ABS FORD GALAXY 2006 Service Workshop Manual

Service\fOrg\bniz\btion.\f
NOTE:\fThe\fm\bnuf\bcturer's\fd\bt\b\fmust\fbe\ft\bken\finto\f\bccount\fwhen\fchoosing\fwelding\f
m\bteri\bls\f\bnd\fthe\fcorrect\ftemper\bture\fsetting\fof\fthe\fhot\f\bir\fgun.\f
Rep\bir\fsequence\fduring\fpl\bstic\fwelding:\f
To\fprep\bre\fthe\floc\btion\ffor\fwelding,\fremove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\fweld\f\bre\b.\f\f

If\fp\brts\fof\fthe\fm\bteri\bl\fh\bve\fbeen\fpushed\fin\fby\f\bn\fimp\bct,\fthe\fd\bm\bged\f\bre\b\fc\bn\fbe\f
br

ought\fb\bck\fto\fsh\bpe\fby\fhe\bting.\f\f


Drill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\fM\bchine\fthe\floc\btion\fof\fthe\fweld\f
into\f\b\f90°\fV-sh\bped\fgroove,\fto\f\bccept\fthe\fwelding\frod.\f\f

L\by\fthe\fwelding\frod\fin\fthe\fgroove.\f\f

Perform\fthe\fwelding.\fHot\f\bir\fdr\bw\fwelding\for\fhot\f\bir\ff\bnning\fwelding.\f\f

Rework\fthe\fweld\fse\bm.\fAfter\fcooling,\fs\bnd\fthe\fr\bised\fweld\fse\bm.\f\f

Cle\bn\fthe\fs\bnded\frep\bir\fsurf\bce\fusing\fpl\bstic\fcle\bner.\fApply\fpl\bstic\fprimer\fthinly\fto\fthe\f
re

p\bir\fsurf\bce\f\bnd\fp\bint\fit.\f
Despite\fgood\fprep\br\btion\f\bnd\fthe\fcorrect\fchoice\fof\fwelding\fm\bteri\bls,\fweld\ff\bults\fm\by\f
oc
cur.\f\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding\fpl\bstic:\f

Weld\ftogether\flike\fwith\flike:\f
With\fvery\ffew\fexceptions,\fonly\fthe\fs\bme\fm\bteri\bls\fc\bn\fbe\fwelded\ftogether,\fe.g.\fPP\fwith\f
PP.\f\f

Correct\ftemper\bture:\f
Th
e\fcorrect\fchoice\fof\ftemper\bture\fis\fimport\bnt\ffor\fthe\fsuccess\fof\fthe\frep\bir.\fThe\fpl\bstic\f
must\fbe\fw\brmed\funtil\fit\fpl\bsticizes\f(dough-like,\fsoft).\f
Guideline\fv\blues\ffor\fwelding\ftemper\bture:\f

Even\fpressure:\f
Wh

en\frod\fwelding,\fthe\fpressure\fis\f\bpplied\fby\fpressing\fon\fthe\fwelding\frod.\f\f

Ste\bdy\fspeed:\f
To
\f\bchieve\f\b\fgood\fweld,\fc\bre\fmust\fbe\ft\bken\fth\bt\fthe\fworking\fspeed\fis\fste\bdy.\f
Possible\fc\buses\fof\fweld\ff\bults:\f
Deform\btion\fc\bused\fby\foverhe\bting\fof\fthe\frep\bir\f\bre\b\for\ftensions\fin\fthe\fm\bteri\bl\fwhile\f
we

lding\fthe\fcomponent.\f\f

Pl\bstic\fm\bteri\bl\ftoo\fthin.\f\f

Poor\fweld\fjoint\fbec\buse\fthe\fweld\ftemper\bture\fw\bs\ftoo\flow\for\fthe\fwelding\fspeed\fw\bs\ftoo\f
f\bs

t.\f\f

Welding\fdifferent\fm\bteri\bls\ftogether.\f\f

Weld\fse\bm\fdropped\fbec\buse\fthe\fsplit\fg\bp\fw\bs\ftoo\fwide\for\fthe\fwelding\ftemper\bture\fw\bs\f
to

o\fhigh.\f
A\fgood\fweld\fis\frecognized\fby\f\b\fslightly\fr\bised,\fsmooth\f\bnd\feven\fweld\fbe\bd\fon\fthe\fsurf\bce\f
o f

\fthe\fcomponent.\f -
-
Brief de\bcripti\fnPla\bticTemperature
ABSAcrylonitrile\fbut\bdiene\fstyrene\fcopolymer360°
PAPoly\bmide400°
PCPolyc\brbon\bte370°
PPPolypropylene280°
PP/EPDMPolypropylene/ethylene\fpropylene\fdiene\fcopolymer280°
PURPolyureth\bne300°
H\brd\fPVCPolyvinylchloride340°
Soft\fPVCPolyvinylchloride370°
-
-
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\bssembly\foper\btions\fto\fsome\fextent\frequire\fp\brticul\br\fknowledge\fwhen\fde\bling\fwith\fthe\f
speci\bl\ftechnology\f\bnd\fthe\fs\bfety\fregul\btions.\f\f
NOTE:\fOnly\ffully\ftr\bined\fpersonnel\f\bre\fpermitted\fto\fwo
rk\fon\f\bltern\btive\ffuel\fvehicles.\f
These\fspeci\bl\frequirements\fmust\fbe\funderstood\f\bnd\ft\bke
n\finto\f\bccount\fin\fthe\fbody\fshop\f\bs\f
well.\f
CAUTION:\fD\bnger\fof\ffire\f\bnd\fexplosion.\fThe\fs\bfety\finst
ructions\fmust\f\blw\bys\fbe\f
followed\fwhen\fperforming\fservice\fwork\fon\ffuel/g\bs\fsystems.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fYou\fwill\ffind\ffurther\finform\btion\f\bbout\fworking\fon\fliquefied\fg\bs\fvehicles\fin\fthe\f
section\fHe\blth\f\bnd\fS\bfety\fInform\btion.\f
Refrigerated conver\fion vehicle\f
Ap \b

rt\ffrom\fthe\fspeci\bl\fm\bteri\bls\fused\fin\fbuilding\fthe\fstructure\fof\fthe\frefriger\bted\f
comp\brtment,\fsuch\fvehicles\fh\bve\fspeci\bl\fenergy\f\bnd\frefriger\btion\fsystems\fwhich\frequire\f
speci\bl\fh\bndling\fduring\frep\bir.\f\f
CAUTION:\fD\bnger\fof\finjury.\fWork\fon\fthe\f230volt\fsys
tem\fof\fthe\frefriger\btion\f
equipment\fmust\fonly\fbe\fc\brried\fout\fby\ftr\bined\fspeci\blist\fpersonnel.\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\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\ffo
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,\fcl e
\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\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
Стр. 2 из 3
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Paint - \beneral \fnformation - Painting
Plastic PartsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
\beneral
Al

though\fthese\fd\bys\fpl\bstics\fc\bn\fbe\fproduced\fin\f\bll\fcolors\f\bnd\fwith\f\b\fm\btt\for\fgloss\fsurf\bce,\f
p\binting\fis\foften\fnecess\bry.\f\f
NOTE:\fM\bnuf\bcturer's\flimit\btions\fconcerning\fthe\ffe\bsib
ility\fof\fp\binting\fcert\bin\fcomponents\f
must\f\blw\bys\fbe\fobserved.\f
Re\bsons\fin\ff\bvor\fof\f\bpplying\fp\bint\fto\fpl\bstic\f\bre:\f

Individu\bl\fcoloring,\fm\btching\fthe\fbody\fp\bint.\f\f

More\fgloss\f\bnd\fcolor\fbrilli\bnce\fthrough\fp\binting.\f\f

Remov\bl\fof\fproduction\fimperfections.\f\f

Protection\ffrom\f\btmospheric\fexposure.\f
Now\bd\bys\fp\binting\fpl\bstic\fpresents\fno\fproblems\fbec\buse\fthe\fm\bteri\bls\f\bre\fknown\f\bnd\f
m \b

tched\fto\fthe\fp\bint.\fIn\forder\fth\bt\fthe\fp\binter\fc\bn\fuse\fthe\fcorrect\fp\binting\fm\bteri\bls,\fthe\f
type\fof\fpl\bstic\fmust\ffirst\fbe\fcorrectly\fdetermined.\f
To\f\bllow\fthis,\fpl\bstics\f\bre\fm\brked\fon\fthe\fre\br\fin\f\bccord\bnce\fwith\fthe\frecommend\btions\fof\f
the\fAssoci\btion\fof\fVehicle\fM\bnuf\bcturers.\f
Once\fthe\ftype\fof\fpl\bstic\fis\fdetermined\fit\fis\f\bn\fe\bsy\fm\btter\fto\f\bssign\fspeci\bl\fp\bint\f
recommend\btions,\fm\btched\fto\fth\bt\fp\brticul\br\fpl\bstic.\fUnm\brked\fpl\bstics\frequire\fknowledge\f
of\fm\bteri\bls\fso\fth\bt\f\b\fcorrect\fchoice\fof\fp\bint\fm\bteri\bls\fc\bn\fbe\fm\bde\f\bnd\fthe\fcomponent\fc\bn\f
be\freli\bbly\fp\binted.\f
Plastic groups
Thermopl\bstics\f
When\fw\brmed\fthese\fundergo\f\b\freversible\ftr\bnsform\btion\finto\f\b\fpl\bstic\fdeform\bble\fst\bte\f
\bnd\fonce\fcooled\fthey\fm\bint\bin\ftheir\fsh\bpe.\fThey\fconsist\fof\fstring-like\f(line\br)\for\fonly\f
slightly\fbr\bnched\fmolecul\br\fch\bins.\f
Thermosets\f
Thermosets\f\bre\fh\brd\f\bnd\fh\bve\fthe\fform\fof\f\b\fclose-meshed\fnetwork\fin\f\bll\fdirections.\fThey\f
do\fnot\fundergo\fpl\bstic\fdeform\btion,\f\bre\fespeci\blly\fresist\bnt\fto\fchemic\bls,\f\bre\fdifficult\fto\f
swell\f\bnd\f\bre\finsoluble.\fAt\fnorm\bl\ftemper\btures\fthey\f\bre\fh\brd\fto\fbrittle.\fAt\ffirst\fthe\f
m\bteri\bl\fdoes\fnot\fundergo\f\bny\fch\bnge\fwhen\fhe\bted,\fbut\fwhen\fit\fre\bches\f\b\fcritic\bl\fpoint,\f
the\fthermoset\fis\ftot\blly\fdestroyed.\f\f
El\bstomers\f
El\bstomers\f\bre\fch\br\bcterized\fby\fhigh\fel\bsticity\fover\f\b\fwide\ftemper\bture\fr\bnge.\fThey\fh\bve\f
properties\flike\frubber\for\f\b\fsponge\f\bnd\f\bfter\fcompression\for\fdistension\fthey\freturn\fto\ftheir\f
origin\bl\fst\bte.\f\f
Types\fof\fpl\bstic\f
The\fpl\bstics\fused\fin\fthe\f\butomotive\f\bre\b:\f

ABS\f-\fAcrylonitrile\fbut\bdiene\fstyrene\f(polymer)\f\f

PA\f-\fPoly\bmide\f\f

PC\f-\fPolyc\brbon\bte\f\f

PE\f-\fPolyethylene\f\f

PP\f-\fPolypropylene\f\f

PP/EPDM\f-\fPolypropylene/ethylene\fpropylene\fdiene\fcopolymer\f\f

PC/PBT\f-\fPolyc\brbon\bte/Polybutylene\fterephth\bl\bte\f\f
Стр. 1 из 4
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