 of 6 DCN 25123 Rev. 04
We reserve the right to make changes in design or add improvements without incurring the obligation to make such changes in equipment
previously manufactured. The content of this publication is for information only and will not be considered for warranty reimbursement.
2. When the overhead guard is replaced it is not necessary to replace the shims originally
installed on the truck (items 2, 3, 4 in picture 1 and items 7, 8, 9 in picture 2), however all other
bolts and nuts must be replaced with the parts listed below:
Trucks with S/N until →D849T02693N: Please order from EPO Nijmegen the following parts:
Item Quantity P/n Description
6 7 501737903 Nut
5 4 580083689 Bolt
15 3 582054274 Bolt (square neck)
14 2 504071785 Washer
10 1 582042996 Spacer
2 2 582031821 Shim 0.5 mm
3 2 582031820 Shim 1 mm
4 2 582056408 Shim 0.2 mm
These parts are also available as hardware kit p/N: 582056409
Trucks with S/N from D849T02694N→: Please order from EPO Nijmegen the following parts:
Item Quantity P/n Description
6 6 501737903 Nut
5 5 580083689 Bolt
15 2 582054274 Bolt (square neck)
14 2 504071785 Washer
10 1 582042996 Spacer
7 2 582049501 Shim 0.5 mm
8 2 582049500 Shim 1 mm
9 2 582049502 Shim 0.2 mm
3. Remove the old overhead guard using a bridge crane, considering that the weight of the
overhead guard is around 70 kg.
Page 2 of 6 DJ003R00EYE
4. Install the new overhead guard.
5. Install the two bolts under the operator seat (items 6 and 5 in the picture below), adding Loctite
thread locker p/n 580041148. Do not tighten these two bolts.
6. Install the two bolts close to the dash display (items 5 and 6 in the picture below), adding
Loctite thread locker p/n 580041148. Do not tighten these two bolts.
7. Install the two bolts behind the operator seat (items 15 and 6 in the picture below), adding
Loctite thread locker p/n 580041148. Between the nut and the OHG there will be one washer
(item 14 in the picture below). Do not tighten these two bolts.
8. For trucks with S/N until →D849T02693N, please go to step 9 of this bulletin.
For trucks with S/N from D849T02694N→ please go to step 10 of this bulletin.
9. Install the spacer (item 10 in the picture below) and the bolt with nut (items 15 and 6 in the
picture below), adding Loctite thread locker p/n 580041148.
Please use different shims (items 2, 3 and 4 in the picture below) in order to eliminate
any gap between the overhead guard and the truck frame.
Tighten the bolt with a tightening torque of 75 Nm.

Please go to step 11 of this bulletin.
10. Install the spacer (item 10 in the picture below) and the bolt (item 5 in the picture below),
adding Loctite thread locker p/n 580041148.
Please use different shims (items 7, 8 and 9 in the picture below) in order to eliminate
any gap between the overhead guard and the truck frame.
Tighten this bolt with a tightening torque of 75 Nm.
11. Tighten all the installed bolts with a tightening torque of 75 Nm.
12. Re-install the plastic cover previously removed.
13. Re-install all the devices fitted on the OHG (i.e. flash beacon, work lights…)

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SERVICE

See list with

SUBJECT: Overhead guard replacement

Affected Models: MR1.4-2.5, MR1.6N, MR1.6-2.0HD (D849)

Reason: Technical service information

Picture 1: S/N until →D849T02693N Picture 2: S/N from D849T02694N→

Tighten the bolt with a tightening torque of 75 Nm.

Tighten this bolt with a tightening torque of 75 Nm.

12. Re-install the plastic cover previously removed.

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