2004 DACIA SUPERNOVA Repair Manual

40
GENERAL
40 - 5
The replacement (repara tion) operations of t he weldable elements descri bed i n t his
chapter a re specified subject to: cutting out of t he parts t o be replaced; the a ccess to the
welded elements, tools and checking devices accessibility, etc.
In case the vehicle body has suffered import ant deform ations it is recommended the
str aightening of t he damaged body elements, by means of some hydraulic pre sses, the
operation being performed slowly and at cold. For this range of vehicles, the e lements re sistance structure which a re a ffecting the
vehicle securi ty, are not to be partially re placed ( not to be cut), but entirely.
After welding detaching, the body elements must remain stra ight, without breakage or
cracks, the possible holes being covere d out with filling material or by tinning. The body
elements surfaces are t o be pickled ( to eliminate possible oxidation marks) , dried and
initially applied a paint layer. The electric welding detaching of the body elements, is performed as follows:
- with a well sharpen chisel, this method may lead to part s deformation or even
parts breaking.
- by using some extractors equipped with steel cutter type Bre ndeo or Pickvant
max. 6 mm, having the cutting head as per shape shown in pict.1.
1. Centeri ng point
2. Sharpen slope
3. Drill acting edges
4. Gap for catching the welding materialP = aprox. 0.4 mm
Whatever method is used, the remaining element m ust be in good order a nd to allow
performing of a good quality welding point.
The pl ates cutting it is recommended t o be pe rformed ( subject of importance and thick-
ness ) using manual scissors or pneumatic portable tools for plates cutting.
Du ring cutting or welding of the body elements it is necessary to protect the electric
wir ing from the interi or of the body structure.
The cutting, welding, or strengthening operation done on body welded elements, are to
be performed on body checking/ straightening bench type CELETTE .
IMP ORTANT
When removing or straightening the body resistance e lements i t i s forbidden t he
total or partial heating, in order to avoid the mechanical resistance and metal elasticity
decreasing. REPAIRIN
G GENERAL CONDITIONS
vnx.su

40
GENERAL
40 - 6
WELDING TYPES AND P
ARAMETERS
At the reparation of the welded body elements, thre e welding categories may be used:
prot e c t ion ga s weldi ng (CO2), e l e ctri c spot weldi ng and fi l l ing m a teri als wel ding
(autogenous). At the autogenous welding, it is recommended that flame must be slightly inclined so
that arch can be seen and the flame extremity to be maintained at aprox. 5 m m from the
part to be welded.
1. Spot welding resistive para meters for steel plates with carbon c ontent C < 0,15 %.
Plate thic kness (mm) Welding current (KA) Welding time (per) Tightening force ( daN m. )
0,5 6,5 5 130
0,8 8,0 8 200
1,0 9,5 10 250
1,25 10,5 10 295
1,5 10,0 14 310
2,0 12,0 16 350
NOTE
1 period = 1/50 part of a second
2. Welding parameters for the welding in protector gas for carbon steel plates or low-
alloyed steel.
Horizontal welding position ( pict.1)
Plate thickness (mm) 0,61,0 1,5 2,0
Electrode diamet er (mm) 0,6 0, 80,8 1,00 ,8 1,0 0,8 1,0
Welding wire speed (m/min) 2,5 1,9 3,2 2,4 4,4 3,8 5,7 4,4
Welding current (A) 35 35 55 80 80 120 100 130
Welding speed (m/min) 0,25 0,25 0,35 0,33 0,33 0,50 0,45 0,45
Welding voltage (V) 17 17 18 18 19 19 20 20
Protection gas flow (1/min) 12 - 17
Electrode fr ee length (mm) 6 - 12
plates welding
in tiers end to end
welding corner
welding
0-1,5mm 0-1,5mm
vnx.su

40
GENERAL
40 - 7
WELDING TYPES AND P
ARAMETERS
NOTE
In case of using the Ar + CO2 mixture, the welding voltage will decrease with 2 V.
Ve rtical welding position ( obligatory from top to bottom) pict. 2
Plate thickness 0,6 12 2,0
Electrode diameter (m m) 0,6 0,8 0,8 1,0 0,8 1,0
We l ding wire speed (m /min) 2,5 1,9 3,3 3,2 5,7 4,4
We l ding current (A) 35 35 70 100 100 130
We l ding speed (m/min) 0,25 0,25 0,38 0,48 0,50 0,50
We l ding voltage (V) 17 17 18 18 20 20
Pr otection gas flow (1/min) 12 - 17
Electrode fre e length (mm) 6 - 12
vnx.su

40
GENERAL
40 - 8
C
OLLISION DIAGNOSIS
Du ring the vehicle exploitation, the carriage body may suffer different distortions, that
lead many times to the wheels setting angles change, body elements breakage, vibra tions
or even mechanical parts wear. In these conditions, be fore performing the vehicle body re paration, some checking is
necessary:
Visual checking - consisting in the e xamination of the mechanical elements attachments
and of the distortions occurring in the vehicle damaged areas.
Checking with the bar (control gauge) – consisting in comparing the measurements
done in symmetric points. The ge ometry checking of t he rol ling t ransmissions – this checking is t he only one
enabling to find out if the body damage was not affecting the vehicle road behavior.
IMP ORTANT
This checking must be not ignored, except some border-line cases, the checking of
the rolling transmissions leading to t he identification of the distortions occurred further
to an accident.
C OLLISION DIAGNOSIS
vnx.su

40
GENERAL
40 - 9
C
OLLISION DIAGNOSIS
CENTRAL PA RT CHECKING
This c hecking is performed in the purpose to establish if one of the distortions is not
affecting this floor part, from where the checking starts. Compare the followings lengths : EI = FJ; EJ = FI.
FRONT LONGITUDINAL GIRDERS CHECKING Compare the followings lengths: CG = DH; CH = DG.
If the lengths ( CH - DG) and the diagonals (CG - DH ) are not identical, check again
the point ( 3).
If points (1) and ( 2) are good, the front axle angles may be checked.
vnx.su

40 -10
C
OLLISION DIAGNOSIS
REAR LONGITUDINAL GIRDERS CHECKING
Compare the following lengths: EK = FL; EL = FK.
RE AR ARM CHECKING
Compare the following lengths: FM = EN.
If a difference is noticed when measuring the lengths ( FM – EN ), the rear arms are to
be replaced.
The checking operation of the rear arm s is followed by a checking performed with the
gauge fixed on the arm and on the central longitudinal girde r.
40
G ENERAL
vnx.su

FLOOR FRAME CHECKING
G.M.P. SUPPORT ASSEMBLY CHECKING
40 - 11
GENERAL
COLLISION DIAGNOSIS40
vnx.su

40
GENERAL
40 - 12
12
Fo r checking, straightening or repairing the DACIA vehicles bodies, the use of the
CELLETTE bench is recommended. The checking/straightening bench type CELETTE ( service code CAR 500 ) is composed of:
-C AR 501 (1 mobile bench with four wheels, four parts for vehicle anchori ng, one
traction arm of 10 t, type
“CAIMAN“).
-C AR 502 - set modular c ross bars
-C AR 503 - set of 22 towers MZ
-C AR 504 - set accessories for traction
-C AR 505 - set of specific supports for DACIA Bl, Bk
-C AR 506 - set of specific supports for DACIA 1304, 1307
-C AR 507 - set of specifi c supports for DACIA NOVA.
NOTE
The purchase of the checking / straightening bench - CELETTE type- is to be done
through Automobile Dacia S.A.
1. CAR 501
The mobile bench (1) is provided with four a nchoring parts (2) - (fig 1), which can be
used when a carriage body straightening operation is performed.
(pict.1)
CAR
RIAGE BODY CHECKING/ STRAIGHTENING
BENCH CELETTE TYPE
vnx.su