Cab, Body Repair - Heavy Haulers RV Resource Guide
Contents
1. 6 Remove the carpet from the luggage compartment floor Remove any other part that blocks the replacement pro cedure Group 81 Cab Body Repair Service Procedures W8001514 W8001512 Use a face shield to protect eyes and face when Use a face protection mask to shield the face and gloves to protect the hands when using the heat gun Failure to follow these recommendations may result in burns on face or hands drilling Use gloves to protect hands from sharp metal weld channel using a heat gun and a edges Failure to follow these recommendations may Remove the sealer from the panel scraper result in personal injury to eyes or skin Drill out the spotwelds using the spe cial drill bit for spotweld removal For proper panel removal procedures see Body Panel Removal page 21 29 Group 81 Cab Body Repair W8001506 Do not use an air chisel without proper safety equip ment such as eye protection and heavy gloves Failure to follow these recommendations may result in personal injury to eyes or skin Rough cut the panel out using an air chisel 30 Service Procedures Group 81 Cab Body Repair Remove all joint sealer around the seam between the back panel and the rest of the cab Grind off all weld seams around the beam and bracket ends Try not to remove any material from the cab structure that will be reused Note Remove the welds in such a manner that it can2. Order number PV776 TSP145522 2000 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents A 17 ee ee 3 al BOO me e mmm 3 OCCA GINS sis npe ce Oa AA a KK Bk UC 5 EP E 5 Panel Fit MBASURCINGWIS use en 5 DISS ENING sia leon 6 Cab Cross Measurement Points esee 8 o xe E 13 Cab Body Special Equipment and Materials sss 13 DESIGN and PONCHO ouo vero RW ere e Re e e e re Re 17 B o een 17 ip E E ION UF AI an 18 Measuring POMS E 18 Bud FAR ads 19 e E rere 19 Pil ESI ad 20 Service Procedures a 21 Body Panel Removal anne 21 Panel Installation Spotwelding eese 21 Panel Ihstallalon Pi gweliind een 21 Using Spotweld Removal Tool nennen ken 21 LANDE essen 21 Armada TRCN aria aa 22 WEINE arras 22 Prior TO Weldind aa 23 MAC WERNI ai 23 Hesiglance Spot Waldin a 24 A 25 Frame Frame ROBA n 25 Jointing Assembled Profiles era 25 Areas to Avoid Joining Mete 26 Rustproofing After Repair exc saie iuo Ra Xp X BER AER XE a dx RR n X XA 26 GUI TROC COA jsi 26 Body Panel Replacement u a 27 Rear Gab Panel Replacement u un 28 B
3. It should be large enough to cover the damage and approximately 50 mm 2 in to the sides of the dam age Apply FUSOF repair adhesive to the backer panel W8001818 Secure the backer panel on the re verse side of the damage Allow the adhesive to set before continuing work At room temperature the adhe sive will set in approximately 1 hour and will be completely cured in 24 hours For faster set use a heat lamp or heat gun to set the adhesive Group 81 Cab Body Repair Service Procedures W8001819 Use a respirator when sanding to protect lungs from foreign matter Failure to follow these recommenda tions may result in personal injury On the outer surface bevel the panel down on both sides of the damage us ing a No 50 grit disc W8001820 Remove paint from the surrounding damage and feather out several inches W8001821 Apply a light coat of FUSOR repair adhesive Spread out the adhesive W8001822 Place a pre cut piece of fiberglass re inforcement cloth onto the adhesive 37 Group 81 Cab Body Repair Service Procedures 9 11 Saas Fass TEE Tr Hi Hie HE p A Ma001823 Rough sand the area with a No 80 Apply a second coat of FUSOR re grit disc and a sander pair adhesive Use the applicator to work the adhesive into the cloth to re move all trapped air 12 10 Reinforcement Cloth e oe FUSOR ADHESIVE ROS au it e HE Bonding Strip
4. 2915 114 7 2915 114 7 2915 114 7 E 2088 82 2 2990 117 8 2990 117 8 2990 117 8 2990 117 8 N A N A F 2413 95 0 2425 95 5 2405 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 7 G N A 2250 88 6 2250 88 6 2250 88 6 2250 88 6 2250 88 6 2420 95 3 Group 81 Cab Body Repair Cab Cross Measurement Points To determine that a cab is within design specifications after an accident the following guide lines should be used to determine if the cab should be straightened or if it needs to be replaced Some of the guide lines stated are made on the basis that the interior is removed when measuring Inside Roof A2 DAYCAB VHD Specifications There are two types of measurements that can be made distance between two defined points within specification also the distance checked against the measurement from the other diagonal No diagonal measurement is complete without comparison with the corresponding di agonal A2 VN 420 A2 VN 610 A2 VN 770 W8002878 Cab Type Daycab VHD VN 420 mm VN 610 mm VN 660 mm VN 770 mm mm in in in in in Diagonal measurement A1 A2 1979 0 2325 5 2820 5 2820 5 3201 0 Measured from the front edge of 77 913 91 555 111 045 111 045 126 020 the rectangular hole on sleeper cabs 610 660 amp 770 the hole is covered to the center of the indi cated hole in the rear corner Group 81
5. Cab Body Repair Specifications Cab Brackets Below Floor W8001806 Cab Type Daycab VHD VN 420 mm VN 610 mm VN 660 mm VN 770 mm mm in in in in in Diagonal measurement D1 D2 1755 0 2425 0 2832 0 2832 0 3203 0 Measured from the center of the cab 69 094 95 472 111 496 111 496 126 100 bracket bolt hole to the center of the air spring bolt hole spring must be re moved Straight measurement I1 12 Measured from the center of the cab bracket bolt hole across to the same hole on other side All cabs 1042 0 41 024 Group 81 Cab Body Repair Windshield Opening G1 Specifications H2 W8001802 G2 Diagonal measurement G1 G2 Measured from the furthest point of the radius on one side to the furthest point of the radius on the other side allowing a space of 10mm 3 8 in from the flange 1981 0 mm 77 992 in Straight measurement H1 H2 Measured in the middle of the windshield opening allowing a space of 10 mm 3 8 in from the flange 709 0 mm 27 913 in 10 Group 81 Cab Body Repair Specifications Door Opening W8001803 Straight measurement J1 J2 1526 0 mm 60 079 in Measured from the furthest point of the radius on one side to the furthest point of the radius on the other side allowing a space of 10 mm 3 8 in from the crease Straight measurement K1 K2 1590 0 mm 62 598 in Measured from
6. Note Instructions in the service procedures are based on resistance spotwelding or MAG Metal Active Gas plug welding Spotwelding is the same method that was used when the cab was manufactured and also pro duces good results in a workshop environment When done according to recommended practices MAG welding meets strength and appearance requirements Important Oxy acetylene welding must not be used in body repair work on these cabs The High Strength Steel will alter its material properties when heated too much Adequate ventilation air evacuation equipment must be used when welding inside the cab Breathing weld ing exhaust may be hazardous to your health Always use a welding face mask to protect eyes and face Use welding gloves to protect hands Failure to follow these recommendations may result in personal injury to eyes or skin Do not section any body panel All panels and parts of the cab structure are designed to be load bearing The cab structure can be weakened if patching in panels or welding methods other than those de scribed in this manual are used Note Take care not to overheat the material when welding Group 81 Cab Body Repair Always disconnect the main battery ground last If there are other ground cables connected to the battery such as engine ECU satellite system etc discon nect those grounds first then remove the battery ground cable Electronic modules may be damaged when additi
7. W8001824 Lay a second layer of reinforcement cloth over the second coat of FUSOR adhesive Work the air out and cover the area again with bonding adhesive At room temperature the new bond will set in approximately 1 hour and will totally cure in 24 hours For better and faster curing use a heat lamp and Using No 220 to No 320 grit paper heat the bond to 80 C 180 F for 60 finish block sanding until the surface is minutes then allow the bond to cool smooth completely before working with it W8001826 38 Group 81 Cab Body Repair 8121 03 02 02 3 Roof Replacement SMC AN DANGER Before working on a vehicle set the brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Personal injury hazard Always wear safety goggles while using a heat gun and pry bar to remove scrap material Failure to use safety goggles could result in damage to the eyes The cab roof replacement described in this procedure can be used in the 610 VNL 660 VNM and 770 VN models Note Some Body Shops may not be equipped to re move the top cap as a complete assembly The following procedure demonstrates removal of the roof assembly in Remove the side windows in the left two sections Section one The left side Section two and right sides of the window in the The right side cab roof Removal 4 1 Always wear a
8. be clearly seen where the welds go when the new panel is in place Note Numbers 1 to 11 on the figure above show weld points Service Procedures W8001518 Use a face protection mask to shield the face and gloves to protect the hands when using the heat gun Failure to follow these recommendations may result in burns on face or hands Use a respirator when grinding to protect lungs from foreign matter Failure to follow these recommenda tions may result in personal injury 31 Group 81 Cab Body Repair 11 W8001513 Use a face shield to protect eyes and face when grinding Use gloves to protect hands from sharp metal edges Failure to follow these recommendations may result in personal injury to eyes or skin Cut the welds loose from the outside of the lower cab rails and remove the panel 32 Service Procedures 12 On the parts of the cab that will be reused grind the surface smooth at the removed spotwelds Take care not to grind off any material except the spotwelds 13 W8001511 Place the new panel securely into the opening Apply weld primer Press the panel in until it fits tightly against the opening Hold the panel in place with clamps Make sure the clamps are evenly distributed around the rim of the panel at the points indicated Group 81 Cab Body Repair W8001495 Service Procedures Check panel alignment before starting to weld Weld all adjoini
9. more information about rustproofing procedures refer to Service 182 500 Manual Rustproofing Cab VN VHD IMPACT Function Group 182 Information Type General Rustproofing Information Surface Coating Volvo VN series cabs are made to the highest quality standards All body repair practices should follow the same principle Always use genuine Volvo replacement parts in repairs Use the correct tools and correct meth ods Sand and clean the surface well use etch primer on any exposed metal fill any irregularities and use primer for the whole area Use sealant before painting Group 81 Cab Body Repair Body Panel Replacement For more work information also see Rear Cab Panel Replacement page 28 AN DANGER Before working on a vehicle set the brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids Before welding disconnect batteries and any Elec tronic Control Units ECUs equipped on the vehicle Failure to disconnect batteries and ECUs can result in damage to the electrical system or ECUs Disconnect batteries Disconnect all ECUs This includes the instrument cluster and control units for engine air bag ABS brakes air conditioning data concentrator Volvo engine Combi Rela
10. panels which are welded to the HSS frame profiles to form an integrated unit HSS has a higher strength to weight ratio than traditional steel or truck grade aluminum This process makes the cabs light and strong SLEEPER 660 Design and Function W8002879 W8001410 Group 81 Cab Body Repair Cab Frame The cab frame and body panels form a cage that protects the driver and passenger The cab exceeds pro tection safety standards in case of collisions or rollovers Unlike conventional cab structures where a load carry ing frame supports the outer body panels both the VN and VHD cab frame and body panels are designed to be part of the load carrying structure Therefore it is very important to follow the recom mended practices for repairing the cab body whether straightening panels or exchanging parts Measuring Points To inspect or check cabs that have been in an accident measuring points are used to determine the integrity of the cab structure Measurements with tolerances are given in Cab Cross Measurement Points page 8 18 Design and Function W8001354 D 770 VNL 610 660 W8002889 Group 81 Cab Body Repair Body Panels When major body damage occurs you should replace entire sections instead of changing parts within a sec tion Replacing an entire section perserves the structural integrity of the cab and generally t
11. the furthest point of the radius on one side to the furthest point of the radius on the other side allowing a space of 10 mm 3 8 in from the crease Straight measurement L1 L2 1011 0 mm 39 803 in Measured from the rear upper center of the hole for the door latch nose to the bottom edge of the A pillar flat area Group 81 Cab Body Repair Specifications Back Of Cab W8001805 Cab Type Other mm in VN 770 mm in Diagonal measurement M1 M2 2633 0 103 661 2721 0 107 130 Measured from the seam to the furthest point of the inside radius on the other side allowing for a space of 10 mm 3 8 in from the edges Group 81 Cab Body Repair Tools Tools Cab Body Special Equipment and Materials The 300 or 600 ml pneumatic dispenser can be ordered in different sizes from Lord Corp telephone 800 234 FUSOR see part numbers below P N 300ml 304 P N 600ml 312 W8002881 Supermix pneumatic dispenser available from Lord Corp telephone 800 234 FUSOR t P N 305 W8001 102 300 ml manual dispenser available from Lord Corp telephone 800 234 FUSOR P N 301 W8002291 Group 81 Cab Body Repair FUSOR Materials For repair and maintenance of the VN Series cab SMC panels and cab roofs Volvo recommends the use of FU SOR Bonding and Repair Materials The following items are available from Lord Corp telephone 800 234 FU
12. the roof cap with 80 grit sandpaper W8002821 Use a face shield to protect eyes and face when gringing Use gloves to protect hands from sharp metal edges Failure to follow these recommendations may result in personal injury to eyes or skin Epoxy prime all bare metal NIOSH approved respirator should be used for this step 44 Group 81 Cab Body Repair Service Procedures Installation 2 Adhesive Preparation 1 W8002604 FUSOR Manufacturer s Warning Attach a mixing tip and dispense a small amount of adhesive which is about the length and width of the IN WARNING mixer Dispense until evenly mixed This should be done with every tube This product contains a chemical known to the state used of California to cause Cancer W8002614 FUSOR Manufacturer s Cautionary Information Before using FUSOR adhesives refer to the specific material Safety Data Sheet MSDS for additional cau tionary and safe handling information If the MSDS is not in your files please request one from Lord Regu latory Compliance at 814 868 3611 ext 3407 Using the dispenser gun P N 304 305 or 312 squeeze out a small amount of product from each side of the catridge to level the plungers and purge out air W8002824 Apply T 20 or TF 24 FUSOR to the primed surface of the cab 45 Group 81 Cab Body Repair W8002825 Note See FUSOR technical data sheet for cure time The technical data s
13. 2 01 Rear Cab Panel Replacement For additional work information also see Body Panel Replacement page 27 AN DANGER Before working on a vehicle set the brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Always use a welding mask to protect eyes and face when welding Use a respirator and ensure good ven tilation when welding to protect lungs from foreign matter Failure to follow these recommendations may result in personal injury Use a face shield to protect eyes and face when grinding Use gloves to protect hands from sharp metal edges Failure to follow these recommendations may result in personal injury to eyes or skin Before welding disconnect batteries and any Elec tronic Control Units ECUs equipped on the vehicle Failure to disconnect batteries and ECUs can result in damage to the electrical system or ECUs 28 Service Procedures 1 Remove rear and side upholstery pan els Remove rear headliner 2 Remove bunk support Remove any other components that are blocking the replacement procedure 3 Remove the upright exhaust stack s from the rear of the cab 4 If equipped remove the air fairing side skirts and brackets for the roof fairing Lift off the entire air fairing T8006650 On sleeper cabs only remove the lug gage compartment door from both sides
14. SOR FUSOR Repair 12 80z P N T20 Bonding Adhesive 10 oz P N T21 FUSOR Factory Match Neutral P N T24 Urethane Seam Sealer Black in two colors 300 x 300 ml FUSOR Repair Adhesive P N T10 Heat gun kit Available from local tools distributor Windshield tool Kit J 42391 available from Kent Moore telephone 800 328 6657 14 FUSOR Expandable Foam Tools P N 121 W8002891 W8002882 W8002884 Group 81 Cab Body Repair Tools Heat Lamp available from local body shop parts distribu tor W8002885 Reciprocating Saw available from local tool distributor W8002886 Spot weld tongs Order from local welding supplier W0001456 Group 81 Cab Body Repair Tools Rivet nut insertion tool kit available from Kent Moore telephone 800 328 6657 P N J 42405 Spotweld removal tool available from Snap On or MAC P N C117X MAC P N YA2550 4 Snap On W0001457 16 Group 81 Cab Body Repair Design and Function Cab General There are five models of the VN series cab Day Cab and Sleeper Cabs 420 610 660 and 770 The sleeper model numbers refer to the measurement from the rear of the seats to the back wall 42 61 66 or 77 inches All exposed surfaces are streamlined for the best aero dynamic effect Panels and accessories mount flush to the cab surfaces Mounting hardware does not show All cabs are manufactured from high strength steel HSS body
15. Service Manual Trucks Group 810 500 Cab Body Repair VN VHD PV776 TSP145522 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to November 2000 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur Volvo Trucks North America Inc Greensboro NC USA
16. akes less time Because of the high strength steel used in the body parts it is typically harder to straighten and align a dam aged part High Strength Steel HSS HSS should not be treated as ordinary steel when repaired It is recommended that panels are replaced in stead of the general practice of cutting out and welding in smaller parts of a panel or sectioning HSS yield point increases when it is heat treated This means that panel straightening should be done while cold Heating the steel would make it harder to straighten Roof On 610 660 and 770 sleeper cabs the roof cap is made of SMC material Sheet Moulded Compound It is bonded riveted and screwed to the metal cab structure to form an integral part of the cab See Body Panel Re pair SMC page 36 or Roof Replacement SMC page 39 for work procedures Design and Function W8001801 W8001799 19 Group 81 Cab Body Repair Design and Function Air Fairings Air fairings are available for all models For more infor mation on Air Fairings please refer to Service 891 008 Bulletin Air Fairing Repair VNL VNM IMPACT Function Group 891 SS Information Type Bulletin Air Fairing Repair VNL VNM f f if WD P4 A A W8001364 20 Group 81 Cab Body Repair Service Procedures Service Procedures Body Panel Removal AN DANGER Before working on a vehicle set the brakes
17. er than 12 gauge 23 Group 81 Cab Body Repair Distance Between Holes Material Thick hess Distance A Distance B 0 6 mm 25 mm 10 mm 24 gauge 1 0 in 0 375 in 0 8 mm 30 mm 10 mm 21 gauge 1 1875 in 0 375 in 1 2 mm 35 mm 12 mm 18 gauge 1 375 in 0 50 in W8001810 W8001811 Use welding primer on all mating surfaces Allow to dry for 15 minutes If there is any grinding damage outside the welding surface apply filler primer and allow to dry for 15 minutes Apply sealant in all seams before priming and painting Check weld quality when complete Grind down plug welds with a grinding disc Grind off any weld splatter from the edges of weld spots Note Grind only the part of the weld that extends over the level of the panel Do not grind below thickness of panel W8001813 24 Service Procedures Resistance Spot Welding Always use a welding face mask to protect eyes and face Use welding gloves to protect hands Failure to follow these recommendations may result in personal injury to eyes or skin With spotwelding it is necessary to expose the metal in the weld seam for the necessary electric contact Re move any coating on panels where they are to be joined Note Compared to regular steel High Strength Steel parts need spotwelds closer together Before welding e Thoroughly check the area where parts are joined together Look for unevenness Use ham
18. he high standards of our literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America INC 0 eesssssee IIIImmemeeeennnehhhenehyennn Dept 516 Service Publications 2222526 7900 National Service Road 1 1 222mm RO Box20115b aaa eaa raare aea Greensboro NC 27402 6115 1 22221 nnenenrnn nennen nnne USA Fax 336 393 3170 Comments proposals Operation Numbers 8121 03 02 02 Roof Replacement SMC 8172 03 02 01 Rear Cab Panel Replacement VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http www volvotrucks volvo com PV776 TSP145522 1000 11 2000 Volvo Trucks North America Inc 2000
19. he right side of the cab roof Service Procedures W8002819 Always wear appropriate eye protection dust mask and gloves to prevent the risk of eye or skin injury due to contact with hot glue Remove supports and screws at the rear of the cab Note You may need to heat the adhe sive around the supports for removal Do not discard the supports and Screws they can be reused 10 W8002820 Cover the top edges of the cab with paper to protect it from debris 41 Group 81 Cab Body Repair Service Procedures Note Heat the remainder of the top cap with the heat lamp and heat gun Remove the remainder of the cab roof 42 Group 81 Cab Body Repair Service Procedures W8002818 Once the cab roof is completely off remove the excess adhesive from the top of the cab 43 Group 81 Cab Body Repair Service Procedures 13 15 Personal injury hazard Always wear safety goggles and a respirator while using a disc sander Failure to use safety goggles may result in damage to the eyes Failure to use a respirator may result in for eign material in the lungs Remove old paper and cover with new paper to protect paint from epoxy primer and sealer overspray 14 W8002823 Use a respirator when sanding to protect lungs from foreign matter Failure to follow these recommenda tions may result in personal injury Scuff primed area with 180 220 grit sandpaper also scuff the bottom side of
20. heet is enclosed with FUSOR prod ucts when ordered 46 Service Procedures W8002822 Move A frame in place and hook lift ing straps to the top cap Lift top cap up with A frame and move into posi tion Lower onto the cab Note Make sure the top cap is seated completely and square on all four cor ners Fork lift may be used if shop does not have an A frame 6 Remove any excess adhesive Re move paper when the FUSOR is cured Note See FUSOR technical data sheet for cure time The technical data sheet is enclosed with FUSOR prod ucts when ordered 7 Install the support screws at the rear of the cab Tighten screws 8 Install front sunvisor Tighten screws 9 Install rear left and right top air fairings and support brackets Tighten screws Group 81 Cab Body Repair 10 W8002828 W8002827 Install left and right top cap windows To install skylight refer to Service 800 500 Manual Skylight Glass Replacement 770 Supplement IMPACT Function Group 8439 Info Type Repair Cab General Cab Doors and Cab Glass VN VHD Note The repair time may vary de pending on whether a forklift or an A frame is used Service Procedures 47 48 Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain t
21. ission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death SMC although its appearance is similar to fiberglass is not a conventional fiberglass panel The repair tech niques may be similar but the composition of SMC and the materials used to repair it are quite different At this time only FUSOR bonding materials have been ap proved and recommended for panel bonding structural repairs and cosmetic repairs on the Volvo SMC metton and telene panels Fiberglass resin and ordinary polyester fillers should not be used In time the ad hesion of these materials weakens and the repair will fail 1 W8001815 Inspect the damaged area and clean out loose material If damage extends completely through the panel a backer panel will be necessary W8001816 36 Service Procedures Use a respirator when sanding to protect lungs from foreign matter Failure to follow these recommenda tions may result in personal injury Prepare the backer panel for bonding by scuffing the back side of the dam aged area using a No 80 disc on a sander W8001817 The backer panel can be fabricated from a scrap piece of SMC or fiber glass reinforcement cloth saturated with FUSOR T20 T21 or T10 adhe sive See Fusor Materials in the following section Cab Body Special Equipment and Materials page 13 for information on recommended adhe sive
22. le front edge of the luggage com 4 0 2 0 mm Parallell 2 0 mm partment door to the cab side 0 16 0 08 in Parallell 0 08 in 3 Measured over the whole top edge of the luggage com 5 0 2 0 mm Parallell 2 0 mm partment door to the cab side 0 20 0 08 in Parallell 0 08 in 4 Measured on both sides for centering the vent in the cab 8 0 2 0 mm N A opening 0 31 0 08 in 5 Measured on both sides for centering the vent in the cab 7 0 2 0 mm N A opening 0 28 0 08 in Group 81 Cab Body Repair Specifications Overall Dimensions t Front Axle t Front Axle VNL 660 VNL 770 W8002888 Group 81 Cab Body Repair A WB Front Axle VHD AXLE BACK W8002890 Specifications As WB gt Front Axle VHD AXLE FORWARD For tire size 275 80R22 5 VHD mm VNM mm VNL mm in VNL 420 mm VNL 610 mm VNL 660 mm VNL 770 mm in in in in in in AF 740 A AD Le 1295 51 0 1435 56 5 1435 56 5 1435 56 5 1435 56 5 1435 56 5 51 1 B 2885 13 6 2870 113 0 3120 122 8 3935 154 9 4405 173 5 4405 173 5 4805 189 2 C 1888 94 3 1995 78 5 1995 78 5 1995 78 5 2350 92 5 2975 117 1 2975 117 1 D N A 2930 115 4 2930 115 4 2930 115 4
23. mer and counterhold to straighten metal e If grinding damage extends outside of the immedi ate welding area apply a coat of filler primer to the area Allow to dry for 15 minutes e Before welding apply welding primer to the inside surface of the flanges on both sides Allow to dry for about 15 minutes Before starting on the panels weld some test pieces first then check the weld quality by forcing them apart This tests the capacity of the spotwelding tongs Spacing between spotwelds should be approximately Spacing A Spacing B Sheet Gage Between Welds From Edge 0 6 mm 11 mm 5 mm 24 gage 7 16 in 3 16 in 0 8 mm 14 mm 5 mm 21 gage 9 16 in 3 16 in 1 0 mm 18 mm 6 mm 19 gage 11 16 in 1 4 in 1 2 mm 22 mm 7 mm 18 gage 7 8 in 9 32 in 1 4 mm 25 mm 8 mm 16 gage 1 in 5 16 in Grinding spotwelds is usually not necessary Only clean the surface and use filler before painting Group 81 Cab Body Repair Alignment Do not use welded anchorages on sheet metal parts which will not be replaced For best results continuously check alignment W8001809 Do not use heat when aligning The yield point of High Strength Steel increases with heat treatment W8001812 Frame Profile Repair The damaged section should be replaced with a corre sponding section taken from a spare part that has been cut out and matched Cut a strip approximately 40 mm 15 in long from the remainder of
24. ng points be tween panel crossmembers and the sides of the cab Welds should be the same length and in the same location as the removed welds Note Numbers 1 to 11 on the figure above show weld points on the left figure shows welding by hand W8001518 33 Group 81 Cab Body Repair Service Procedures W8001510 The panel can be either spotwelded or plugwelded in place For plugweld weld through the holes made when the panel was removed or see MAG Welding page 23 for more information For spotweld see Frame Profile Re pair page 25 for more information Group 81 Cab Body Repair 16 W8001507 If the panel was plugwelded grind the welds until smooth Do not grind off any material from the panel 17 Put primer on all areas to be seam sealed Let the primer dry for at least 15 minutes before applying seam sealer Service Procedures 18 W8001508 Seal all joints and weld areas inside and outside with seam sealer 19 Prepare surface for priming and paint ing If needed apply rustproofing on any inside surfaces or on the inside of profiles For information on rustproof ing procedures refer to Service Manual IMPACT Rustproofing Cab VN VHD Function Group 182 Information Type General Rustproofing Infor mation 35 Group 81 Cab Body Repair Body Panel Repair SMC AN DANGER Before working on a vehicle set the brakes place the transm
25. ody Panel Repair SMG une 36 Roof Replacement SMG savia anaoa 39 Feedback Operation Numbers Group 81 Cab Body Repair General General Cab Body This service manual covers the repair or replacement of body panels for VN series cabs which includes day cab VHD sleeper cabs 420 610 660 and 770 Additional information for working in and around the cab can be found in the Service Information Manuals in Group 8 These include Cab General Cab Doors and Cab Glass Cab Suspension Cab Upholstery Climate Control Cab Interior Equipment and Supplemental Re straint System SRS W8001801 AN DANGER Vehicles equipped with the Supplemental Restraint System SRS must be treated with care when repairs are made To avoid injury when carrying out a repair or to avoid damage or malfunction of the SRS system refer to the SRS Service Manual for information Fail ure to follow the correct service procedures may cause severe personal injury or cause the SRS not to deploy during an accident This could result in severe injury or death to the driver of the vehicle Group 81 Cab Body Repair Specifications Specifications Cab Panel Fit Measurements W8001409 Measure A B 1 Measured over the whole length of the rear edge of the 8 4 1 5 mm Parallell 88 mm door to the cab side 0 33 0 06 in Parallell 9 in 2 Measured over the who
26. onal grounds are connected disconnected without the main battery ground connected Prior To Welding Plan the job in advance Do not remove more components than necessary Locate wiring harnesses Note Disconnect batteries before welding Also discon nect any Electronic Control Unit ECU in the electrical system especially the Engine ECU Airbag ECU Instru ment cluster Air conditioning control module and ABS control module Other ECUs may be installed Check the wiring diagram for the vehicle In general control units can not have long term exposure more than 15 min utes to temperatures greater than 90 C 195 F W8001801 Service Procedures MAG Welding Always use a welding face mask to protect eyes and face Use welding gloves to protect hands Failure to follow these recommendations may result in personal injury to eyes or skin With MAG Metal Active Gas welding it is not necessary to clean the panels of electro deposits or phosphating primer Note Compared to regular steel High Strength Steel parts need slightly larger holes for plug welds Punch Replacement Part for Plug Welding If the panel does not already have holes made for plug welding select the hole size according to the metal thickness 6 mm 0 25 in for thickness less 1 5 mm Wal ee 16 gauge 8 mm 0 3125 in for thickness 2 5 mm less than ces 12 gauge 10 mm 0 375 in or over for 2 5 mm thickness great
27. place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Always wear a face shield or safety goggles when drilling or grinding When sanding or grinding off sur face coating wear a respirator Failure to follow these recommendations may result in personal injury to the eyes or lungs Before removing panels determine the type of welding method to be used for installation of the new panels Dif ferent removal approaches should be used depending on whether the new panel is MAG metal active gas welded or spotwelded Panel Installation Spotwelding If spotwelding is used to install the new panel remove the damaged panel with a spotweld removal tool work ing from the side of the damaged panel This puts the holes in the damaged panel and leaves the undamaged panel whole after grinding off of the welds to leave a good spotwelding surface w 7 f 9f Kr N WP i A4 W8001807 Panel Installation Plugwelding If MAG welding is used to install the new panel remove the panel with a spotweld removal tool working from the side of the undamaged panel or drill through the spotweld from either side This puts holes in the undam aged part that will be used for plug welding the new panel in A NER ENE NEN ERENCE f N 1 f f N W8001808 Using Spotweld Removal Tool To drill out spot
28. ppropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids Remove the rear top air fairing on the right and left sides of the cab Remove the support brackets Use a respirator when grinding to protect lungs from foreign matter Failure to follow these recommenda tions may result in personal injury Remove the exterior sunvisor discon nect wiring Service Procedures W8002811 W8002812 39 Group 81 Cab Body Repair Service Procedures N Psal ane W8002828 Note Possible need for use of a lubri cant on the rubber molding around the window to help with removal If the skylight is not damaged refer to Service 800 500 Manual Skylight Glass Replacement 770 Supplement W8002813 Draw a line starting 299 mm 9in IMPACT Function Group 8439 from the base of the cab roof around Info Type Repair to the bottom of cab roof Cab General Cab Doors and RER m Cab Glass VN VHD Note This will be your cutting line for the cab removal 5 W8002814 Remove all wiring from the left and right sides of the cab roof Remove any foam rubber 40 Group 81 Cab Body Repair W8002816 1 amp 2 Forklift Forks 3 Lifting Straps Remove one section of the cab roof at a time Note Cut a hole 406 mm 16in from the opening of the window Remove window with a forklift or A frame ny lon lifting straps 8 Repeat the previous step for removal of t
29. the spare part This should then be cut lengthwise and fitted inside the profile Drill holes in the undamaged part and in the aligned spare part Spotweld or plugweld the joint strip approxi mately 20 mm 8 in on the undamaged part Place in Service Procedures position and spotweld or plugweld the piece taken from the spare part Then seamweld the joint 40 T8006462 Jointing Assembled Profiles When jointing an assembled profile offset the joints in the profile approximately 100 mm 4 in When aligning assembled profiles make sure that the inner profiles are aligned and do not have residual defor mations T8006463 25 Group 81 Cab Body Repair Areas to Avoid Jointing In load bearing structures jointing must not be done within the intermediate panel or within the floor member W8002304 1 Intermediate panel 2 Floor member 26 Service Procedures Rustproofing After Repair The area needs to be treated with rustproofing oil e after a panel has been replaced e if repair has been done to the panel e if sealant was removed Warranty against cab rust is only valid for the cab as it is delivered from the plant If repairs are done the repaired area is not covered by the rust warranty If the vehicle is exposed to a corrosive atmosphere salt sulphur or other oxidizing elements it is recommended that the initial rust protection be inspected and added to if necessary For
30. welds a special drill bit should be used We recommend using a 13 mm 0 5 in hole cutting bit which is available from many tool suppliers It can be or dered from Snap P N YA2550 4 On MAC P N C117X The cutting depth of the bit is adjustable and provides a quick clean cut Note Work with care so that the surfaces on parts to be reused are not damaged Use whichever method that causes the least damage W8001814 Using Drill In some places such as the rear wall panel the spot welds can be drilled out using a 13 mm 0 5 in drill bit to drill through both sheets The hole remains in the panel that is to be saved and becomes the hole used for plug welding the new panel to the cab Note This method should be used only when the new panel is plug welded into place 21 Group 81 Cab Body Repair uy O W8001827 Grinding Plugwelds The remaining bumps from spot welding or plug welding are ground off Grind only to the surface of the panel Take care not to remove any material from the panel that is reused W8001813 22 Service Procedures Welding AN DANGER Before working on a vehicle set the brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids
31. y Road Relay etc Do not section any body panel All panels and parts of the cab structure are designed to be load bearing The cab structure can be weakened if patching in panels or welding methods other than those de scribed in this manual are used Determine the method of installation for the new panel This dictates the method of removal see Body Panel Removal page 21 3 Check the new panel and the reused parts of the cab for a good fit Align the reused parts if necessary see Alignment page 25 Service Procedures 4 Prepare the surfaces of the panels for welding If using spotwelding see Frame Profile Repair page 25for more information If using plugwelding see MAG Welding page 23 5 Line up the parts and hold in place with clamps or self threading sheet metal screws until the part is welded into place 6 Before welding check settings by do ing test welds on scrap pieces that are of the same thickness as in the parts to be welded 7 Weld the part into place using either spotwelding or plugwelding Remove clamps 8 Prepare surface for filler and seam sealer Grind down plugweld humps and any spatter Do not remove any material from the panel 9 Coat all ground areas with primer and let it dry for about 15 minutes Use seam sealer for all seams and weld area FUSOR Seam Sealer is paintable in approximately 30 minutes 27 Group 81 Cab Body Repair 8172 03 0
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