Prepare reinforcement plate and weld on

AR49.20-W-0002-01A

Prepare reinforcement plate and weld on

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

 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

General information and guidelines for welding on the exhaust aftertreatment unit

AH49.20-N-0001-01A

Engine

470.9, 471.9 in model 963

with code C5A (ADR chassis)

with code C8Z (Side skirts, aerodynamic)

with code K7D (Exhaust system, tailpipe to right and outwards)

with code M5Z (Engine version, Euro VI)

Engine

470.9, 471.9 in model 964

with code C5A (ADR chassis)

with code K7D (Exhaust system, tailpipe to right and outwards)

with code M5Z (Engine version, Euro VI)

1

Cut off brackets (1) at exhaust gas aftertreatment unit (2).

 Do not damage the electrical lines (3, 4) when cutting off the bracket (1).
For damage to the electrical lines (3, 4) the functionality of the EATU (2) is no longer given.

2

Smoothen weld seams (5) on the EATU (2).

3

Check smoothening the weld seams (5) as to whether cracks (6) are present in the sheet metal of the EATU (2).

If no cracks (6) are present,



Continue with operation step 7.

4

Drill a hole (7) with a 3 mm drill bit at the beginning and end of the cracks (6).

 By drilling out the beginning and end of cracks (6) further cracking is prevented after welding shut.

5

Weld shut cracks (6) and holes (7).

6

Smoothen welded shut cracks (6) and holes (7).

7

Check whether a repair panel (8) must be welded-in.

If no repair panel (8) needs to be welded in,



Continue with operation step 11.

8

Fabricate repair panel (8).

 Only an alloyed stainless steel plate (DIN 1.4301) with a material thickness of 0.8 mm may be used for the repair panel (4). If the hole in the exhaust gas aftertreatment unit (2) exceeds a size of 10 x 10 cm, the unit must be replaced.

9

Weld repair panel (8) onto the exhaust gas aftertreatment unit (2).

10

Smoothen weld seam of repair panel (8).

11

  Screw template (10.1, 10.2) to the repair panel (9).

 Repair panel (9) (A 000 490 56 40)

12

Lay repair panel (9) with the   template (10.1, 10.2) to the EATU (2).

If the edges of the repair panel (9) protrude too far from the exhaust gas aftertreatment unit (2),



mark repair panel (9) at bending points (arrows),   remove template (10.1, 10.2) and then plastically deform the repair panel (9) under the hydraulic press. Attach   template (10.1, 10.2) again to the repair panel (9) and again check the distance of the edges of the EATU (2).

13

Attach a repair panel (9) to four points on the EATU (2).

14

  Remove template (10.1, 10.2).

15

Weld repair panel (9) onto the EATU (2).

 The length and the position of the weld seams (A, B, C, D, E, F, G) must be observed.

A

Weld seam (88 mm long)

B

Weld seam (32 mm long)

C

Weld seam (28 mm long)

D

Weld seam (18 mm long)

E

Weld seam (89 mm long)

F

Weld seam (87 mm long)

G

Weld seam (19 mm long)