Remove/install side section

AR63.10-W-0010A

Remove/install side section

16.2.12



Removing

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnecting the battery



Notes on battery

AH54.10-P-0001-01A

 Danger!

Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust

Wear protective respiratory mask, protective gloves and safety glasses.

Use suitable, grounded vacuum cleaner

AS60.00-Z-0007-01N

2

Remove inner and outer detachable parts*

3

Separate glue joint between cab rear wall and C-pillar*

4

Drill out rivet nuts*

 Drill out all rivet nuts which prevent installation of inserts in cab channels.* Reattach all rivet nuts drilled out after completing repair.

5

Mark separation points on side part*

AR63.10-W-0010-01A

6

Separate damaged side part (2)*

Body jig saw
gotis://K_58.1_01.0

7

Mark gluing and rivet holes as well as holes for pushrod and center punch*

 When centerpunching do not hit too hard to avoid deformation of the riveted surfaces.

- Mark gluing and rivet holes on B-pillar*

AR63.10-W-0010-02A

- Mark gluing and rivet holes on C-pillar*

AR63.10-W-0010-03A

- Mark gluing and rivet holes on top rear wall cross member*

AR63.10-W-0010-04A

- Mark gluing and rivet holes on bottom rear wall cross member*

AR63.10-W-0010-05A

- Mark gluing and rivet holes on cab floor cross member*

AR63.10-W-0010-06A

- Mark gluing and rivet holes on entry member*

AR63.10-W-0010-07A

- Mark pushrod holes*

AR63.10-W-0010-08A

8

Drill gluing holes in cab (1) and side part (2, new part) *

 Rivet holes are drilled only after gluing.*

9

Drill holes for pushrods in side part (2, new part)*

10

Drill locating holes*

 Insert inserts into B and C-pillars of cab precisely half way and drill one rivet hole each.*

11

Remove inserts and deburr holes on both sides*

12

Remove drilling chips by vacuuming*

13

Preliminarily treat bonding surfaces on cab (1) and side part (2, new part)

 The inserts are already pretreated ready for use.*



Pretreatment of bonding surfaces

AH60.00-N-0008-01B



Install

14

Insert inserts into cab*

 Touch pretreated inserts only with clean gloves.*

 Insert inserts into B and C-pillars precisely half way and fasten against falling out with one rivet each.*

Insert insert flush into rear wall cross member.*

Insert insert flush into floor cross member.*

Insert insert flush into entry.*

15

Position side part (2, new part) on cab, align and fasten with shop-made tool*

 Observe interior width.*



Pushrods for positioning inserts*

WF58.50-W-6320-01A

16

Screw in pushrod*

 Screw in pushrod into inserts from outside.*

 In order to position the inserts precisely it is necessary to mark the connecting rods.

17

Position inserts*

 Pull inserts out exactly half way (marking on pushrods), then unscrew pushrods.*

18

Inject glue into gluing holes at repair points*

 It is necessary for the separating gap to be covered with adhesive tape to ensure that the glue reaches all surfaces and does not exit at the separation gap between the cab and new part.*

Wind a number of layers of adhesive tape around gap.*

After gluing remove adhesive tape.

*BR00.45-Z-1006-08A



Notes on gluing aluminum channels

AH60.00-N-0018-01A

19

Drill remaining rivet holes

20

Rivet side part (2, new part) to cab*



 Position rivets and rivet before glue has hardened.*

21

Install side window

Remove and install glued side window*

AR67.30-W-2400A

22

Install detachable parts

AR61.10-W-5814A

Number

Designation

Order number

BR00.45-Z-1006-08A

Repair kit replaced by: A 009 989 36 71

A 957 600 00 93