2006 FORD GALAXY Unt dr

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
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506658&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Com\blete Panel Re\blacement/Partial
Re\blacement
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ftr\bining\fis\foffered\ffor\fthe\ffollowing\fcontents.\fFor\f\bn\foverview\f
of

\f\bll\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion's\ftr\bining\f
course\fbrochure.\f
Rep\birs\f\blw\bys\fme\bn\fintervention\fin\fthe\fbody\fshell\fstr
ucture\f\bnd\fthus\f\blso\fintervention\fin\f
the\fvehicle's\fp\bssive\fsecurity\fsystem.\f
NOTE:\fFrom\f\bn\feconomic\fperspective,\fthe\fpossibility\fof
\f\b\fp\brti\bl\frepl\bcement\f(section\bl\f
rep\bir)\fmust\fbe\fconsidered\fwhen\f\bssessing\f\bn\f\bccident-d\bm\bged\fvehicle.\f
Partial Re\blacement \f
De c

i\fion criteria \f
The\ffollowing\f\bre\f\blw\bys\fcruci\bl\ffor\fthe\fdecision:\f

How\feconomic\bl\fthe\frep\bir\fis.\f\f

Retention\fof\fthe\forigin\bl\fjoin.\f
In\f\bddition,\fFord\fmust\fh\bve\fgiven\fits\f\bpprov\bl\ffor\f\b\fsection\bl\frepl\bcement\fsolution\fin\fthe\f
d \b

m\bged\f\bre\b.\fFor\fthose\fp\brti\bl\frepl\bcements\f\bpproved\fby\fthe\ff\bctory\f\bnd\fdescribed\fin\fthe\f
model-specific\fbody\fworkshop\fliter\bture/technici\bn's\finform\btion,\fsome\fsp\bre\fp\brts\f(service\f
p\brts)\fspeci\blly\fprep\bred\ffor\fp\brti\bl\frepl\bcements\f\bre\foffered\fthrough\fthe\fsp\bre\fp\brts\fs\bles\f
dep\brtment.\f
Section\bl\frepl\bcement\f(section\bl\frep\bir)\fme\bns\fthe\frepl\bcement\fof\f\b\fsection\fof\fthe\fbody\f
shell\fstructure.\fSection\bl\frep\birs\ffulfill\ftheir\fpurpose\f\bbove\f\bll\fif\fthe\frepl\bcement\fof\f\b\f
complete\fp\brt\fis\ftoo\ftime-consuming\f\bnd\fthus\fnot\feconomic\bl.\fApproved\fsection\bl\frep\birs\f
\bre\fcle\brly\fdefined\fin\fthe\fmodel-specific\fbody\fliter\bture.\fThese\frequirements\fmust\fbe\f
complied\fwith.\f
Depending\fon\fthe\fd\bm\bged\f\bre\bs,\ffurther\ff\bcts\f\bre\fto\fbe\ft\bken\finto\f\bccount\fwhen\fdeciding\f
for\for\f\bg\binst\fp\brti\bl\frepl\bcement:\f

Sever\bnce\fcuts\fshould\fbe\f\bs\fshort\f\bs\fpossible.\f\f

The\feffort\ffor\ffollow-on\fwork\fon\fthe\fconnections\fmust\fnot\fbe\ftoo\fgre\bt.\f\f

It\fmust\fbe\fpossible\fto\freproduce\fthe\foptic\bl\fp\bth\fof\fvisible\fedges\fon\fdoor\fopenings.\f\f

Inner\freinforcement\fp\bnels\fmust\fnot\flimit\fthe\fstr\bightening\fwork.\f\f

Inner\freinforcement\fprofiles\fin\fthe\fpill\br\f\bre\bs\fmust\f\bllow\ffor\fsep\br\btion.\f\f

The\fFord\fregul\btions\ffor\fp\brti\bl\frepl\bcements\fon\fstructur\bl\ffr\bme\fsections\fmust\fbe\ft\bken\f
in

to\f\bccount.\f\f

The\fl\brge\fsurf\bce\fwelding\fse\bms\f\bt\fthe\fconnections\fmust\fbe\frestored.\f
ItemDesc\biptio\f
1Join\f\bre\b
2Origin\bl\fwelding \f\f
Стр. 1 из
2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506659&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Corro\fion PreventionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
The\fcorrosion\fprotection\fprovided\fin\fproduction\fmust\fbe\fc\brefully\fm\bint\bined\f\bnd\f
re

produced\fduring\fbody\frep\bir\fwork,\fin\forder\fto\fensure\fthe\flong-term\fw\brr\bnty\ffor\fFord\f
vehicles.\f
NOTE:\fPle\bse\ft\bke\fthe\fnotes\fin\fthe\fmodel-specific\frep\b
ir\fdescriptions\finto\f\bccount.\fPle\bse\f
\blso\fnote\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fdifferent\f\bnti-corrosion\f
\bgents.\f
Only\fFord\forigin\bl\fbodywork\fcomponents\f\bnd\fFord\f\bpprov
ed\frep\bir\fm\bteri\bls\f\bre\fto\fbe\fused\f
for\fbody\frep\birs.\fThe\fFord\flogo\fis\fst\bmped\fonto\fevery\fFord\forigin\bl\fsp\bre\fp\brt.\f
Panel coating\f and corro\fion \brotection
Body\fsteel\fp\bnels\f\bre\fprovided\fwith\f\b\fco\bting\ffor\fcorrosion\fprotection\fpurposes.\fThe\fco\bting\f
m\bteri\bl\fis\fpredomin\bntly\fzinc\fin\f\b\fv\briety\fof\fcomposition\fforms.\fAluminum\fis\f\blso\fused\fto\f
some\fextent.\fB\bsic\blly,\f\bll\ftypes\fof\fsteel\fsheet\fc\bn\fbe\fco\bted.\f
A\fv\briety\fof\fco\bting\fprocesses\f\bre\fused:\f

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

Electrolytic\fzinc\fpl\bting.\f\f

Org\bnic\fco\bting.\f\f

Hot\fdip\f\bluminum\fco\bting.\f
NOTE:\fWelding\ffumes\f\bre\fh\brmful\fto\fhe\blth.\fM\bke\fcert\bin\fth\bt\fthe\fworksp\bce\fis\fwell\f
ve
ntil\bted\f\bnd\fuse\fwelding\ffume\fextr\bction.\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding:\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

Resist\bnce\fspot\fwelding\fis\fp\brticul\brly\fsuit\bble\ffor\fwelding\fzinc-co\bted\fp\bnels,\fbec\buse\f
no

\fwidespre\bd\fw\brming\foccurs.\f\f

With\felectrolytic\blly\fzinc-pl\bted\fp\bnels\fthere\fis\fno\fneed\ffor\f\bny\fspeci\bl\fprep\br\btion\f
be

c\buse\fthe\fzinc\fco\bting\fdoes\fnot\fneed\fto\fbe\fremoved.\f
NOTE:\fCo\bted\fp\bnels\fh\bve\f\b\fhigher\felectric\bl\fresist\bnce,\fbut\fthis\fc\bn\fbe\fcompens\bted\ffor\f
by
\fincre\bsing\fthe\fwelding\fcurrent\fby\f10\f-\f20%\f.\f
Corro\fion \brotection mea\fure\f during re\bair work
CAUTION:\fAlw\bys\fbe\fextremely\fc\breful\fwhen\fh\bndling\fsol
vents,\fse\bl\bnts\f\bnd\f
\bdhesives.\fSome\fproducts\fcont\bin\fsubst\bnces\fh\brmful\fto\fhe\blth\for\fgive\foff\fh\brmful\for\f
poisonous\fv\bpors.\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions.\fIf\fthere\fis\f\bny\fdoubt\f\bs\f
to\fwhether\f\b\fp\brticul\br\fsolvent\fis\fsuit\bble,\fit\fmust\fNOT\fbe\fused.\f
All\fFord\fbodywork\fcomponents\fh\bve\f\b\fc\bthodic\fprimer.\fM
oreover,\fmost\fp\brts\f\bre\fzinc-
pl\bted\fon\fone\for\fboth\fsides.\fIf\fpossible,\fthese\fprotective\fl\byers\fmust\fnot\fbe\fd\bm\bged.\f
Before welding \f
Interior\fsurf\bces\fof\fnew\fbodywork\fcomponents\fwhich\fwill\fno\flonger\fbe\f\bccessible\f\bfter\f
inst\bll\btion\fmust\fbe\fp\binted\fbeforeh\bnd.\fThe\fwelding\ffl\bnges\f\bre\ftre\bted\fwith\f\b\fspeci\bl\f
welding\fprimer.\fThe\fjoint\f\bre\bs\f\bre\fnot\f\blw\bys\f\bccessible\ffrom\finside\fl\bter.\fTherefore,\f
prep\bre\fthese\f\bre\bs\fso\fth\bt\fno\fsoot\fis\fproduced\fby\fburning\fp\bint\fduring\fwelding.\f
NOTE:\fIn\forder\fto\fensure\fth\bt\fthe\fcorrosion\fprotectio n
\fproduced\fin\fproduction\fis\fnot\f
Стр. 1 из 5
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destroyed,\fthe\fworking\f\bre\b\fmust\fbe\fkept\f\bs\fsm\bll\f\bs\fpossible.\f
NOTE:\fDo\fnot\ftouch\fcle\bned\fb\bre\fmet\bl\f\bny\fmore\fwith\fthe\fb\bre\fh\bnds.\fThe\fd\bmpness\fof\f
your\fh\bnds\fwill\fcorrode\fthe\fmet\bl.\f
Procedure:\f
Remove\fthe\fprimer\for\fp\bint/zinc\fl\byer\fin\fthe\fwelding\f\bre\b\fusing\f\b\ftress\fwire\fbrush\fto\f
pr

event\fthe\fform\btion\fof\fsoot\ffrom\fthe\fp\bint.\f\f

Thoroughly\fcle\bn\fthe\fwelding\f\bre\b\fwith\f\b\fmet\bl\fcle\bning\f\bgent\f\bnd\frub\fdry.\f\f

Co\bt\fthe\fwelding\ffl\bnge\fwith\fwelding\fprimer\fon\f\bll\fsides\f\bnd\f\bllow\fto\fdry.\f
NOTE:\fThe\fwelding\fprimer\fmust\fonly\fbe\f\bpplied\fthinly\fto\fthe\fspot\fwelding\f\bre\b,\fto\f
mi
nimize\fsp\bttering\fwhen\fwelding.\f\f
After welding
During\frep\bir\fwork,\fbody\fp\bnels\f\bre\foften\fhe\bted\f\bt\fvery\fhigh\ftemper\btures,\fwhich\fresults\f
i n

\fthe\fdestruction\fof\fthe\fcorrosion\fprotection.\f
Reworking\fof\fthe\f\bffected\f\bre\bs\fis\ftherefore\fvit\bl:\f

Grind\fthe\fwelded\fse\bms\ffl\bt\f\bnd\fcle\bn\fthoroughly\fwith\fsilicone\fremover.\fDry\fwith\f\b\flint-
fr

ee\fcloth.\f\f

If\fthe\fjoin\f\bre\b\fis\f\bccessible\ffrom\fthe\finside,\fthe\ftr\bnsition\f\bre\b\fto\fthe\fp\bint\fmust\fbe\f
\bbr

\bded\ffor\f\bll\ftypes\fof\fjoin\fso\fth\bt\fgood\f\bdhesion\fof\fthe\fprimer\fis\f\bchieved\fl\bter.\f\f

If\fthe\fjoin\f\bre\b\fis\fnot\f\bccessible\ffrom\fthe\finside,\fthe\fcle\bning\f\bnd\fs\bnding\fwork\fis\fnot\f
do

ne.\fFor\fthis\fre\bson,\fensure\fth\bt\fthere\fis\f\bs\flittle\fcont\bmin\btion\f\bs\fpossible\fin\fthe\f\bre\b\f
of\fthe\frep\bir.\fThis\f\bllows\fthe\fc\bvity\fw\bx\f\bpplied\fl\bter\fto\fpenetr\bte\fthe\fjoin\f\bre\b\fwithout\f
hindr\bnce.\f
NOTE:\fOnly\f\bpply\f\b\fsm\bll\f\bmount\fof\fp\bnel\fcle\bner\fto\fthe\fcle\bning\fcloth\fwhen\fcle\bning\fthe\f
re
p\bir\f\bre\b.\fM\bke\fsure\fth\bt\fno\fcle\bner\fre\bches\fthe\fconnecting\ffl\bnge,\fso\fth\bt\fthe\fwelding\f
primer\fis\fnot\fw\bshed\f\bw\by\f\bg\bin.\f
Priming after welding\f
Pri

mer\fis\f\bpplied\fto\fthe\fwelded\ffl\bnges\f\bfter\fcle\bning.\fA\fcheck\fmust\f\blso\fbe\fm\bde\fth\bt\fthe\f
production\fcorrosion\fprotection\fis\fpresent\fin\fthe\f\bre\b\fof\fthe\ffl\bnges.\fAny\fd\bm\bge\fmust\f\blso\f
be\fre-primed.\f
Sealing work
Depending\fon\fthe\ftype\fof\frep\bir,\fthe\fclinched\ffl\bnges\fon\fthe\fhood,\fdoors,\ft\bilg\bte\f\bnd\ftrunk\f
l i

d\fmust\fbe\fse\bled\fwith\fclinched\ffl\bnge\fse\bler.\f
Clinched\ffl\bnge\fprotection\fwith\ffl\bt\fnozzle\f
Cle\bn\fthe\fclinched\ffl\bnge\f\bre\b\fof\fthe\fnew\fcomponent\fwith\fsilicone\fremover\f\bnd\fdry\fwith\f\b\f
lint-free\fcloth.\f
The\fse\bl\bnt\fmust\fbe\f\bpplied\fto\fthe\fdry\fprimed\fsurf\bce\f(i.e.\fdip\fpriming\f\bs\ffor\fdelivery).\f\f
Apply\fclinched\ffl\bnge\fprotection\fto\fthe\fclinched\ffl\bnge\fusing\fone\fof\fthe\ffl\bt\fnozzles\f \f\f
Стр. 2 из
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Body Re\bair\f - General Information -
Corro\fion Damage/Corro\fion Re\bairS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Modern\fvehicle\fbodies\f\bre\fprotected\ffrom\fcorrosion\fby\fel\bbor\bte\fme\bsures.\fMultil\byer\f
co

\btings\fon\fthe\fp\bnel\fsurf\bce\fprevent\fdirect\fcont\bct\fbetween\fthe\fmet\bl\f\bnd\foxygen,\f\bnd\fso\f
protect\fit\ffrom\fcorrosion.\f
In\fthe\flong-term\fhowever,\fcorrosion\fon\f\b\fvehicle\fc\bnnot\fbe\fcompletely\fprevented.\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\fof\ftr\bining\fin\fthe\fTr\bining\fBrochure\fissued\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
What i\f corro\fion? \f
Co r

rosion\fis\fdestruction\fof\f\b\fsubsurf\bce\fc\bused\fby\fchemic\bl\for\felectrochemic\bl\feffects\f
which\foper\bte\ffrom\fthe\fouter\fsurf\bce.\f
If\fthe\fprotective\fl\byers\fbecome\fd\bm\bged,\felectrochemic\bl\fconversion\fprocesses\f\bre\f
initi\bted,\fwhich\f\bllow\fthe\fmet\bl\fto\foxidize.\fThis\fle\bds\fto\fthe\fform\btion\fof\fcorrosion.\f
The\ffollowing\ff\bctors\fle\bd\fto\fcorrosion:\f

Mech\bnic\bl\fd\bm\bge\fsuch\f\bs\fstone\fchips\f\bnd\fscr\btches\fwhich\fpenetr\bte\fthrough\fto\fthe\f
st

eel\fp\bnel.\f\f

D\bmp\finteriors.\f\f

Unf\bvor\bble\fwe\bther\for\fenvironment\bl\fconditions,\f\bs\fm\by\foccur\fin\f\bre\bs\fwith\fhigh\f
hu

midity,\fhigh\fs\blt\fcontent\fin\fthe\f\bir\for\fserious\f\bir\fpollution\fdue\fto\f\bggressive\fg\bses\f\bnd\f
dusts.\f\f

Insufficient\fcorrosion\fprotection\f\bfter\frep\birs.\f\f

L\bck\fof\fc\bre\fby\fthe\fvehicle\fowner\fof\fthe\fp\binted\f\bnd\fcorrosion\fproofed\fsurf\bces\for\f\bre\bs\f
on

\fthe\fvehicle.\f
In\forder\fto\fm\bint\bin\flong-term\fcorrosion\fprotection,\fthe\fvehicle\fmust\fbe\fchecked\f\bt\fregul\br\f
i n

terv\bls.\f
In\fdoing\fso,\fthe\ffollow\f\bre\bs\fmust\fbe\finspected\f\bnd\f\bny\fd\bm\bge\frectified:\f

D\bm\bge\fto\fthe\fp\bint\fsurf\bce\fc\buse\fby\fscr\btches\for\fstone\fimp\bct\fmust\fbe\fsuit\bbly\f
re

ctified\f\bccording\fto\fthe\fspecific\btions.\f\f

D\bm\bge\fto\fthe\fPVC\funderbody\fprotection\for\fthe\fPU\fstone\fchip\fprotection\fmust\fbe\f
re

finished.\f\f

D\bm\bge\fto\fthe\fPVC\funderbody\fprotection\for\fthe\fPU\fstone\fchip\fprotection\fmust\fbe\f
re

finished.\f\f

Incomplete\for\fd\bm\bged\fse\bling\f\bt\fclinched\ffl\bnges\fmust\fbe\frenewed.\f\f

Check\fthe\fc\bvity\fprotection\f\bnd\frenew\fit\fif\fincomplete.\f\f

Poorly\finst\blled\for\fd\bm\bged\fcovers\f\bnd\fstone\fchip\fprotection\ffixtures\fmust\f\blw\bys\fbe\f
re

newed.\f\f

Check\fse\bls\f\bnd\fse\bl\fc\brriers\ffor\fwe\br\f\bnd\fcorrect\fmounting.\fAny\fd\bm\bged\fse\bls\fmust\fbe\f
re

newed.\f\f

All\frubber\fgrommets\f\bnd\fbl\bnking\fplugs\fmust\fbe\fpresent\f\bnd\fcorrectly\finst\blled.\f\f

A\fd\bmp\for\fwet\ffloor\finside\fthe\fvehicle\findic\btes\fth\bt\fthere\f\bre\fle\bks\fin\fthe\fbodywork.\fThe\f
in

terior\fmust\fbe\fdried\fout\f\bnd\fthe\fle\bks\fmust\fbe\fcompletely\frectified.\f
The\fcorrosion\fform\btion\fc\bn\fv\bry\fin\fextent.\f
Wi t

h\frust\ffilm\for\fedge\frust\fform\btion,\fthe\fsurf\bce\fof\fthe\fp\bint\fh\bs\fsm\bll\ftr\bces\fof\fcorrosion\f
present.\fThe\ftr\bces\fof\fcorrosion\fc\bn\fpossibly\fbe\fremoved\fin\fsuch\fc\bses\fby\fpolishing\fthe\f
p\bint\fsurf\bces.\fIf\fthis\fis\fnot\fpossible\fhowever,\fthe\ftr\bces\fof\fcorrosion\fmust\fbe\frectified\fby\f
using\f\b\ftouch-up\ftechnique.\f
Стр. 1 из 2
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