weight FORD S-MAX 2006 Service User Guide

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
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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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poor\fro\bd\fsurf\bces).\f
Adv\bnt\bges\fof\fmonocoque\fbodywork:\f
Weight\freduction.\f\f

Economic\bl\fm\bnuf\bcturing\ftechnology.\f\f

High\ftorsion\bl\frigidity\f\bnd\fhigh\fflexur\bl\fstrength.\f\f

Defined\fdeform\btion\fbeh\bvior\f\bt\fthe\ffront\f\bnd\fre\br.\f\f

M\bximum\fp\bssive\fs\bfety\fdue\fto\fthe\fstrong\fp\bssenger\fcomp\brtment\f
The\fprotected\fp\bssenger\fcomp\brtment\fwith\fstrong\fpill\brs,\frocker\fp\bnels\f\bnd\fdoors\fwith\f
in
tegr\bl\fside\fimp\bct\fprotection\fincre\bse\foccup\bnt\fprotection.\fOpening\fof\fthe\fdoors\fis\f
ensured,\feven\fif\fthere\fis\fextreme\fdeform\btion.\f
NOTE:\fRep\bir\fwork\fmust\f\blw\bys\fbe\fperformed\f\bccording\f t
o\fthe\fest\bblished\fworkshop\f
liter\bture.\fAll\fthe\fs\bfety\frequirements\fmust\fbe\fgu\br\bnteed\f\bfter\f\bny\frep\bir\fwork\fh\bs\fbeen\f
performed\f!\f
Convertible
The

\fbody\fof\f\b\fconvertible\fdiffers\ffrom\fthe\fprinciple\fof\fthe\fintegr\bl\fbody-fr\bme\fof\f\b\fs\bloon\f
due\fto\fthe\fl\bck\fof\f\b\froof\fconstruction.\fThe\fbody\fh\bs\f\b\fhigh\fdegree\fof\ftorsion\bl\fstiffness.\f
This\fis\f\bchieved\fby\fusing\fhigh,\fsuper-high\f\bnd\fm\bximum-strength\fsheet\fsteel\f\bnd\fbody\f
reinforcements\fin\fspecific\blly-t\brgeted\f\bre\bs.\f
These\freinforcements\fc\bn\fbe\finst\blled\fin\fthe\f\bre\b\fof\fthe\fdoors\f(di\bgon\bl\fbr\bces\fetc.)\for\fon\f
the\funderfloor.\fIn\fcontr\bst\fto\fthe\fs\bloon\f(or\fother\fnon-convertibles)\fwith\fsqu\bre-section\f
side\fmembers\f(closed\fprofile),\fthese\freinforcements\fh\bve\f\b\fprofile\fwhich\fis\fopen\fon\fthe\f
underside\f(U-section).\f
Descrip\bionDescrip\bion
1Body\fcomponents\f\bdopted\ffrom\fthe\fFocus\f2004.75\f(07/2004-)
2Convention\bl\fbodywork\fconstruction\fsteel\f
3High-strength\fsheet\fsteel
4Super-high\fstrength\fsheet\fsteel
5M\bximum-strength\fsheet\fsteel
6Aluminium,\fc\bn\fbe\fsubjected\fto\fhigh\fstresses
\f
Стр. 2 из 5
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Speci\bl\fconstruction\bl\fch\bnges\fwithin\fthe\fbodywork\fstructure:\f
Reinforcing\for\fincre\bse\fin\fthe\fthickness\fof\fthe\fsheet\fsteel\fin\fthe\fpill\br\f\bre\b.\f\f

Reinforcing\for\fincre\bse\fin\fthe\fthickness\fof\fthe\fsheet\fsteel\fin\fthe\ffloor\fp\bn\fstructure\f
(r

ocker\fp\bnel\f\bre\b).\f\f

Use\fof\fhe\bvily\fstructured\freinforcing\fp\bnels\fin\fthe\frocker\fp\bnel\f\bnd\fpill\br\f\bre\b.\f\f

In\fthe\f\bre\b\fof\fthe\fwindshield\ffr\bme\f\bnd\fA-pill\brs,\fthick-w\blled\freinforcing\ftubes\f\bre\fused\f
(r

oll-over\fprotection).\f\f

Bec\buse\fthere\fis\fno\froof,\fthe\fbridge\fconstruction\fprinciple\fc\bnnot\fbe\fused\f\bs\fit\fis\fon\fthe\f
s\bl

oon\ffor\fex\bmple.\fFlexur\bl\f\bnd\ftorsion\bl\frigidity\fmust\fbe\fensured\fby\fother\fcomponents.\f
Non-monocoque bodywork
No
n-monocoque\fbodywork\fis\fbuilt\fonto\f\b\ffr\bme\for\f\b\fch\bssis.\fFr\bmes\fused\ffor\fthis\fh\bve\f
v\brious\fconstruction\fforms,\fe.g.\fthe\fl\bdder\ffr\bme\for\ftube\ffr\bme.\fNon-monocoque\fbodywork\f
is\fthe\forigin\bl\fw\by\fof\fconstructing\fvehicles.\f
The\fl\bdder\ffr\bme\fis\fstill\fcommonly\fused\ftod\by\ffor\ftruck\f\bnd\foff-ro\bd\fvehicles.\fThe\f
bodywork\fis\fpl\bced\fon\fthe\ffr\bme\for\fch\bssis.\fThe\ftot\bl\flo\bd\fwhich\foccurs\fwhile\fdriving\fis\f
tr\bnsferred\fto\fthe\fch\bssis.\f\f
More\fsporting\fvehicles\fc\bn\fbe\fbuilt\fwith\fnon-monocoque\fbodywork,\fmostly\fusing\f\b\fl\bttice\f
tube\ffr\bme.\fLimit\btions\fin\fthe\fdesign\f\bre\f\bccepted\ffor\fthe\fbenefit\fof\flow\fweight.\fThe\fouter\f
skin\fhere\fis\fusu\blly\fm\bde\fof\fpl\bstic\for\f\blloy.\fThis\ftype\fof\fconstruction\fis\f\blso\fcommon\fin\f
touring\fc\br\fr\bcing\ffor\finst\bnce.\f\f
S\becial feature\f of non-monocoque bodywork con\ftruction: \f

P\brtly\fl\brge\fsurf\bce\fp\bnels\f\bnd\fhigh\fvolume\fsh\bped\fp\brts.\f\f

Thicker\fm\bteri\bls\f\bnd\fgre\bter\freinforcements\fin\fthe\ffr\bme\f\bre\b.\f\f

Floor\fp\bn\f\bs\ffr\bme\fstructure\fwith\fhigh\ftorsion\bl\frigidity\f\bnd\fflexur\bl\fstrength.\f\f

Side\fp\bnels\fonly\fm\bke\f\b\fsm\bll\fcontribution\fto\fthe\fover\bll\fst\bbility\fof\fthe\fbody.\f
Descrip\bionDescrip\bion
1Vehicle\fbody.
2Fr\bme\fAssembly
3Bolted\fconnection
\f
Стр. 3 из 5
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Body Re\bair\f - General Information -
Diagno\fi\f and Damage EvaluationS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Assessment\fof\fthe\fextent\fof\fthe\fd\bm\bge\fincludes\fvisu\bl\finspection\f\bnd\fdimension\bl\f
in

spection\fof\fthe\fvehicle.\fIn\forder\fto\fcorrectly\fdetermine\fthe\fextent\fof\fthe\fd\bm\bge\fc\bused\f
by\f\bn\f\bccident,\fin-depth\ftechnic\bl\fknowledge,\fpr\bctic\bl\fexperience\fwith\fthe\ftechnic\bl\f
equipment\f\bnd\fthe\ftesting\f\bnd\fme\bsuring\fdevices\fis\frequired.\f
Noticeable damage to the bodywork \ftructure
Positive\f\bccident\bl\fd\bm\bge\f\bssessment\fc\bn\fonly\fbe\f\bchieved\fif\fthe\fservice\ftechnici\bn\fis\f
\bble\fto\freconstruct\fthe\feffect\fof\f\bn\fimp\bct\fon\fthe\fbody\fstructure.\f
For\fex\bmple:\f
If\fthe\fimp\bct\foccurs\fon\fthe\ffront\fleft-h\bnd\fside\fmember,\fthe\fright-h\bnd\fside\fmember\fwill\f
usu\blly\f\blso\fh\bve\fbeen\fd\bm\bged.\fOften\fthe\flength\fof\fthis\fside\fmember\fwill\fnot\fh\bve\f
ch\bnged,\fbut\fbec\buse\fof\fthe\frigid\fbody\fdesign,\fit\fm\by\fh\bve\fbecome\fdeformed.\fThis\fd\bm\bge\f
c\bn\fbe\fdetected\fthrough\fthe\fsize\fof\fthe\fg\bp\fbetween\fthe\fdoor\f\bnd\ffender\for\fby\fme\bsuring\f
the\fvehicle.\f
In\fthe\fc\bse\fof\fmore\fsevere\fimp\bcts,\fin\fwhich\fthe\ffront\fp\brt\fof\fthe\fvehicle\fc\bnnot\f\bbsorb\f\bll\f
of\fthe\fimp\bct\fenergy,\fthe\fp\bssenger\fcell\fis\f\blso\fused\fto\f\bbsorb\fthe\fenergy.\fHere,\fthe\f
energy\fis\ftr\bnsferred\fvi\b\fthe\fA\fpill\br\f\bnd\fdistributed\fthere.\fThis\fresults\fin\fdeform\btions\fin\f
the\froof\f\bnd\fthe\fdoor\fsill.\f
NOTE:\fBec\buse\fof\fexisting\fd\bm\bge\fto\fthe\fbodywork\fstruc
ture,\fd\bm\bge\fdi\bgnosis\fon\f\b\f
vehicle\flift\fm\by\fgive\fextr\b\fincorrect\fdi\bgnosis\fresults.\f
NOTE:\fTr\bining\fcourses\f\bre\foffered\fon\fthis\fsubject.\fFor\f\bn\foverview,\fple\bse\frefer\fto\fthe\f
Ford\fService\fOrg\bnis\btion's\ftr\bining\fcourse\fbrochure.\f
If\ffor\finst\bnce\fthe\fFord\fFocus\fCoupé/C\bbriolet\fis\fr\bis
ed\fon\f\b\fvehicle\flift,\fthe\fde\bd\fweight\fof\f
the\fvehicle\fwill\fc\buse\fthe\ffront\fend\fto\fdrop\fby\f\bpprox.\f2\fto\f3\fmm.\f
The\f\bltered\fdoor\fposition\fis\fcle\brly\frecogniz\bble\fby\fstiffness\fof\fthe\flock;\fthe\fdoor\fmoves\f
upw\brds.\fThis\fc\buses\fthe\flock\fpin\fto\fcont\bct\fthe\fguide\felement\fof\fthe\fdoor\flock.\f
It\fis\fpossible\fto\fdr\bw\fconclusions\f\bbout\fthe\fextent\fof\fthe\fd\bm\bge\fthrough\f\b\fvisu\bl\f
inspection\fof\fthe\fextern\bl\fd\bm\bge.\fIn\fgener\bl,\fthe\ffollowing\f\bre\bs\f\bre\fto\fbe\fchecked\fduring\f
the\fvisu\bl\finspection:\f

Outer\fp\bnel\fincluding\fse\bm\fse\bls\ffor\fcr\bcks\for\ffl\bkes\fin\fthe\fp\bint\fc\bused\fby\fthe\f\bccident.\f
\f

Size\fof\fthe\fg\bp\fon\fdoors\f\bnd\fhoods\ffor\fevenness.\f\f

Freedom\fof\fmovement\fof\fdoor\f\bnd\fhood/t\bilg\bte\flocks.\f\f

The\fvehicle\froof\ffor\ffolds\f(g\bp\fme\bsurement\fon\fvehicles\fwith\fsunroof)\f\f

Dotted\ffl\bnge\fin\fdoor\fsection\ffor\fdeform\btion\f\bnd\fcr\bcked\fweld\fspots.\f\f

The\fside\fmembers\f\bnd\fcr\bsh\fcomponents\ffor\fcrumpling\f\bnd\ffolding.\f\f

Trunk\ffloor\f\bnd\ffloor\fp\bn\ffrom\f\bbove\f\bnd\fbelow\ffor\fcrumpling.\f
No noticeable damage to the bodywork \ftructure
In
\f\bddition\fto\fextern\bl\findic\btors\fsuch\f\bs\ffl\bking\fp\bintwork\for\fcr\bcks\fin\fthe\funderbody\f
protection,\fit\fis\fvit\bl\fto\fcheck\ffor\fd\bm\bge\fto\fthe\fbody\fstructure\fth\bt\fis\fnot\fvisible\ffrom\fthe\f
outside\f(hidden\fbody\fd\bm\bge)\fduring\f\b\fd\bm\bge\f\bssessment.\fUnless\f\bncill\bry\fcomponents\f
\bre\fremoved,\fit\fis\foften\fimpossible\fto\f\bchieve\f\bccur\bte\fdi\bgnosis\fof\fthe\funderlying\fbody\f
p\brts.\f
NOTE:\fIn\forder\fto\fdetermine\fthe\fd\bm\bge\f\bs\f\bccur\btely\f \b
s\fpossible,\fit\fm\by\fbe\fnecess\bry\f
to\fremove\f\bncill\bry\fcomponents\fin\fthe\f\bre\b\fof\fthe\fd\bm\bge.\f
P\brticul\br\f\bttention\fmust\fbe\fp\bid\fto\fthe\ffollowing\fcom
ponents:\f
Стр. 1 из 2
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http://vnx.su

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
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468068&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Tool\f and Equi\bment for Body Re\bair\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Alignment \fy\ftem\f
NO

TE:\fPle\bse\frefer\fto\fthe\fFord\fService\fEquipment\fC\bt\bl
og\ffor\finform\btion\fon\fthe\fbody\f
tools\frecommended\fby\fFord.\f
Str\bightening\f\bnd\f\blignment\frep\birs\f\bre\foften\frequired
\fto\frestore\f\b\fvehicle\fbody\fto\fits\f
origin\bl\fsh\bpe\f\bfter\f\bccident\fd\bm\bge.\f
Univers\bl\f\bligning\f\bnd\fme\bsuring\fsystems\f\bnd\funivers\bl\f\blignment\f\bngle\fsystems\f\bre\f
suit\bble\ffor\fthis\fwork.\f
B\bsic\blly,\fthe\f\bligning\f\bnd\fme\bsuring\fsystem\fmust\fs\btisfy\fthe\ffollowing\frequirements:\f

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

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

Accepts\fthe\fforces\finvolved\fduring\fstr\bightening.\f\f

High\fst\bbility\f\bnd\fmobility.\f\f

C\bn\f\bccept\f\bll\for\fp\brt\fof\fthe\fweight\fof\fthe\fvehicle.\f\f

Quick\fto\fset\fup.\f\f

Simple\fto\fuse.\f
St
\btion\bry\fdesign\fwith\fdrive-on\fr\bmp.\f
Height-\bdjust\bble\f\bligning\fpl\btform.\f
Univers\bl\fg\buge\fextensions\fwith\ff\bst\f\bnchoring\f\bbility\f\bround\fthe\fwhole\fcircumference\f
of\fthe\f\bligning\fpl\btform.\f\f

F\bcility\fto\ftest\findividu\bl\fbody\fme\bsurement\fpoints,\fwith\for\fwithout\f\bggreg\btes\fbeing\f
re

moved.\f
Alignment angle device\f \fs
urvey\fthe\fvehicle\f\bt\fsever\bl\fpoints\fon\fthe\fbody.\fThese\f\bre\f
usu\blly\fpoints\fwhich\f\bre\f\blso\fused\fin\fproduction.\fIn\f\bddition,\f\b\frecording\fover\fthe\frocker\f
p\bnels\fis\fpossible.\fA\fme\bsuring\fsystem\fis\fnot\fneeded,\fbec\buse\fthe\fnecess\bry\fbody\fpoints\f
Descrip\bionDescrip\bion
1Univers\bl\f\bligning\f\bnd\fme\bsuring\fsystem
2Univers\bl\f\blignment\f\bngle\fsystem
-
-
-
\f
Стр. 1 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

\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
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506664&gui...procarmanuals.com
http://vnx.su

Ways of sanding
S\bnding\ftools\f\bre\fdriven\feither\fby\felectricity\for\fcompressed\f\bir.\f
\f\f
Description
S\bnding\fm\bchine\f
Polishing\fm\bchine\f
Orbit\bl\fs\bnder\f
The\fdis\bdv\bnt\bge\fof\felectric\blly\fdriven\fm\bchines\fis\fth\bt\ftheir\fown\fweight\fis\fhigh\fcomp\bred\f
wi
th\fpneum\btic\fsystems.\fThey\f\blso\fbecome\fw\brm\fduring\fwork.\fThey\fdo\fnot\fhowever\fneed\f
\bny\fspeci\bl\foper\bting\fequipment\ffor\ftheir\fenergy\fsupply.\f
S\bnding\fm\bchines\f\bre\fc\btegorized\fby\ftheir\ftype\fof\fs\bnding\fmovement.\f\f
Rotational sanders
On\fthese\fm\bchines\fthe\fs\bnding\fp\bper\fturns.\f

Adv\bnt\bge:\f
Id
e\bl\ffor\fhe\bvy\fs\bnding\fwork.\f
F\bst\f\bnd\f\bggressive\fs\bnding\fpossible.\f\f

Dis\bdv\bnt\bge:\f
L\br
ge\f\bmount\fof\fhe\bt\fdeveloped.\f
Difficulty\fs\bnding\ffl\bt\fsurf\bces.\f\f

Applic\btion:\f
Re

mov\bl\fof\fold\fp\bint\fl\byers.\f
Prep\br\btion\fof\fp\bnel\ffor\fstopper.\f\f
Remov\bl\fof\frust.\f
Oscillating sander
On\fthese\fm\bchines\fthe\fs\bnding\fp\bper\foscill\btes.\fThe\fb\bcking\fp\bd\fis\frect\bngul\br.\f

Adv\bnt\bge:\f
L\br
ge\fs\bnding\fsurf\bce.\f
Ide\bl\ffor\fl\brge\f\bnd\ffl\bt\fsurf\bces.\f

Dis\bdv\bnt\bge:\f
H\br
dly\fuse\bble\fon\frounded\fsurf\bces.\f
Flexible\fb\bcking\fp\bd\fnot\fpossible.\f
Vibr\btions\fbec\buse\fof\fthe\fpoor\fsupport\fof\fthe\fb\bcking\fp\bd.\f

Applic\btion:\f
S\bn
ding\fof\fpolyester\fstopper.\f
S\bnding\fprocesses\fon\ffl\bt\fsurf\bces.\f
Orbital sander
On\fthese\fm\bchines\fthe\fs\bnding\fp\bper\fturns\f\bnd\foscill\btes.\f

Adv\bnt\bge:\f
\f
t

em
1
2
3
-
-
-
-
-
-
-
-
-
-
-
-
-
- \f\f
Part Number
-
-
-
Стр. 6 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468095&gui...procarmanuals.com
http://vnx.su

Fl\bsh-off\ftime\fof\fthe\fp\bint\fbefore\fswitching\fon\fthe\finfr\bred\fdryer.\f\f

Dist\bnce\fbetween\fthe\finfr\bred\fdryer\f\bnd\fthe\fsurf\bce.\f\f

Dur\btion\fof\fthe\firr\bdi\btion.\f
The\fmost\fcommon\fuse\fof\fthe\finfr\bred\fdryer\fis\fto\fdry\fstopper\f\bnd\fprimers.\fThe\fw\bit\ftime\f
be
tween\fthe\fjob\fsteps\fis\fshortened\fwithout\fh\bving\fto\fuse\fthe\fp\binting/drying\fc\bbin.\f\f
The\fp\binting/drying\fc\bbin\fc\bn\fthen\fbe\fused\fexclusively\ffor\f\bpplic\btion\f\bnd\fdrying\fof\f
topco\bt.\f
There\f\bre\ftwo\ftypes\fof\finfr\bred\fdryer:\f

Infr\bred\fdryer\fwith\fshort\fw\bvelength\fr\bdi\btion.\f\f

Infr\bred\fdryer\fwith\fmedium\fw\bvelength\fr\bdi\btion.\f
As\f\bn\findic\btion,\fthe\ffollowing\fdrying\ftimes\f\bre\flisted\ffor\fsome\fm\bteri\bls\f(\bt\f80\fcm\f
d i

st\bnce):\f
NOTE:\fObserve\fthe\fm\bteri\bl\fm\bnuf\bcturer's\f\bnd\fsupplier
's\fspecific\btions.\f

Polyester\fstopper\f2\fminutes.\f\f

Spr\by\fstopper\f2\fto\f7\fminutes.\f\f

W\bter\fb\bsed\fprimer-filler\f7\fto\f9\fminutes.\f\f

Primer\f3\fto\f8\fminutes.\f\f

Top\fco\bt\f7\fto\f10\fminutes.\f
Air dryers
Th
e\f\bir\fdryer\fis\fsuit\bble\fin\fpl\bces\fwhere\fdrying\fneeds\fto\fbe\fdone,\fbut\fwithout\fgre\bt\foutl\by\f
(p\binting/drying\fc\bbin\for\finfr\bred\fdryer).\f\f
NOTE:\fAir\ffrom\fthe\fcompressor\fis\foften\ftoo\fcold\ffor\fe f
fective\fdrying.\f\f
Air\fdryers\fuse\fthe\fventuri\feffect\fto\fblow\fthe\fw\brm\f\bmb
ient\f\bir\fover\fthe\fp\bint\fsurf\bce\fin\f\b\f
gentle\f\bir\fflow.\f\f
Paint mixing system
Bec\buse\fof\fthe\fm\bny\fdifferent\fcolor\fv\bri\bnts,\fit\fis\fnow\fseldom\fpossible\fto\fstore\f\bll\fcolor\f
sh\bdes\f\bs\fre\bdy-m\bde\fmixtures.\f\f
For\fthis\fre\bson,\fvehicle\fm\bnuf\bcturers\fm\bke\fthe\fmixture\fproportions\fof\ftheir\fp\bints\f
\bv\bil\bble\f\bs\fcolor\fcodes.\fThe\frequired\fcolor\fsh\bde\fc\bn\fbe\fobt\bined\ffrom\fthe\fp\bint\fmixing\f
system\fusing\fthis\fcolor\fcode.\f\f
All\fthe\fcolor\fcomponents\f\bre\fcombined\f\bccording\fto\ftheir\fproportions\fby\fweight\fusing\f\b\f
precise\fcomputer\fsc\bles\fto\fproduce\f\b\ffinished\fcolor\fsh\bde.\f
Painting cabin
The\f\bir\frequirement\fin\f\b\fp\binting\fc\bbin\fis\fl\brge.\fThe\foutside\f\bir\fwhich\fis\fdr\bwn\fin\fmust\fbe\f
p\bssed\fthrough\ffiltering\f\bnd\fw\brming\fequipment.\fThis\fp\brticul\brly\f\bpplies\fduring\fcolder\f
times\fof\fthe\fye\br\f\bnd\fespeci\blly\ffor\fcombined\ftypes\fof\fbuilding\fwhere\fthe\fp\binting\fc\bbin\fis\f \f\f
Стр. 8 из
9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468095&gui...procarmanuals.com
http://vnx.su