Unt dr FORD GALAXY 2006 Service Repair Manual

The\frefriger\btion\fsystem\fis\ffilled\fwith\frefriger\bnt\fR134\b.\fThis\fc\bn\fc\buse\ffrostbite\fif\fit\f
cont\bcts\fthe\fskin.\fP\by\f\bttention\fto\fthe\fcorresponding\fw\brning\fnotices\f\bnd\finstructions\fin\f
the\fch\bpter\fAir\fConditioning\fSystems.\f
NOTE:\fWork\fon\fthe\frefriger\bnt\fcircuit\fm\by\fonly\fbe\fperformed\fby\fpersons\fwho\fh\bve\f\b\f
relev\bnt\fcertific\bte\fof\fcompetence.\f
Vehicles\fwith\f\b\frefriger\bted\fcomp\brtment\f\bre\foften\fuse
d\fto\ftr\bnsport\ffoodstuffs.\fFor\fthis\f
re\bson,\f\bddition\bl\fhygiene\fregul\btions\fmust\fbe\fcomplied\fwith\fduring\frep\bir\fwork.\f
Aluminum\f\bnd\fpl\bstic\f\bre\fused\fto\fconstruct\fthe\ftwo\fdifferent\ftypes\fof\fcomp\brtment\ffound\f
on\frefriger\bted\fvehicles.\f
The\f\bluminum\fconversion\fis\f\b\fvery\fst\bble\f\bnd\ftechnic\blly\fperfect\fv\bri\bnt.\fHowever,\f\bg\binst\f
this\fthe\frel\btively\fhigh\fproduction\fcosts\f\bnd\f\b\flower\fp\bylo\bd\fmust\fbe\ft\bken\finto\f\bccount,\f
bec\buse\fof\fthe\fweight\fof\fthe\f\bluminum\fconversion\fitself.\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ff o
llowing\ftopics.\fYou\fwill\ffind\f\bn\f
overview\fof\fthe\fcomplete\fr\bnge\flisted\fin\fthe\fTr\bining\fbrochure\fpublished\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
The\fpl\bstic\fconversion\fh\bs\fdeveloped\finto\f\b\flight,\fcle
\bn\f\bnd\feconomic\bl\f\bltern\btive\fbec\buse\f
of\fconst\bnt\ffurther\fdevelopment\fof\fm\bteri\bls\f\bnd\fworking\ftechniques.\f
NOTE:\fThe\fm\bteri\bl\fcombin\btions,\fthe\fworkm\bnship\f\bnd\ft
he\fworking\fmethods\fmust\f
comply\fwith\fthe\fcurrent\ffood\fhygiene\fregul\btions.\fFor\fthis\fre\bson,\fservice\f\bnd\frep\bir\fwork\f
on\fthe\frefriger\bted\fconversion\fm\by\fonly\fbe\fperformed\fby\f\buthorized\f\bnd\fspeci\blly\ftr\bined\f
technici\bns.\f
Refriger\bted\fcomp\brtment\fconstructions\f\bre\foften\fm\bde\f
using\fboth\fm\bteri\bls.\fThe\ffloor\fp\bn\f
is\fm\bde\fof\fstructured,\fslip-proof\f\bluminum\fp\bnels\f\bnd\fthe\fw\bll\f\bnd\fceiling\fcl\bdding\fis\fm\bde\f
of\fsmooth\fsurf\bced\fpl\bstic\felements.\f
CAUTION:\fPUR\fh\brd\ffo\bm\fis\ffl\bmm\bble.\fIf\fPUR\fh\brd\ffo\bm\f
is\foverhe\bted,\fit\fwill\fburn\f
on\fits\fown\fwith\f\b\fbrilli\bnt\fyellowish\ffl\bme.\fIt\fproduces\funple\bs\bnt\fchoking\f\bnd\ftoxic\f
fumes.\fSpeci\bl\fme\bsures\fmust\fbe\ft\bken\fwhen\fwelding\fthe\fvehicle\fbody.\f
Polyureth\bne\fw\bll\f\bnd\fceiling\felements\f\bre\fm\bnuf\bcture
d\fusing\f\b\fs\bndwich\fprinciple.\fAn\f
insul\bting\fpolyureth\bne\fcore\fis\fco\bted\fwith\ffood\fgr\bde\fABS\fpl\bstic\fon\fone\fside.\f
PUR\fh\brd\ffo\bm\fdoes\fnot\fdecompose,\fis\frot\fresist\bnt\f\bnd\fis\fodorless.\fThese\fproperties\fm\bke\f
it\fsuit\bble\ffor\fuse\f\bs\finsul\btion.\f
Bec\buse\fof\fits\fclosed\fcell\fstructure,\fw\bter\fupt\bke\fby\fPUR\fh\brd\ffo\bm\fis\ffor\fthe\fmost\fp\brt\f
only\f\b\fproblem\f\bt\fedges.\fCut\fedges\for\fother\fmech\bnic\blly\fworked\fsurf\bces\fmust\fhowever\f
be\fse\bled\fwith\fthe\fgre\btest\fc\bre.\f
The\fconversion\fto\f\b\frefriger\bted\fvehicle\fis\fperformed\f\bs\fm\bde-to-order\fproduction.\fThe\f
l\brge\fsurf\bces\fof\fthe\fw\bll\f\bnd\fceiling\fcl\bdding\fc\bn\fbe\fch\bnged\f\bnd\f\bre\fp\brticul\brly\fe\bsy\fto\f
rep\bir.\f
If\f\bccess\fto\fthe\fb\bck\fof\f\b\fbody\fp\bnel\fsection\fis\fneeded\fbec\buse\fof\fbody\fstr\bightening\fwork,\f
in\fsome\fcircumst\bnces\fit\fis\fche\bper\fto\fperform\f\b\fcut-out\frep\bir\finste\bd\fof\fremoving\f\bn\f
element.\f
The\frep\bir\fprocess\fis\ffully\fdescribed\fin\fthe\fStudent\fInform\btion\fbooklet\fRefriger\btion\f
System\fTechnology,\fTr\bnsit\f2000.5\fFreshline.\f
Стр. 4 из 4
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Body Re\bair\f - General Information -
Environmental Regulation\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Orderly\f\bnd\fresponsible\fw\bste\fm\bn\bgement\fis\fnot\fonly\fvery\fimport\bnt\ffor\fthe\fprotection\fof\f
he

\blth\f\bnd\fthe\fenvironment,\fbut\fit\f\blso\fh\bs\fgre\bt\fimport\bnce\fwhere\fs\bving\fn\btur\bl\f
resources\fis\fconcerned.\f
In\fbody\frep\bir\fshops,\fsince\fthe\fintroduction\fof\fthe\fEU\fdirectives\fon\fthe\f\bvoid\bnce\fof\fvehicle\f
w\bste\f\bnd\fthe\fpromotion\fof\freturn,\fre-use\f\bnd\frecycling\fof\fvehicles\f\bnd\ftheir\fcomponents\f
(2000/53/EU),\fmore\frigorous\f\bttention\fth\bn\fbefore\fis\f\blso\fp\bid\fto\f\bvoid\bnce\f\bnd\frecycling\f
of\fw\bste\fm\bteri\bls.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\foper\btion\fm u
st\fcomply\fwith\fthe\fcountry\fspecific\f
w\bste\fregul\btions:\f\f
In\fthis\frespect,\fbody\frep\bir\fshops\fmust\ft\bke\finto\f\bcco
unt\f\bnd\fcomply\fwith\fthe\ffollowing\f
requirements:\f\f

Sep\br\bte\fw\bste\f\bccording\fto\fits\frecycling\f\bnd\fdispos\bl\fmethods.\f\f

Produce\fevidence\ffor\fthe\fcorrect\ftr\bnsport\f\bnd\fdispos\bl\fof\fw\bste.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\fpl\bnt\fmust\fcomply\fwith\fthe\frequirements\fof\fthe\f
W\bs
te\fAvoid\bnce\f\bnd\fM\bn\bgement\fAct.\f\f
The\f\bvoid\bnce\f\bnd\frecycling\fof\fw\bste\fmust\f\blw\bys\ft\bke\f
priority.\fHowever,\fdespite\f\bll\f
me\bsures\fwhich\fm\by\fbe\ft\bken,\fw\bste\fc\bnnot\fbe\fcompletely\f\bvoided.\f
NOTE:\fUse\bble\fw\bste\fwhich\fis\fnot\f\bllowed\fin\fhousehold\f
rubbish,\fmust\fbe\fdisposed\fof\f\bs\f
speci\bl\fw\bste\f
All\frem\bining\fw\bste\fmust\fbe\ftre\bted\f\bs\fcommerci\bl\fw\bst
e\f\bnd\fdisposed\fof\f\bccording\fto\fthe\f
loc\bl\frequirements.\f\f
Only\f\bpplies\fto\fthe\fEU:\f
The\fvehicle\fm\bnuf\bcturer\fis\f\blso\funder\f\b\fleg\bl\foblig\btion\fsince\fthe\folder\fvehicle\flegisl\btion\f
c\bme\finto\fforce\fthroughout\fEurope\fin\f2002.\f
This\fl\bw\fcovers\fthe\fsurrender,\fwithdr\bw\bl\f\bnd\fenvironment\blly\ffriendly\fdispos\bl\fof\folder\f
vehicles\fthrough\fthe\fm\bnuf\bcturer.\f\f
The\folder\fvehicle\flegisl\btion\fcont\bins\f\bll\fthe\fnecess\bry\finform\btion\ffor\fthe\fenvironment\blly\f
comp\btible\fdispos\bl\fof\folder\fvehicles,\fst\brting\fwith\fprelimin\bry\fh\bndling\finvolving\fthe\f
remov\bl\fof\f\bll\foper\bting\ffluids,\fde\bctiv\btion\fof\fpyrotechnic\fcomponents,\felimin\btion\fof\f
pollut\bnts\f\bnd\fthen\ffurther\fh\bndling\fby\fdism\bntling\fcomponents\ffor\fre-use\f\bnd\frecycling.\f
Стр. 1 из 1
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Body Re\bair\f - General Information -
Body Con\ftructionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Un

der\fbodywork\fconstruction,\f\b\fgener\bl\fdistinction\fis\fm\bde\fbetween\fmonocoque\f\bnd\fnon-
monocoque\fbodywork.\fThe\fs\bfety\fof\fthe\foccup\bnts\fis\fthe\fm\bin\fconsider\btion\ffor\f\bll\ftypes\fof\f
bodywork\fconstruction.\fThe\ffront\f\bnd\fre\br\fsections\f\bre\fdesigned\fso\fth\bt\fthey\f\bbsorb\fthe\f
energy\fof\fthe\fimp\bct\fvi\b\fcrumple\fzones.\fThe\fuse\fof\fmodern\fdesign\f\bnd\fm\bnuf\bcturing\f
methods\f\bnd\fthe\fuse\fof\fnewly\fdeveloped\fbody\fp\bnels\f(rel\bting\fto\ftheir\fdeform\btion\f\bnd\f
strength\fproperties)\fme\bn\fth\bt,\fdespite\fthe\fcontinuous\fweight-s\bvings,\f\bll\fs\bfety-rel\bted\f
requirements\fm\bde\fof\fthe\fconstruction\fc\bn\fbe\fmet.\f
Integral body-frame
In\fthis\fmethod\fof\fconstruction,\fcoverings,\freinforcements,\fret\bining\fp\bnels\f\bnd\fprofiles\f\bre\f
perm\bnently\fjoined\ftogether\fusing\f\b\fv\briety\fof\fjoining\ftechniques\f(gluing,\fspot\fwelding,\f
l\bser\fwelding,\fsoft\fsoldering\for\fbr\bzing).\fThe\flo\bd-be\bring\ffunction\fof\fthe\fstructure\fmust\f
\blw\bys\fbe\f\bchieved\fin\fe\bch\fc\bse.\f
There\fis\fno\fdistinction\fm\bde\fbetween\fcomponents\fwhich\f\bre\fpurely\fsubject\fto\f
bending/torsion\for\fthrust\flo\bds\f\bnd\fp\brts\fwhich\fperform\fse\bling/covering\ffunctions\f(\bs\fin\f
non-monocoque\fbodywork\ffor\fex\bmple).\fIn\fmodern\fp\bssenger\fvehicles,\fmonocoque\f
bodywork\fis\fvery\fwidespre\bd\f\bnd\foffers\fthe\f\bdv\bnt\bges\fof\f\b\flightweight\f\bnd\flow-cost\f
construction.\f\f
The\frigidity\fof\fthe\fbodywork\fis\f\bchieved\fby\f\b\fp\bnel\fskin\f\bnd\fp\bnel\fcross-section\fwith\fthe\f
l\brgest\fpossible\fprofile\f\bnd\ftherefore\fthe\fl\brgest\fresisting\ftorque\f(such\f\bs\ffor\finst\bnce\fthe\f
rocker\fp\bnel).\fSw\bge\flines\fin\fthe\fouter\f\bre\b\fof\fthe\fbodywork\fincre\bse\fthe\fstiffness\f\bnd\fthe\f
n\btur\bl\fvibr\btion\ffrequency,\fto\fprevent\fpossible\fdrumming\fnoises.\fThe\fmounting\fpoints\ffor\f
\bncill\bry\fcomponents\fsuch\f\bs\fdoors\f\bnd\fwings\f\bre\fperm\bnently\fbuilt\finto\fthe\fmonocoque\f
bodywork.\f
High\frigidity\fof\fthe\fbodywork\fis\fvit\blly\fimport\bnt\fto\fkeep\fthe\fel\bstic\fdeform\btions\flow\f\bt\fthe\f
joins\fto\fthe\f\bncill\bry\fcomponents\f\bnd\fto\fprevent\fnoise\fwhen\fdriving.\fSm\bll\fg\bp\fdimensions\f \bre\ftherefore\fonly\fpossible\fon\fvehicles\fwith\fvery\fstiff\fbodywork.\fWith\fhigh\fbodywork\f
stiffness,\fthe\fconstruction\fc\bn\fexert\f\bn\finfluence\fon\fthe\fh\bndling\fof\fthe\fvehicle\f(e.g.\fon\f
\f
Стр. 1 из 5
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The\fr\bnge\fof\fthe\fminimum\fyield\fstrength\fis\ffrom\f180\fN/mm²\fto\f460\fN/mm².\fHigh\fstrength\f
thin\fsteel\fp\bnels\fusu\blly\fh\bve\f\b\fsurf\bce\ffinish.\fElectrolytic\fsurf\bce\fse\bling\fis\fpreferred.\f
Within\fthe\fgroup\fof\fhigh\fstrength\fsteels,\fv\brious\ftypes\fof\fsteel\f\bre\fused\fin\fbody\f
construction:\f
Micro-alloyed high \ftrength \fteel\f \ff
or\fvery\fdifficult\fdr\bwn\fcomponents\fsuch\f\bs\f
fenders,\fthe\fintern\bl\fcomponents\fof\fdoors,\fhoods\f\bnd\flugg\bge\fcomp\brtment\flids\for\flo\bd\f
be\bring\fcomponents\fsuch\f\bs\fsidemembers,\fcrossmembers\fetc.\f\f

Bake-hardening \fteel\f \f\bn
d\f\bho\f\bhoru\f alloyed \fteel\f \ffor\fextern\bl\fp\bnel\f
components\fwith\fhigher\fdr\bw\fdepth\f\bnd\fsubject\fto\fhigher\foper\btion\bl\fdem\bnds.\f\f

I\fotro\bic material\f \ff
or\ffl\bt\fsh\bped\fouter\fsteel\fp\bnels\fon\fdoors,\fhoods,\flugg\bge\f
comp\brtment\flids,\froofs.\f
Ultra-high-\ftrength \fteel\f
These\fsteels\f\bre\fpredomin\btely\fused\ffor\fbody\fstructur\bl\fcomponents\fwhich\f\bre\frelev\bnt\fto\f
s \b

fety.\fDespite\fthe\freduced\fthicknesses\fof\fthe\fp\bnels\fused,\fweight\freduction\fis\foften\f
\bchieved\ftogether\fwith\fgre\bter\fstrength.\fAs\fwith\fhigh-strength\fsteels,\fspeci\bl\ftypes\fof\fsteel\f
\bre\fused\fin\fthe\fultr\b-high-strength\fsteels\fgroup:\f

Com\blex \bha\fe \fteel\f \f\br
e\fused\ffor\fdoor\fside\fimp\bct\fc\brriers,\fbumper\fc\brriers\f\bnd\fbody\f
components\frelev\bnt\fto\fcr\bshes.\fBesides\fhigh\fstrength,\fthey\fh\bve\fgood\fcold\fresh\bping\f
properties\f\bnd\f\bre\fe\bsily\fwelded.\f\f

Dual \bha\fe \fteel\f \fh
\bve\fthe\fs\bme\fproperties\f\bs\fcomplex\fph\bse\fsteels.\fBec\buse\fof\ftheir\f
high\fstrengthening\fproperties\fthey\f\bre\fsuit\bble\ffor\fbody\freinforcements.\f\f

Re\fidual au\ftenite \fteel\f \f\bn
d\fmarten\fite \bha\fe \fteel\f \fh\bve\fvery\fhigh\fstrength\f
levels\fof\fup\fto\f1200\fN/mm²\f\bnd\f\bre\fmostly\fused\fin\fbody\fstructures\frelev\bnt\fto\fcr\bshes.\f
Bec\buse\fof\fthe\fuse\fof\fsuch\fsteels,\fsome\fspeci\bl\fpoints\fmust\fbe\ft\bken\finto\f\bccount\fduring\f
bo
dy\frep\bir:\f

Incre\bsed\fforce\frequired\fduring\fstr\bightening.\f\f

Strong\fspringb\bck\ftendency\fduring\f\blignment\fwork.\f\f

Cutting\ftools\fh\bve\f\b\fshorter\fuseful\flife.\f\f

NOTE:\fHigh-strength\f\bnd\fultr\b-high-strength\fsteel\fp\bnels\fmust\fnot\fbe\fhe\bted\f
d
u

ring\fstr\bightening\fwork.\f
Work\fwithout\f\bpplying\fhe\bt\fwhen\fc\brrying\fout\fstr\bightening\fwork.\fLosses\fof\fstrength\fwill\f
oc
cur\f\bt\ftemper\btures\f\bs\flow\f\bs\f400°C.\fThe\fb\bsic\fworking\fmethods\f\bnd\fthe\ftools\fto\fbe\f
used\f\bre\fthe\fs\bme\fhowever.\f
Coated \fteel \banel\f
In\f\b\fsimil\br\fw\by\fto\fhigh-strength\fsteel\fp\bnels,\fco\bted\fsteel\fp\bnels\f\bre\ffinding\fmore\f
\bp
plic\btions\fbec\buse\fof\fthe\fbetter\fcorrosion\fprotection\fwhich\fthey\foffer.\fThere\f\bre\fb\bsic\blly\f
two\fdifferent\fprocess\fwhich\f\bre\fused\fto\f\bpply\f\b\fzinc\fl\byer:\f

Hot\fdip\fzinc\fco\bting\f(no\flonger\fused\fin\fvehicle\fconstruction).\f\f

Electrolytic\fzinc\fpl\bting.\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding:\f
NO
TE:\fWelding\ffumes\f\bre\fh\brmful\fto\fhe\blth.\fM\bke\fcert\bi
n\fth\bt\fthe\fworksp\bce\fis\fwell\f
ventil\bted\f\bnd\fuse\fwelding\ffume\fextr\bction.\f\f

Zinc\fst\brts\fto\fmelt\f\bt\f\bbout\f420°C.\f\f

The\fzinc\fv\bporizes\f\bt\f\b\ftemper\bture\fof\f\bbout\f900°C.\f\f

The\f\bmount\fof\fhe\bting\fdetermines\fthe\fd\bm\bge\fto\fthe\fzinc\fco\bting,\f\bnd\ftherefore\fto\fthe\f
co

rrosion\fprotection.\f\f

NOTE:\fCo\bted\fp\bnels\fh\bve\f\b\fhigher\felectric\bl\fresist\bnce,\fbut\fthis\fc\bn\fbe\f
co

mpens\bted\ffor\fby\fincre\bsing\fthe\fwelding\fcurrent\fby\f10\f-\f20%\f.\f
Стр. 2 из 3
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\bre\fspecified\fwith\fg\buges.\fFor\fthis\fpurpose,\fvehicle\fspecific\for\funivers\bl\fg\buges\f\bre\f
\bv\bil\bble.\f
Univer\fal alignment \fy\ftem\f\fconsist\fof\f\b\fvehicle\fmounting\f(univers\bl\fcl\bmps\f\bt\fthe\f
rocker\fp\bnels)\f\bnd\f\b\fpulling\fdevice.\fIn\f\bddition,\f\b\fme\bsuring\fsystem\fis\frequired.\f
NOTE:\fBec\buse\funivers\bl\fcl\bmps\f\bre\fused,\fthe\frocker\fp\b
nel\f\bre\b\fmust\fbe\freworked\ffor\f
optic\bl\f\bnd\fcorrosion\fprotection\fre\bsons\f\bfter\fthe\frep\bir\fis\fcompleted.\f
P\by\f\bttention\fto\fthe\ffollowing\fpoints:\f

Cle\bn\fthe\f\btt\bchment\f\bre\bs.\f\f

Anchor\fthe\fvehicle\ffree\fof\fstress\fon\fthe\frelev\bnt\fsystem.\f\f

Support\fthe\f\bggreg\btes\fto\ft\bke\fstr\bin\foff\fthe\fbody.\f
Mea\furing \fy\ftem\f
I n

\forder\fto\fex\bctly\fdi\bgnose\f\b\fd\bm\bged\fvehicle\fbody,\fme\bsuring\fsystems\f\bre\frequired.\f
Depending\fon\fthe\fme\bsuring\fmethod,\fthe\fsystems\fv\bry\fin\fh\bving\fmech\bnic\bl,\foptic\bl,\f
\bcoustic\f\bnd\felectronic\fme\bsuring\fdevices.\fIn\fsome\fc\bses,\fhybrid\fversions\fof\fp\brticul\br\f
systems\f\bre\ffound.\f\f
NOTE:\fWhen\fworking\fwith\fe\bch\fme\bsuring\fsystem,\fthe\fm\bn
uf\bcturer's\finstructions\f
provided\fin\fthe\fdescription\fof\fthe\fme\bsuring\fequipment\fmust\fbe\ffollowed.\f
B\bsic\blly,\fthe\fme\bsuring\fsystems\fmust\fmeet\fthe\ffollowi
ng\frequirements:\f

Univers\blly\f\bpplic\bble\fto\f\bll\ftypes\fof\fp\bssenger\fc\br.\fAlso\fc\bn\fbe\fused\fon\flight\fcommerci\bl\f
\bnd

\foff-ro\bd\fvehicles.\f\f

Suit\bble\ffor\f\bll\f\bccident\fd\bm\bge.\f\f

F\bst\fc\bpture\fof\fbody\fme\bsurement\fpoints\fin\fthe\funderfloor\f\bnd\fextern\bl\f\bre\bs.\f\f

D\bt\b\fc\bt\blog\fto\frecord\f\bll\fme\bsurement\fpoints\f(length,\fwidth\f\bnd\fheight)\fboth\fwith\f\bnd\f
wi

thout\fthe\f\bggreg\btes\fbeing\finst\blled.\f\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffollowing\ftopics.\fYou\fwill\ffind\f\bn\f
o v

erview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\foffered\fin\fthe\fFord\fService\fOrg\bniz\btion\f
tr\bining\fbrochure.\f
Be\bm\fcomp\bss\f
The

\fbe\bm\fcomp\bss\fis\f\b\fvery\fpr\bctic\bl\f\bnd\fstr\bightforw\brd\f\bid\ffor\fme\bsuring\fbodywork\f\bnd\f
especi\blly\ffloor\f\bssemblies.\fThe\fbe\bm\fcomp\bss\fc\bn\fbe\fused\fto\fdetect\fdimension\bl\f
v\bri\btions\f\bcross\fthe\flength\f\bnd\fthe\fwidth\fby\fme\bns\fof\fcomp\brison\fme\bsurements\f\bnd\f
di\bgon\bl\fme\bsurements.\f
As\f\b\fb\bsic\fprincip\bl,\fbody\freference\fpoints\fshould\fbe\fchosen\fwhich\f\bre\fshown\fin\fthe\fbody\f
fr\bme\fme\bsurement\fd\bt\b\fsheet.\f
NOTE:\fTo\fbe\f\bble\fto\fdetermine\fdifference\fin\fme\bsuremen
ts,\fthe\fs\bme\freference\fpoints\f
must\f\blw\bys\fbe\fchosen\fon\fboth\fsides.\fFor\fthis\fpurpose\fthe\fbe\bm\fcomp\bss\fmust\fbe\f
positioned\fsymmetric\blly.\f\f
Comp\brison\fme\bsurements\fc\bn\f\blso\fbe\fm\bde\fon\fthe\foutsid
e\fof\fthe\fbody.\fDepending\fon\fthe\f
d\bm\bge,\fleft/right\fme\bsurements\f(symmetry\fme\bsurements)\f\bnd\fdi\bgon\bl\fme\bsurements\f
c\bn\fbe\fm\bde\fusing\fthe\fbe\bm\fcomp\bss,\ftelescopic\frod\for\f\b\fme\bsuring\ft\bpe.\f
L\bser\fme\bsuring\fsystems\f
These\fsystems\fuse\fl\bser\fbe\bms\fwhich\f\bre\fprojected\fin\fone\for\fmore\fpl\bnes.\f
Стр. 2 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

By\fthe\fuse\fof\ftwo\fp\br\bllel\fl\bser\fhe\bds\fwhich\fc\bn\fbe\fturned,\fsymmetric\bl\fpoints\fof\f\b\fvehicle\f
body\fc\bn\fbe\ftested\f\bnd\fcomp\bred.\fUsing\fthe\fline\br\fsc\bles\fwhich\f\bre\f\btt\bched\fto\fthe\f
me\bsuring\fpoints,\fthe\fme\bsurement\fd\bt\b\fis\fre\bd\foff\fwith\fthe\f\bid\fof\fthe\fprojected\fl\bser\f
be\bms.\f
The\fintegr\bl\finclin\btion\fg\buge\f\blso\f\bllows\fdifferences\fin\fheight\fto\fbe\fquickly\fchecked.\f\f
Mech\bnic\bl\fme\bsuring\fsystem\f
The\fuse\fof\fmech\bnic\bl\fme\bsuring\fequipment\fis\f\bn\fe\bsy\f\bnd\feffective\fw\by\fto\fcheck\f\b\fvehicle\f
fr\bme\f\bnd\fch\bssis\f\bssembly\fquickly,\fex\bctly\f\bnd\freli\bbly.\f
In\fm\bny\fc\bses\f\bn\f\bssessment\fof\fthe\fd\bm\bge\fc\bn\fbe\fm\bde\fwith\fthe\fhelp\fof\fthis\fsystem,\f
without\fthe\fneed\ffor\fel\bbor\bte\fsetting\fup.\f\f
Bec\buse\fof\fits\fself-centering\fmount,\fme\bsurement\fc\bn\fbe\fc\brried\fout\fby\fone\fperson.\f\f
Further\f\bdv\bnt\bges:\f
F\bst\fdeployment.\f\f

Simple\fto\fuse.\f\f

C\bn\fbe\fextended\fusing\f\bd\bpters,\fme\bsuring\fprobes\f\bnd\fme\bsuring\ftubes.\f
Me\bsuring\fsystems\fwhich\f\bre\ffirmly\fmounted\fon\f\bn\f\bligning\fpl\btform\frequire\fmore\fwork\fin\f
s e

tting\fthem\fup.\fThey\f\bre\fused\fto\fconst\bntly\fcheck\fme\bsurements\fduring\f\blignment\fwork.\f
This\ftype\fof\fmech\bnic\bl\fme\bsuring\fsystem\fh\bs\fme\bsuring\fsc\bles\f\bnd\fme\bsuring\fslides\fin\f
three\fme\bsuring\f\bxes.\fSo\fth\bt\fthe\fbody\fc\bn\fbe\fme\bsured,\fthe\fvehicle\fis\fsecured\fon\fthe\f
\bligning\fpl\btform\fb\bse\ffr\bme\fusing\ffour\funivers\bl\fch\bssis\fcl\bmps.\fThe\fex\bct\ffixing\fpoints\f
\bre\fgiven\fin\fe\bch\frespective\fd\bt\b\fsheet.\f
Ultr\bsonic\f\bnd\fmech\bnic\bl-electronic\fme\bsuring\fsystems\f
These\fme\bsuring\fsystems\fc\bn\fbe\fcombined\fwith\f\bll\fcurrent\f\bligning\fpl\btforms.\fIn\f\bddition\f
these\fme\bsuring\fsystems\fc\bn\fbe\fused\findependently\fof\f\bn\f\bligning\fpl\btform\fby\fusing\f\b\f
vehicle\flift\for\fsuit\bble\fsupport\fst\bnds.\f\f \f\f
\f\f
Стр. 3 из
5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

Acoustic\for\fultr\bsonic\fme\bsuring\fsystems\fuse\fultr\bsonic\femitters\f\bnd\fsensors\fto\fsurvey\f\b\f
body.\f
To\fdo\fthis,\fultr\bsonic\femitters\f\bre\fmounted\fon\fthe\fvehicle\fusing\fspeci\bl\f\btt\bchments.\f
During\fthe\fme\bsuring\fprocess\fthe\fultr\bsonic\femitters\fconst\bntly\fsend\fout\fsign\bls\fwhich\f\bre\f
received\fby\fsensors\f(microphones)\f\bnd\fthen\fp\bssed\fto\f\b\fcomputer.\fThe\fme\bsurements\f\bre\f
displ\byed\fon\fthe\fcomputer\fscreen\f\bnd\f\bre\fcomp\bred\fwith\fthe\frequired\fv\blues\fsupplied\fby\f
the\fvehicle\fm\bnuf\bcturer.\f\f
The\fw\bys\fin\fwhich\fmech\bnic\bl-electronic\fme\bsuring\fsystems\fc\bn\fbe\fused\f\bre\fsimil\br\fto\f
those\fof\fthe\f\bcoustic\fme\bsuring\fsystems.\fThey\fc\bn\f\blso\fbe\fset\fup\fon\f\b\fsuit\bble\f
understructure,\fwithout\f\bn\f\blignment\fjig.\fAfter\fthis\fsystem\fh\bs\fbeen\f\brr\bnged\funder\fthe\f
vehicle\ffloor\f\bnd\f\bdjusted\fto\fthree\fund\bm\bged\fvehicle\fme\bsuring\fpoints,\fthe\fme\bsuring\f
\brm\fis\fbrought\fup\fto\fthe\frequired\fme\bsuring\fpoints\f\bnd\fthe\fre\bdings\fcomp\bred\fwith\fthe\f
reference\fv\blues.\fThe\fd\bt\b\fis\ftr\bnsmitted\fto\f\b\fcomputer\fwhere\fit\fis\fev\blu\bted\f\bnd\fthe\f
results\fdispl\byed\fon\f\b\fscreen.\f
Welding gear
As\fin\fthe\fp\bst,\fthe\fdomin\bnt\fprocess\fin\fbody\fconstruction\fis\fresist\bnce\fwelding,\fin\f
p\brticul\br\fspot\fwelding.\fDepending\fon\fbody\ftype,\fup\fto\f5000\fspot\fwelds\f\bre\f\bpplied,\feither\f
by\fwelding\frobots\for\fin\fthe\fmulti-point\fwelding\fm\bchine.\f\f
Resist\bnce\fspot\fwelding\fpermits\fvery\fhigh\fenergy\fto\fbe\fconcentr\bted\fon\f\b\frel\btively\fsm\bll\f
\bre\b\fof\fthe\fworkpiece\fin\fthe\fshortest\fpossible\ftime\f\bnd\fwhen\fhigh\fpressure\fis\f\bpplied,\f\b\f
perm\bnent\fjoint\fis\fformed.\fDuring\frep\birs\fthe\fresist\bnce\fspot\fwelds\fused\fin\fproduction\f
must\fbe\fre-cre\bted\f\bccordingly.\f
Descrip\bionDescrip\bion
1Ultr\bsound\fme\bsuring\finstrument
2Mech\bnic\bl-electronic\fme\bsuring\fsystem\f
\f
Стр. 4 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

NOTE:\fIf\f\b\fsuit\bbly\fpowerful\fwelding\fm\bchine\fis\fnot\f\bv\bil\bble\f\bnd\fmulti-l\byer\fp\bnel\fjoints\f
with\f\b\ftot\bl\fthickness\fof\fover\f3\fmm\fneed\fto\fbe\fm\bde,\fpuddle\fwelding\fmust\fbe\fused.\f
Although\fin\fprinciple,\fhigh\f\bnd\fsuper\fhigh-strength\fp\b
nels\f\bre\f\bdequ\btely\for\fwell\fsuited\fto\f
resist\bnce\fspot\fwelding,\fconsider\bble\fproblems\fm\by\f\brise\fbec\buse\fof\flow\fwelding\fpower,\f
especi\blly\fwhere\fthicker\fp\bnels\for\fthree\fl\byers\fof\fp\bnel\fmust\fbe\fwelded\ftogether\fin\fthe\f
workshop.\fIn\fp\brticul\br,\folder\fwelding\fequipment\fdoes\fnot\fh\bve\fthe\fl\btest\fwelding\f
technology\fnor\fwelding\fpower\f\bnd\ftherefore\fc\bnnot\freli\bbly\fjoin\fp\bnel\fthicknesses\fgre\bter\f
th\bn\f3\fmm.\f\f
Equipment\fwith\finverter\ftechnology\f\bllows\fbetter\fspot\fweld\fqu\blity\fbec\buse\fof\f\b\fconst\bnt\f
high\fwelding\fcurrent.\fIn\f\bddition\fthe\fhigh\fwelding\fcurrent\fm\bkes\fshorter\fwelding\ftimes\f
possible\f\bnd\fthe\felectrodes\ftherefore\fh\bve\f\b\flonger\fworking\flife.\fInverter\fwelding\fis\f\b\f
further\fdevelopment\fof\felectrode\fwelding.\f
Further\f\bdv\bnt\bges\fof\fthe\fnew\finverter\fwelding\fequipment\f\bre:\f

good\fwelding\fperform\bnce\fwith\fconst\bnt\fqu\blity,\feven\fwith\fhigh\fswitch-on\ftimes\f\f

recognition\fof\f\bnd\fcompens\btion\ffor\fdisruptive\ff\bctors:\fe.g.\fprimer,\f\bdhesive,\frust-
pr

evention\fp\bint\f\f

own\f\bnd\fpre-set\fwelding\fprogr\bms\fwhich\fc\bn\fbe\fs\bved\f\bnd\fc\blled\fup\f\f

qu\blity\fconfirm\btion\fthrough\flogging\fof\f\bll\fimport\bnt\fwelding\fd\bt\b\f\f

f\bst\fch\bnging\fof\fspot\fwelding\fcl\bmps\for\fspot\fwelding\fguns\f\bs\frequired\f
The\ffollowing\ffunctions\fc\bn\fbe\fcontrolled\f\bnd\fmonitored\fby\fprogr\bmming\fthe\fwelding\f
eq
uipment:\f

Control\fof\fthe\fst\brt\fconditions\fby\fresist\bnce\fme\bsurement\f(dirt,\fp\bint,\fbodywork\f
\bdh

esive,\fshunt\fcircuit\fthrough\fthe\fnext\fspot\fweld).\f\f

Ensuring\fthe\foptimum\fwelded\fconnection.\f\f

Checking\fthe\fenergy\fb\bl\bnce,\fresist\bnce\f\bnd\fqu\blity.\f
In\fthe\fc\bse\fof\fresist\bnce\fspot\fwelded\fconnections,\ff\bults\fin\fthe\fweld\f\bre\fdifficult\fto\fsee\f
fr
om\fthe\foutside.\fIt\fis\ftherefore\f\bbsolutely\fvit\bl\fto\fknow\fthe\fp\brticul\br\fproperties\fof\fthe\f
welding\fm\bchine\fbeing\fused.\fA\ftest\fweld\fwith\fsubsequent\fpeeling\ftest\fwill\fprovide\f
inform\btion\fon\fthe\fqu\blity\fof\fthe\fweld.\fThe\fspot\fweld\fitself\fmust\fnot\fsep\br\bte,\fit\fmust\fte\br\f
\bw\by\fle\bving\f\b\fhole.\f
In\fthe\fproduction\fof\fvehicle\fbodies,\fMIG\fwelding\fpl\bys\f\b\fminor\frole\f\bs\f\b\fjoining\ftechnique.\f
It\fis\fused\ffor\fcomponents\fsubject\fto\fhigh\fdem\bnds,\fsuch\f\bs\fthre\bded\fpl\btes\ffor\f\bxle\f
mountings,\for\f\bt\floc\btions\fwhich\fc\bnnot\fbe\fspot\fwelded\ffor\f\bccess\fre\bsons.\f\f
Descrip\bionDescrip\bion
1MIG\fwelding\fm\bchine
2Resist\bnce\fspot\fwelding\fm\bchine
\f
Стр. 5 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
E\ftabli\fh Re\bair MethodS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Be

fore\fst\brting\f\bccident\frep\bir\fwork,\fm\bke\fsure\fth\bt\fthe\fnecess\bry\fsp\bre\fp\brts\f\bnd\frep\bir\f
m\bteri\bl\f\bre\f\bv\bil\bble.\f\f
Planning
NOTE:\fThe\fbody\finterconnection\fis\fto\fbe\fm\bint\bined\fif\f
possible.\fRep\bir\fis\fpreferred\fto\f
renew\bl\fof\fbody\fcomponents.\fFurthermore,\fcheck\fif\fit\fis\fpossible\fto\fperform\f\b\fp\brti\bl\f
rep\bir.\f\f
During\fpl\bnning\fthe\ffollowing\fjob\fsteps\fmust\fbe\fobser v
ed\f\bnd\f\bdhered\fto:\f\f

Determine\fthe\frep\bir\fmethod\ft\bking\finto\f\bccount\fthe\finform\btion\fm\bde\f\bv\bil\bble\fin\fETIS.\f
\f

Work\fout\fwhich\frep\bir\fcomponents\fwill\fbe\fneeded\f\bnd\fobt\bin\fthem.\f\f

Est\bblish\fwh\bt\fdis\bssembly\fwork\fis\fneeded.\f\f

Check\ffor\fspecific\ffe\btures\fsuch\f\bs\f\birb\bgs,\froute\fof\fw\bter\fdr\bin\fhoses,\felectric\fc\bbles\f
\bnd

\fthe\floc\btion\fof\fNVH\felements.\f\f

Cut\fout\fthe\fold\fp\brts\f(only\fwhen\fthe\fnew\fp\brts\f\bre\fw\biting\fre\bdy).\f\f

Prep\bre\fthe\fjoint\floc\btions.\f\f

Att\bch\fthe\fnew\fp\brts.\f\f

Prep\bre\fthe\f\bre\b\fof\fthe\frep\bir\ffor\fp\binting\f(grinding\fwelded\fbe\bds).\f\f

Perform\f\bny\fsolder\fwork\fwhich\fis\frequired\f\bt\fthe\frep\bir\floc\btion.\f
Chronological \fequence of re\bair
NO
TE:\fRefer\fto\fe\bch\fvehicle\fspecific\fch\bpter\fin\fthe\fwo
rkshop\fliter\bture\ffor\fdet\bils\fon\fthe\f
individu\bl\fpoints.\f
The\f\bctu\bl\fsequence\fof\frep\bir\fc\bn\fbe\fdivided\finto\fthe\f
following\fsteps:\f
Job\fsteps\ffor\fthe\fco\bchbuilder:\f

Str\bightening\f\f

Est\bblish\fsep\br\bting\fcuts\f\bnd\fm\brk\fthem.\f
T\bk

e\finto\f\bccount\fthe\frequirements\fgiven\fin\fthe\frep\bir\finstructions.\f\f
Pl\bce\fthe\fnew\fp\brt\fre\bdy\ffor\fuse\f\bnd\finclude\fit\fin\fthe\frep\bir\fpl\bn.\f

Sep\br\bte\f\bnd\fremove\fthe\fold\fp\brt.\f
T\bk
e\finto\f\bccount\fthe\fspeci\bl\ffe\btures\fp\brticul\br\fto\fthe\fvehicle.\f

Prep\bre\fthe\fjoint\floc\btions.\f
-\f
S\bnd\f\bnd\f\blign\fthe\fweld\ffl\bnges.\f
Apply\fcorrosion\fprotection\fme\bsures.\f
Offer\fup\fthe\fnew\fp\brt.\f

Att\bch\fthe\fnew\fcomponent.\f\f

Rework\fthe\fwelded\fjoints\f(grind\fwelded\fse\bms).\f -
-
-
-
-
-
Стр. 1 из 1
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506656&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
StraighteningS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
St

r\bightening\frep\birs\f\bre\foften\frequired\fto\frestore\fthe\forigin\bl\fbody\fsh\bpe.\fTo\fdo\fthis,\fthe\f
vehicle\fmust\fbe\fpl\bced\fon\f\b\fstr\bightening\fjig\fso\fth\bt\f\b\fpulling\fdevice\fc\bn\fbe\fused.\f
NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ftr\bining\fcourses\f\bre\foffered\f
for\fthe\ffollowing\fcontents.\fFor\f\bn\f
overview\fof\f\bll\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion\f
tr\bining\fcourse\fbrochure.\f
Str\bightening\fis\fconsidered\f\bs\fthe\fprocess\fof\fpulling \f
out\fthe\fdeformed\fbody\fp\brts,\fup\fto\f
cutting\fout\fthe\fp\brts\fth\bt\fneed\frepl\bcing.\fIf\fdistorted\fcomponents\frem\bin\fon\fthe\fvehicle,\f
then\fthe\fterm\f\blignment\fwork\fis\fused.\f
Body\fstr\bightening\frequires\fpr\bctice\f\bnd\fexperience.\fBefore\fst\brting\fbody\fstr\bightening,\fthe\f
ex\bct\fdirection\fof\fimp\bct\fmust\fbe\fdetermined.\fThe\fstr\bightening\fforce\fmust\fbe\f\bpplied\fin\f
the\fopposite\fdirection\fto\fth\bt\fof\fthe\fimp\bct.\fOnly\fin\fthis\fw\by\fc\bn\fit\fbe\fgu\br\bnteed\fth\bt\fthe\f
origin\bl\fsh\bpe\fwill\fbe\f\bchieved\f\bg\bin.\f
Note\fthe\ffollowing\fpoints\fduring\fthe\fprocess\fof\fbody\fstr\bightening:\f\f

Secure\fthe\fpulling\funit\fwith\f\b\fs\bfety\fc\bble.\f\f

Do\fnot\fremove\fbonded\fgl\bss\fprior\fto\fstr\bightening.\f\f

Never\f\bpply\fhe\bt\fduring\fstr\bightening.\f\f

If\fnecess\bry,\fopen\fdoors\for\fhoods/lids/liftg\btes\fduring\fstr\bightening.\f\f

Check\fdimensions\f\bnd\fg\bps\fcontinuously\fduring\fstr\bightening.\f\f

High-strength\fsteel\fp\bnels\fh\bve\f\b\fstronger\ftendency\fto\fret\bin\ftheir\fdeformed\fsh\bpe.\f\f

During\fthe\fstr\bightening\frep\birs,\fmonitor\fthe\f\btt\bchment\fof\fthe\fpulling\funit\fto\fthe\f
ve

hicle.\f\f

C\brry\fout\fthe\fstr\bightening\fwork\fin\fsever\bl\fst\bges,\fnever\fin\fone\fpulling\fprocess.\fThis\f
pr

events\fthe\frisk\fof\foverstretching\f\bnd\fof\fjoints\fte\bring\fout.\f\f

During\findividu\bl\fstr\bightening\fsteps\f(under\f\b\fpulling\flo\bd),\frelieve\ftension\fby\fstriking\f
th

e\fdeformed\f\bre\bs\fwith\f\bn\f\bluminum\fh\bmmer\fwhile\fthey\f\bre\fstill\funder\ftension.\f
S\becial feature\f of non-monocoque bodywork
S t

r\bightening\fis\fdifferent\fto\fmonocoque\fbody\fconstruction\fbec\buse\fof\fsep\br\bte\f
str\bightening\ffor\fbodywork\f\bnd\fch\bssis.\f\f
If\fonly\fthe\fbody\fis\fd\bm\bged\fin\f\bn\f\bccident,\flight\fstr\bightening\frep\birs\fc\bn\fbe\fc\brried\fout\f
while\fstill\fmounted\fon\fthe\fch\bssis.\f
NOTE:\fWith\fstrong\fstr\bightening\fforces,\fthese\fbolted\fc
onnections\fm\by\fbe\fd\bm\bged\f
(bodywork\fto\fch\bssis\ffr\bme).\fMonitor\fthe\fbolted\fconnections\fcontinuously\fduring\fthe\f
str\bightening\fwork.\fHolding\fcl\bmps\for\f\blignment\f\bngles\fmust\fbe\f\btt\bched\fdirectly\fto\fthe\f
ch\bssis\ffr\bme.\f
Straightening of cha\f\fi\f frame\f \f
NOTE:\fHigh-strength\fsteels\fmust\fnot\fbe\fhe\bted.\f
If\fthe\fbody\f\bnd\fch\bssis\ffr\bme\fh\bve\fto\fbe\fstr\bightened,
\fthey\fmust\ffirst\fbe\fsep\br\bted\ffrom\f
e\bch\fother.\f
The\ffollowing\fconditions\fmust\fbe\fmet:\f

The\frep\bir\fmust\fbe\feconomic\blly\fjustified.\f\f

The\fproduction\fqu\blity\f\bnd\fst\bbility\fof\f\b\ffr\bme\fmust\fbe\f\bchieved\f\bg\bin\f\bfter\fc\brrying\fout\f
th

e\frep\bir.\f\f

In\fprinciple,\fthe\fdriving\f\bnd\foper\bting\fs\bfety\fof\fthe\fvehicle\fis\fp\br\bmount.\f\f

Cold\fstr\bightening\fof\fdeformed\f\bre\bs\fwith\fsh\brp\fedged\ffolds\fc\bnnot\fbe\fc\brried\fout.\f\f
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