Removing and installing side roof frame

AR65.20-L-1200VA

Removing and installing side roof frame

21.6.01



Remove

Danger!

Lethal injuries are possible if vehicle slips off of lifting platform

Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

Danger!

Risk of injury from cuts and grazes on sharp-edged vehicle components

Always wear protective gloves when working in vicinity of sharp, burred vehicle components.

AS00.00-Z-0017-01A



General notes on body repair

All models

AH60.00-N-0001-01A



Guidelines for removing fuel tank when performing welding work on bodies

All models

AH60.00-P-3000-01Z



General notes on riveting

AH60.00-P-0003-01N

1

Remove detachable parts in vehicle interior (repair area)

2

Cover all attached parts remaining in vehicle (area to be repaired)

Use fire-resistant tarpaulin

*WH58.30-Z-1001-40A

3

Remove center roof paneling

AR65.10-L-1000VA

4

Remove outer side wall

AR63.10-L-0805VB

5

Separate side roof frame

AR65.20-L-1200-01VA

Spot weld cutter

*201589005100

 Vario Drill WS 91 spot-weld loosening tool

*WH58.30-Z-1006-01A

 Spherical cutter, 12 mm

*WH58.30-Z-1002-01A

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

 Grinding disc, 115 mm, 80m/s (max.

*WH58.30-Z-1024-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Tarpaulin (fire-proof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Prepare side roof frame for installation

AR65.20-L-1200-02VA

 Round wire brush, braided,  70 mm

*WH58.30-Z-1001-03A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

Danger!

The high voltage used for arc welding presents a lethal hazard.Risk of explosion from welding in areas close to highly inflammable materials.Risk of injury when welding from weld splatter and UV light.Welding gases are poisonous when inhaled.

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

AS00.00-Z-0007-01A

7

Install side roof frame and weld in

AR65.20-L-1200-03VA

Polygrip aluminum/steel flat head rivets  6.414 mm

 Clamps

*WH58.30-Z-1031-02A

 Clamping pliers

*WH58.30-Z-1003-02A

 Screw-clamp grip, dia. 6.4 mm - Clamping range 0-15 mm, identification color silver

*WH58.30-Z-1038-02A

Pop rivet gun, model HN 1

*WH58.30-Z-1001-29A

 Electrode miller

*WH58.30-Z-1003-01A

Spot welder

*WE58.40-Z-1002-02A



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

All models

AH00.00-N-0005-01A

8

Clean welds and metal flanges with wire brush. Clean areas to be repaired.



9

Install outer side wall

AR63.10-L-0805VB

10

Install complete center roof paneling

AR65.10-L-1000VA

11

Prime areas to be repaired with MB-2K primer/filler.



Notes on paintwork repairs

All models

AH98.00-P-9408-02A

12

Supplement standard sealing with MB body sealant

Seam sealing after repairs

AR97.10-L-4000VA



General information on MB materials

All models

AH98.00-P-9409-03A

13

Supplement hollow cavity preservation



Preservation

AP97.20-P-0640A

14

Reinstall all removed assembly parts

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-1003-02A

Clamping pliers

WH58.30-Z-1031-02A

C-clamp

WH58.30-Z-1038-02A

Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver

Firma Hausmann GmbH D-34346 Hann. Münden, Germany

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1024-04A

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

WH58.30-Z-1001-29A

Lever riveting device

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (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