Remove/install front roof frame - AR65.20-P-1006V

MODEL 171, 172 

Shown on model 171 

Fig 1: Identifying Front Roof Frame Remove/Install Components - Shown On Model 171

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of death  caused by high voltage used for electric welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding splatter and UV light while welding. Risk of poisoning  caused by inhaling welding fumes.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.	AS00.00-Z-0007-01A
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Measures for preventing damage to components when performing electric welding and soldering work		AH60.00-P-0001-02A
	General information on body repair		AH60.00-N-0001-01A
	General information on MB materials		AH98.00-P-9409-03A
1	Remove all detachable parts in area to be repaired
2	Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket	Welding protective blanket
3	Equip straightening bench with module members, cross members and straightening tool set.	Observe enclosed set-up plans. Straightening bracket set, passenger cars, cross-country vehicles (Celette)   Straightening system, passenger cars (Car Bench)
4	Place vehicle on straightening bench lift and fasten	Two-column lift 3.0 - -3.5 t electromechanical   Two-post lifting platform, 2.5 - 3.5 t electrohydraulic
5	Separate front roof frame (1)		AR65.20-P-1006-02V
		Spot weld milling cutter Weld-spot milling machine   Round wire brush	Fig 4
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
6	Prepare front roof frame (1) for installation		AR65.20-P-1006-04V
		Round wire brush
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
7	Set up portal frame with welding device	Observe setup plans provided.
		Portal frame	Fig 2
		Welding device	Fig 3
8	Install front roof frame (1)		AR65.20-P-1006-05V
		Portal frame	Fig 2
		Welding device Straightening bracket set, passenger cars, cross-country vehicles (Celette)   Straightening system, passenger cars (Car Bench)   Multifunction device (spot welding)   MIG-MAG inert gas welder   Wet and dry vacuum cleaner   Round wire brush	Fig 3
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
9	Remove portal frame with welding device
10	Release vehicle from straightening bench, lift vehicle and remove straightening bench	Two-column lift 3.0 - -3.5 t electromechanical   Two-post lifting platform, 2.5 - 3.5 t electrohydraulic
11	Clean weld joints and sheet metal flanges with rotary wire brush	Round wire brush
12	Remove welding protection blankets
13	Clean repair area	Wet and dry vacuum cleaner
	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 skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
14	Prime repair area with primer filler	Only use approved primer filler from Daimler AG.
15	Carry out seam sealing after repairs	Model 171	AR97.10-P-4000V
		Model 172	AR97.10-P-4000W
	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 skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
16	Paint repair area adjacent surfaces	Use only paints approved by Daimler AG.
17	Apply additional cavity preservation	Model 171	AR97.20-P-1500V
		Model 172	AR97.20-P-1500W
18	Install all removed detachable parts

Fig 2: Identifying Portal Frame (129 589 03 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Welding Device (171 589 00 23 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42