Replace front longitudinal member up to passenger compartment floor area · ar6220d1240tsf · Mercedes-Benz WIS

AR62.20-D-1240TSF

Replace front longitudinal member up to passenger compartment floor area

16.07.2019

Model

910

Modification notes

15.07.2019	Commercially available devices/tools, added	The whole document	AR62.20-D-1240-12TSF
15.07.2019	Method extension, operation step added	Operation step 1	AR62.20-D-1240-12TSF
15.07.2019	Commercially available devices/tools, added	The whole document	AR62.20-D-1240-13TSF
15.07.2019	Method extension, operation steps, added	Operation steps 16, 17, 18, 19, 20	AR62.20-D-1240-13TSF
15.07.2019	Commercially available devices/tools, added	The whole document	AR62.20-D-1240-14TSF
15.07.2019	Commercially available devices/tools, added	Operation steps 2, 5, 6, 7, 8, 9, 10, 12, 13, 14

Replace front longitudinal member up to passenger compartment floor area

Shown on model 910.631 with code D03 (Roof and rear-end doors, high version), left side of vehicle

1	Front longitudinal member up to passenger compartment floor area

D62.20-0175-05

 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
 Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 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
Topical note	Measures for preventing damage to vehicles or components when performing electric welding work		AH00.00-N-0005-01A
Topical note	General information on body repair		AH60.00-N-0001-01A
	Remove
1	Remove all detachable parts in area of repair point.
2	Cover detachable parts that remain in vehicle with welding protection blankets.	 Commercially available devices/tools Welding protection blanket
3	Set up straightening bench with crossbars and straightening tool set.
	000 588 01 23 00 Body straightening system		WS60.00-P-0023K
4	Place vehicle on straightening bench and fasten.
	000 588 09 80 00 Swivel arm column-type lift		WS00.00-N-0045B
5	Remove upper front longitudinal member.		AR62.20-D-1286-01TS
		 Commercially available devices/tools Spot weld milling machine Rotary wire brush Wet and dry vacuum cleaner
		1K-zinc dust paint	*BR00.45-Z-1056-07A
6	Cut off front longitudinal member up to the passenger compartment floor area (1).		AR62.20-D-1240-12TSF
	000 588 00 84 00 Heat gun		WS54.00-P-0049B
		 Commercially available devices/tools Straight grinder Body power jigsaw Rotary wire brush Spot weld milling machine Wet and dry vacuum cleaner
		1K-zinc dust paint	*BR00.45-Z-1056-07A
7	Prepare front longitudinal member up to the passenger compartment floor area (1).
	000 588 01 84 00 Welder		WS60.00-P-0021K
			AR62.20-D-1240-13TSF
		 Commercially available devices/tools Spot weld milling machine Hole punching pliers 6 mm Rotary wire brush Wet and dry vacuum cleaner
		1K-zinc dust paint	*BR00.45-Z-1056-07A
8	Prepare upper front longitudinal member for installation.		AR62.20-D-1286-02TS
		 Commercially available devices/tools Hole punching pliers 6 mm Rotary wire brush Wet and dry vacuum cleaner
		1K-zinc dust paint	*BR00.45-Z-1056-07A
	Install
9	Install front longitudinal member up to the passenger compartment floor area (1) and weld in.		AR62.20-D-1240-14TSF
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
		 Commercially available devices/tools Clamping pliers (Standard) Rotary wire brush Angular grinder Wet and dry vacuum cleaner
10	Install upper front longitudinal member.		AR62.20-D-1286-03TS
	000 588 01 84 00 Welder		WS60.00-P-0021K
	000 588 02 84 00 Welder		WS60.00-P-0022K
		 Commercially available devices/tools Clamping pliers (Standard) Angular grinder Wet and dry vacuum cleaner
		 Welding device	*907589012300
11	Release vehicle from straightening bench, lift and remove straightening bench.
	000 588 09 80 00 Swivel arm column-type lift		WS00.00-N-0045B
12	Clean weld joints and sheet metal flanges with rotary wire brush.	 Commercially available devices/tools Rotary wire brush
13	Remove welding protection blankets.	 Commercially available devices/tools Welding protection blanket
14	Clean repair area.	 Commercially available devices/tools Wet and dry vacuum cleaner
 Danger	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
15	Prime repair area with a primer filler.
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
		 Use only primer filler approved by Daimler AG: http://xentryportal.mercedes-benz.com
16	Seal seam after repair.		AR97.10-D-4000TS
		 Supplement standard seals with sealant.
 Danger	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
17	Paint repair area and adjacent surfaces.
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
		 Use only paints approved by Daimler AG: http://xentryportal.mercedes-benz.com
18	Supplement cavity preservation		AR97.20-D-1500TS
19	Install all detachable parts in area of repair point.

907 589 01 23 00

Welding device

Repair materials

Number	Designation	Order number
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00

Referenced documents

ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
ah6000n000101a General information on body repair
ah9800p940802a Notes on paintwork repairs
ar6220d124012tsf Cut front longitudinal member to passenger compartment floor area
ar6220d124013tsf Prepare front longitudinal member to passenger compartment floor area
ar6220d124014tsf Install front longitudinal member up to passenger compartment floor area and weld in
ar6220d128601ts Separate upper front longitudinal member
ar6220d128602ts Prepare upper front longitudinal member
ar6220d128603ts Install upper front longitudinal member
ar9710d4000ts Seam sealing following repair
ar9720d1500ts Cavity preservation following repair work
as0000z000701a 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
as0000z001001a Risk of death caused by vehicle slipping or toppling off of the lifting platform.
as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
as9800z000201a Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.
ws0000n0045b 000 588 09 80 00 Above-floor swivel arm vehicle lift 5.0-6.5 t
ws5400p0049b 000 588 00 84 00 Heat gun
ws6000p0021k 000 588 01 84 00 Welder
ws6000p0022k 000 588 02 84 00 Welder
ws6000p0023k 000 588 01 23 00 Body straightening system