1 | Body console |
2 | Mounting rail for front axle |
D61.10-0056-06
Warning | Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. | Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C. When working on these units, disconnect the power supply. | |
Topical note | Notes on performing repair, body work and welding on vehicles with airbags and RTE units | ||
Topical note | General information on body repair | ||
| Remove | ||
1 | Remove floor panel in cab | ||
2 | Remove all detachable parts in repair area | ||
3 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
4 | Separate body console (1) | ||
Work instructions for cutting | |||
Spot weld milling cutter | |||
| Install | ||
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. | |
Topical note | Measures for preventing damage to vehicles or components when performing electric welding work | ||
General notes on welding | |||
5 | Straighten connecting plates, grind down to bare metal and coat with zinc dust paint | Zinc dust paint suitable for spot welding | |
6 | Prepare body console (1) for installation | ||
Zinc dust paint suitable for spot welding | |||
7 | Fit body console (1), align and fix in place | ||
8 | Insert check and attachment plate | ||
Insert check and attachment plate in "repair" position. | |||
9 | Weld in body console (1) | ||
10 | Weld in retaining rail (2) for front axle | Only when installing new body console (1). | |
Zinc dust paint suitable for spot welding | |||
11 | Grind off any residue welding material | ||
12 | Install floor panel in cab | ||
13 | Pulling shock absorber strut mount with puller to prescribed incline angle | Model 909 | |
Use standard 4 t pulling set. | |||
Incline angle of shock absorber strut mount | |||
Choke angle gauge (electronic) | |||
14 | Stamp in vehicle identification number | Only when installing new right body console (1). | |
15 | Remove spark protection blankets | ||
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. | |
16 | Clean areas repaired and priming with MB primer filler | Use only primer filler approved by Daimler AG: | |
17 | Supplement standard seals with MB body sealant | ||
White sealing compound, 310 ml, DBL 6069.20 | |||
18 | Supplement standard underfloor protection with MB permanent underbody 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. | |
19 | Paint repair area adjacent surfaces | Use only paints approved by Daimler AG | |
20 | Add cavity preserving agent | ||
21 | Reinstall all detachable parts removed from repair area |
001 589 88 21 00
Choke angle gauge (electronic)
201 589 00 51 00
Spot weld milling cutter
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