Separating outer side wall - AR63.10-P-0805-01PA

Fig 1: Identifying Weld Spot Miller (201 589 00 51 00)

Fig 2: Identifying Cutting Templates (203 589 06 23 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
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-1004-20A	Hot-air gun

WORKSHOP EQUIPMENT

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

REPAIR MATERIALS

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

Fig 3: Identifying Separation Points On Side Wall

Mark separation points on side wall and separate with body saw (areas A and B).
Mark separation point on side longitudinal member with cutting template.

Fig 4: Identifying Outer Side Wall Spot Welds Area (1 Of 4)
Expose spot welds and cut out with spot weld cutter (areas C, D, M and T).
Expose spot welds and cut out with spot weld cutter (areas E, F, K, N, O, P, Q and R).
Bend up spot welding flange (area P).

Fig 5: Identifying Outer Side Wall Spot Welds Area (2 Of 4)

Fig 6: Identifying Outer Side Wall Spot Welds Area (3 Of 4)
Expose spot welds and cut out with spot weld cutter (areas H, J and L).
Expose spot welds and cut out with spot weld cutter (areas G, H and I).

Fig 7: Identifying Outer Side Wall Spot Welds Area (4 Of 4)
Heat side wall in shaded areas with hot air blower.
Checked areas are foam-protected.
Remove side wall

Fig 8: Identifying Outer Side Wall Heated Area

Fig 9: Identifying Outer Side Wall Spot Welding Flange Grinding Area (1 Of 2)
Grind connection surfaces down to bare metal in shaded areas. Sand spot weld flanges to bare metal on both sides
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.

Fig 10: Identifying Outer Side Wall Spot Welding Flange Grinding Area (2 Of 2)