Partially replace complete side wall in combination with complete side longitudinal member and floor panel

AR63.10-W-0807B

Partially replace complete side wall in combination with complete side longitudinal member and floor panel

13.1.04



Remove

 Danger!

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 undeburred vehicle parts. Deburr replacement panels.

AS00.00-Z-0017-01A



General information on body repair

AH60.00-N-0001-01A

1

Remove detachable parts in area to be repaired

2

Cover remaining detachable body components in area to be repaired

 Use fireproof tarpaulin to avoid damage from flying sparks.

*WH58.30-Z-1001-40A

3

Remove complete side wall (1), complete side longitudinal member (8) and floor panel (3)

AR63.10-W-0807-01B

 Spot weld milling cutter

*201589005100

 Spherical milling cutter, dia. 12 mm

*WH58.30-Z-1002-01A

 Vario Drill WS 91 spot-weld loosening tool

*WH58.30-Z-1006-01A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

*WH58.30-Z-1024-04A

 Cutting disk, dia. 65 mm, 80 m/s
(max. 23.500 rpm)

*WH58.30-Z-1021-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

4

Prepare connection surfaces of body for installation

AR63.10-W-0807-02B

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

*WH58.30-Z-1024-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare complete side wall (1), complete side longitudinal member (8) and floor panel (3) for installation

AR63.10-W-0807-03B

 Hole punching pliers, dia. 7 mm

*WH58.30-Z-1002-02A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

*WH58.30-Z-1024-04A

 Cutting disk, dia. 65 mm, 80 m/s
(max. 23.500 rpm)

*WH58.30-Z-1021-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Set up straightening bench with cross members

 Observe manufacturer's plans for straightening set.

7

Install straightening set

 Observe manufacturer's plans for straightening set.

8

Set cab on straightening bench and fasten.



Install

 Danger!

Risk of death caused by high voltage used for arc welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV-light while welding. Risk of poisoning caused by inhaling welding vapors.

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

AS00.00-Z-0007-01A

9

Install complete side wall (1), complete side longitudinal member (8) and floor panel (3) and weld in

AR63.10-W-0807-04B

 Electrode miller

*WH58.30-Z-1003-01A

 C-clamps

*WH58.30-Z-1031-02A

 Clamping pliers

*WH58.30-Z-1003-02A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

*WH58.30-Z-1024-04A

Celette straightening bench M8S

*WE58.40-Z-1001-01E

Celette straightening bracket set, CC 7942

*WE58.40-Z-1004-01C

Inert gas welder

*WE58.40-Z-1001-02A

Spot welder

*WE58.40-Z-1002-02A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A



Measures for preventing damage to vehicles or components when performing arc welding work

AH00.00-N-0005-01A

10

Weld welding bolt to floor panel (3) and to complete side longitudinal member (8) with stud welder

Stud welder

*WE58.40-Z-1004-02A



Measures for preventing damage to vehicles or components when performing arc welding work

AH00.00-N-0005-01A

11

Supplement seals with MB body sealant in area to be repaired

12

Paint repair area and adjacent surfaces

 See Paintwork Manual

13

Supplement MB cavity preservation

14

Reinstall all detachable body components removed

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1002-02A

Hole punching pliers, dia. 7 mm

WH58.30-Z-1003-02A

Clamping pliers

WH58.30-Z-1031-02A

C-clamp

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1021-04A

Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)

WH58.30-Z-1024-04A

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1004-01C

Josam commercial vehicle straightening system, No. Jo 20 - 40

WE58.40-Z-1001-01E

Celette straightening bench

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1004-02A

Stud welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42