Prepare reinforcement plate and weld on

AR49.20-G-0002-01A

Prepare reinforcement plate and weld on

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

General information and guidelines for welding on the exhaust aftertreatment unit

AH49.20-N-0001-01A

Engine

470.9, 471.9, 473.9 in model 800.310

With end pipe of exhaust system to outer right

1

Cut brackets (1) off the exhaust gas aftertreatment unit (2).

 Do not damage the electrical lines (3, 4) when cutting off the bracket (1).
The functionality of the exhaust gas aftertreatment unit (2) is not ensured otherwise.

2

Smoothen weld seams (5) on the EATU (2).

3

Fabricate repair panel (8).

 For the repair panel (8), only an alloyed stainless steel plate (DIN 1.4301) with a material thickness of 0.8 mm may be used. If the hole in the exhaust gas aftertreatment unit (2) exceeds a size of 10x10 cm, the exhaust gas aftertreatment unit must be replaced.

4

Weld repair panel (8) onto the exhaust gas aftertreatment unit (2).

5

Smooth weld seam of the repair panel (8).

6

Check smoothening the weld seams (5) as to whether cracks (6) are present in the sheet metal of the EATU (2).

If no cracks (6) are present,



Proceed with step 7.

7

Drill a hole (7) with a 3 mm drill bit at the beginning and at end of the cracks (6).

 By drilling out the beginning and end of cracks (6) further cracking is prevented after welding shut.

8

Weld shut cracks (6) and holes (7).

9

Smoothen welded shut cracks (6) and holes (7).

10

Check whether a repair panel (8) must be welded-in.

If a repair panel (8) does not need to be welded in,



Continue with step 11.

11

  Screw templates (10.1, 10.2) to repair panel (9).

 Repair panel (9) (A 000 490 56 40)

12

Lay repair panel (9) with the   templates (10.1, 10.2) on the exhaust gas aftertreatment unit (2).

If the edges of the repair panel (9) protrude too far from the exhaust gas aftertreatment unit (2),



mark repair panel (9) at bending points (arrows),   remove templates (10.1, 10.2) and then plastically deform the repair panel (9) under the hydraulic press. Re-attach   templates (10.1, 10.2) to the repair panel (9) and check the distance of the edges to the exhaust gas aftertreatment unit (2) again.

13

Attach repair panel (9) to 4 points on the exhaust gas aftertreatment unit (2).

14

  Remove templates (10.1, 10.2).

15

Weld repair panel (9) onto the EATU (2).

 The length and the position of the weld seams (A, B, C, D, E, F, G) must be observed.

A

Weld seam (88 mm long)

B

Weld seam (32 mm long)

C

Weld seam (28 mm long)

D

Weld seam (18 mm long)

E

Weld seam (89 mm long)

F

Weld seam (87 mm long)

G

Weld seam (19 mm long)