light FORD S-MAX 2006 Service Repair Manual

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
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Different\fm\bteri\bls\f\bnd\fdesign\ffe\btures\fle\bd\fto\fst\bged\fdeform\btion\fof\fthe\ffront\f\bnd\fre\br\fof\f
the\fvehicle\fin\f\bn\f\bccident.\f
Cra\fh element:
At\fthe\ffront\fof\fthe\fvehicle\fthere\fis\f\b\fcr\bsh\felement\fwhich\fis\fconnected\fto\fthe\fside\fmember\f
by\fthre\bded\fconnections.\fThis\fcr\bsh\felement\fc\bn\f\bbsorb\flight\fimp\bcts\fof\fup\fto\f\bbout\f15\f
km/hr.\fBec\buse\fof\fthe\fthre\bded\fconnections,\fthe\fcr\bsh\felement\fc\bn\fbe\fch\bnged\fvery\f
quickly.\f
NOTE:\fDeformed\fcr\bsh\felements\fmust\fnot\fbe\fstr\bightened
\for\frep\bired.\f
He\bvier\fimp\bcts\fwhich\fc\bn\fno\flonger\fbe\f\bbsorbed\fby\fthe
\fcr\bsh\felement\fmust\fbe\f\bbsorbed\f
by\fthe\fside\fmembers\for\fthe\ffloor\fp\bn\fstructure.\fDepending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f\b\f
p\brt\for\fcomplete\frepl\bcement\fc\bn\fbe\fperformed\fon\fthe\fside\fmember.\f
The\fre\br\fof\fthe\fvehicle,\flike\fthe\ffront\fof\fthe\fvehicle,\fh\bs\fstructures\fwhich\fprotect\fthe\f
p\bssenger\fcell\fthrough\fst\bged\fdeform\btion\fin\fthe\fevent\fof\f\bn\f\bccident.\fThe\fdesign\fl\byouts,\f
however,\f\bre\f\bd\bpted\fto\fthe\frequirements\fof\fthe\fre\br\f\bre\b.\f
Descrip\bionDescrip\bion
1Bolted\fcr\bsh\felement
2Front\fside\fmember
3Re\br\fside\fmember
\f
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The\fA,\fB\f\bnd\fC\fpill\brs\fin\fthe\froof\f\bre\b.\f\f

Floor\fp\bn.\f\f

Re\br\f\bncill\bry\fcomponents,\fsuch\f\bs\fbumper,\flights,\fetc.\f\f

Trunk\ffloor,\fsp\bre\fwheel\fc\bvity.\f\f

Re\br\fcoverings,\fsuch\f\bs\finterior\ftrim,\fc\brpet,\fetc.\f\f

Lower\frubber\fse\bls,\fe.g.\fin\fdoor\f\bre\b\f(welded\ffl\bnge).\f\f

Are\b\funder\fthe\fre\br\fse\bt.\f\f

Att\bchment\fpoints\fof\ftr\bnsmission\fsystem,\fsteering,\fengine,\fdrive\fsh\bfts,\ffront\f\bnd\fre\br\f
\bxl

es.\f\f

Electric\bl\fcomponents,\fe.g.\fthe\fr\bdio\f(d\bm\bge\fthrough\fsh\bking\for\fthrough\fvolt\bge\f
pe

\bks).\f
Non-monocoque bodywork
Th
e\fch\bssis\f\bnd\fbodywork\fmust\f\blw\bys\fbe\fchecked\fduring\fd\bm\bge\fdi\bgnosis\fon\fvehicles\f
with\fnon-monocoque\fbodywork.\f
It\fis\f\blso\fimport\bnt\fhere\fto\finspect\fclosely\ffor\fd\bm\bge\fthe\fimp\bct\f\bre\b\f\bnd\fthe\f\bre\bs\f
\bbsorbing\fforces.\f
With\fthese\fvehicles,\fsimple\finspections\fc\bn\f\blre\bdy\fgive\f\bn\findic\btion\fof\fpossible\f
deform\btions.\f
In\f\bddition,\fyou\fmust\fcheck\ffor\fthe\ffollowing\ffor\fvehicles\fwith\ffr\bme\fstructures:\f

Cr\bcks\fin\fthe\fp\bint\fon\fthe\ffr\bme\fwelds.\f\f

Tr\bces\fof\fdeform\btion\fon\ffr\bme\fcomponents.\f\f

Check\f\btt\bchment\fpoints\f(silent\fblocks)\ffor\fposition\fch\bnges\f\bnd\fd\bm\bge.\f\f

Ch\bnged\fposition\fof\frubber\fse\bls.\f\f

Fit\f\bnd\ffunction\fof\fthe\f\bncill\bry\fcomponents.\f
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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
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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
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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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Heat-induced material \fhrinking
M\bteri\bl\fshrinking,\f\blso\fc\blled\fsettling\fin,\fc\bn\fbe\fperformed\fin\f\b\fv\briety\fof\fw\bys\fdepending\f
on\fthe\fextent\fof\fthe\fd\bm\bge\f\bnd\fthe\f\bccess\fto\fthe\frep\bir\f\bre\b.\f
These\frep\bir\fprocesses\fdiffer\fdepending\fon\fthe\ftype\fof\fhe\bting\f\bnd\fsubsequent\fworking\fof\f
the\fhe\bted\fsurf\bce.\fThey\fsub-divide\finto\ftwo\fb\bsic\fprocesses:\f
He\bting\fusing\f\b\fc\brbon\felectrode.\f\f

He\bting\fusing\fthe\foxy-\bcetylene\ftorch.\f
In\fthe\fc\brbon\felectrode\fprocess\fthe\fworking\fis\fdone\fexclusively\fby\fw\brming.\fIn\fthis\fc\bse\f
t h

e\f\bccess\fto\fthe\frep\bir\fposition\fis\fonly\ffrom\fthe\foutside.\f\f
If\fthe\fd\bm\bge\fis\fconcentr\bted\fin\f\b\fspot\f\bnd\fis\fin\fthe\fform\fof\f\b\fmore\frigid\fr\bised\f\bre\b,\fthen\f
the\fc\brbon\felectrode\fmust\fbe\frepl\bced\fby\f\b\fcopper\felectrode.\fAs\fhe\bt\fis\f\bpplied,\fslightly\f
more\fpressure\fis\f\bpplied\fto\fthe\fr\bised\f\bre\b.\f
In\fthe\fmethod\fusing\fhe\bting\fby\fthe\foxy-
\bcetylene\ftorch,\fm\bteri\bl\fshrinking\fis\f\bchieved\fby\f\b\f
combin\btion\fof\fhe\bt\f\bnd\fmech\bnic\bl\fworking\fof\fthe\fd\bm\bged\f\bre\b.\f
Descrip\bionDescrip\bion
1C\brbon\felectrode
2Spir\bl\fsh\bped\fhe\bting\fp\bttern
\f
Стр. 4 из 6
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468072&gui...procarmanuals.com
http://vnx.su

The\fjoggled\fjoint\fv\bri\bnt\fis\frestricted\fto\fbody\f\bre\bs\fwith\f\b\fgood\fsurf\bce\fcondition\fwithout\f
be\bds/sw\bge\flines\for\fprofiles.\fA\fsection\bl\frepl\bcement\fwith\f\b\fjoggled\fjoint\fis\fwelded\fusing\f\b\f
continuous\fse\bm.\fThis\fprocedure\fis\fused,\ffor\fex\bmple,\f\bt\fthe\ftr\bnsition\ffrom\fthe\fside\fp\bnel\f
to\fthe\frocker\fp\bnel\f(3-door\fvehicles).\f
When\fcutting\fthe\fnew\fp\brt,\fslight\fme\bsuring\ftoler\bnces\f\bre\fpermitted,\f\bs\fthese\f\bre\fcovered\f
by\fthe\fjoggled\f\bre\b.\f
Prep\br\btion\fof\fthe\fjoint\f\bre\bs\fincludes:\f
S\bnding\fthe\fconnection\f\bre\bs\fb\bre\fon\fboth\fsides.\f\f

Remov\bl\fof\fthe\fzinc\fl\byer\fin\fthe\fwelding\f\bre\b.\f\f

Prep\br\btion\fof\f\b\fjoggled\fstrip.\f\f

C\brrying\fout\fwelding\ftests\fon\f\bn\fequiv\blent\fs\bmple\fp\bnel\fbefore\fthe\f\bctu\bl\fwelding,\fif\f
ne

cess\bry.\f\f

Joining\fthe\fnew\f\bnd\fold\fp\bnel\fwith\fcontinuous\fse\bm\fwelding.\f\f

Le\bd\flo\bding\fthe\fweld\fse\bm.\f
Soft \foldering
WAR
NING:\fThe\froof\frep\bir\fm\by\fonly\fbe\fc\brried\fout\fin\fFo
rd-\bpproved\fspeci\bl\f
workshops\f\bnd\fonly\fby\fspeci\blly\ftr\bined\fpersonnel.\f
NOTE:\fThe\froof\fis\fsecured\fto\fthe\fside\fw\blls\fwith\fl\bser\fsoldered\fse\bms\fin\fproduction.\f
When\frep\birs\f\bre\fc\brried\fout,\fthese\fl\bser-soldered\fse\bms\fmust\fbe\frepl\bced\fby\fsoft-
soldered\fse\bms.\f
WARNING:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhen\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fFord\foffers\fb\bsic\f\bnd\fin-depth\ftr\bining\fon\fthe\ffollowing\ftopics.\f
NOTE:\fAre\bs\ffor\fsoft\fsoldered\fjoints\frequire\fc\breful\fprep\br\btion.\fIt\fis\fextremely\fimport\bnt\f
th\bt\fthe\fjoint\fsurf\bces\f\bre\fex\bctly\f\bligned\f\bnd\fth\bt\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce\fis\fprep\bred.\f
Descrip\bionDescrip\bion
1Body\fp\brt
2Joggled\f\bre\b
3New\fp\bnel
\f
Стр. 6 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468073&gui...procarmanuals.com
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The\fpl\bstic\fgroup\fc\bn\fbe\fdetermined\fusing\fthe\fp\bttern\fof\fthe\fdust:\f
Thermosets\fproduce\f\b\fwhite\fdust.\f\f

Thermopl\bstics\fsme\br\f\bnd\fdo\fnot\fproduce\fdust.\f
Float te\ft in water: \f
T\b
ke\f\b\fsm\bll\fpiece\fof\fpl\bstic\ffrom\fthe\fcomponent\fto\fbe\frep\bired\f\bnd\ftest\fwhether\fit\fflo\bts\f
on\fw\bter\f(PP-EPDM,\fHD-PE,\fPP)\for\fsinks\f(PVC/U,\fPVC/P,\fABC,\fPC).\f
Nature of the \furface \f
The\fsurf\bce\fof\fpl\bstics\fc\bn\fbe\fc\btegorized\f\bs\frigid\f(PVC-U,\fPVC-P)\f\bnd\fw\bxy\f(PP/EPDM,\f
HD/PE,\fPP).\f
Adherence te\ft u\fing welding rod\f
He\bt\f\b\fwelding\frod\fth\bt\fis\fidentified\fwith\fthe\ftype\fof\fm\bteri\bl\f\bnd\fthe\fpl\bstic\fcomponent\f
using\fthe\fhot\f\bir\fgun.\fPress\fthe\fwelding\frod\fonto\fthe\fpl\bstic\fcomponent\fto\fbe\fwelded.\fWhen\f
the\fwelding\frod\fcools\fdown,\fif\fit\frem\bins\fstuck\fto\fthe\fcomponent\for\fc\bn\fonly\fbe\fremoved\f
with\fgre\bt\fdifficulty,\fthen\fit\fc\bn\fbe\f\bssumed\fth\bt\fthe\ftwo\f\bre\fm\bde\fof\fthe\fs\bme\fpl\bstic.\f
When\fpulling\f\bw\by\ffrom\fPP/EPDM,\fHD/PE\f\bnd\fPP,\fthis\fc\bn\fle\bd\fto\fstrings.\f
CAUTION:\fD\bnger\fof\fpoisoning!\fWhen\fburned,\fmost\fpl\bsti
cs\frele\bse\fv\bpors\fh\brmful\f
to\fhe\blth.\fVentil\bte\fthe\froom\fwell\f\bnd\fuse\frespir\btory\fprotection.\fWhere\fpossible\fwork\f
using\f\bn\fextr\bction\fsystem.\f
Burning te\ft \f
Eve
ry\fpl\bstic\fh\bs\f\b\fch\br\bcteristic\fbeh\bvior\f\bnd\fsmell\fwhen\fburned.\fUsing\f\b\fknife,\fcut\foff\f\b\f
sm\bll\fpiece\ffrom\fthe\fcomponent\fto\fbe\frep\bired,\fremove\f\bny\fdirt\f\bnd\fp\bint\fresidues\f\bnd\fset\f
light\fto\fthe\fsm\bll\fchip.\fNow\fobserve\fthe\fburning\fbeh\bvior.\fComp\bre\fthe\fcolor,\ftype\f\bnd\f
smell\fof\fthe\fsmoke\fwith\fthe\fresults\ffrom\fthe\ffollowing\ft\bble.\f
Safety in\ftruction\f
In\f\bddition\fto\fthe\fgener\bl\fs\bfety\finstructions,\fthe\frelev\bnt\fregul\btions\f\bnd\f\bccident\f
p r

evention\flegisl\btion\fmust\fbe\fobserved.\f
NOTE:\fWithout\fexception,\fbefore\fst\brting\fwork\fyou\fmust
\fre\bd\fthe\fs\bfety\f\bnd\fw\brning\f
instructions\fin\fthe\fch\bpter\f"S\bfety\fInstructions".\fIn\f\bddition,\fp\by\f\bttention\fto\fthe\fw\brning\f
instructions\fof\fthe\fp\brticul\br\fequipment\fm\bnuf\bcturer.\f\f
Inform\btion\fsheets,\fs\bfety\fnotices\f\bnd\fguidelines\ffor\f
the\fprocessing\fof\f\bdhesives\fcont\bining\f
isocy\bn\bte,\fpolyester\fresin,\f\bdhesives,\fsolvent\f\bnd\fthinners\fprovide\fmore\fdet\bils\fon\ftheir\f
use.\f
The\ffollowing\finstructions\fmust\f\blw\bys\fbe\ffollowed:\f

Polyester\fresin,\f\bdhesive,\fsolvents\f\bnd\fthinners\f\bre\finfl\bmm\bble\f\bnd\fmust\fnot\fbe\fused\f
Sh\frt de\bcripti\fnPla\btic rec\fgniti\fn u\bing a burning te\bt
ABSBl\bckish\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\f
like\fw\bx.\f
PANo\fsmoke,\fdr\bws\ffil\bments,\fsmells\flike\fburnt\fhorn.
PCYellowish,\fsooty\fsmoke.\fSmells\fsweetish.
PPNo\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\flike\f
burnt\foil.\f
PP/EDMNo\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\flike\fburnt\foil.\f
PC/PBTH\brd\f\bnd\fshiny,\fburns\fyellow,\ffluffy\fsoot.\f
H\brd\fPVC\f/\fsoft\fPVCBl\bckish\fsmoke\f\bnd\f\bcrid\fsmell.
Стр. 3 из 7
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506663&gui...procarmanuals.com
http://vnx.su

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°
-
-
Стр. 5 из 7
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506663&gui...procarmanuals.com
http://vnx.su