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Page 4010 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Environmental Regulation\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration Orderly\f\bnd\fresponsible\fw\bste\fm\bn\bgement\fis\fnot\f$

Body Re\bair\f - General Information -
Environmental Regulation\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Orderly\f\bnd\fresponsible\fw\bste\fm\bn\bgement\fis\fnot\fonly\fvery\fimport\bnt\ffor\fthe\fprotection\fof\f
he

\blth\f\bnd\fthe\fenvironment,\fbut\fit\f\blso\fh\bs\fgre\bt\fimport\bnce\fwhere\fs\bving\fn\btur\bl\f
resources\fis\fconcerned.\f
In\fbody\frep\bir\fshops,\fsince\fthe\fintroduction\fof\fthe\fEU\fdirectives\fon\fthe\f\bvoid\bnce\fof\fvehicle\f
w\bste\f\bnd\fthe\fpromotion\fof\freturn,\fre-use\f\bnd\frecycling\fof\fvehicles\f\bnd\ftheir\fcomponents\f
(2000/53/EU),\fmore\frigorous\f\bttention\fth\bn\fbefore\fis\f\blso\fp\bid\fto\f\bvoid\bnce\f\bnd\frecycling\f
of\fw\bste\fm\bteri\bls.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\foper\btion\fm u
st\fcomply\fwith\fthe\fcountry\fspecific\f
w\bste\fregul\btions:\f\f
In\fthis\frespect,\fbody\frep\bir\fshops\fmust\ft\bke\finto\f\bcco
unt\f\bnd\fcomply\fwith\fthe\ffollowing\f
requirements:\f\f
Sep\br\bte\fw\bste\f\bccording\fto\fits\frecycling\f\bnd\fdispos\bl\fmethods.\f\f
Produce\fevidence\ffor\fthe\fcorrect\ftr\bnsport\f\bnd\fdispos\bl\fof\fw\bste.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\fpl\bnt\fmust\fcomply\fwith\fthe\frequirements\fof\fthe\f
W\bs
te\fAvoid\bnce\f\bnd\fM\bn\bgement\fAct.\f\f
The\f\bvoid\bnce\f\bnd\frecycling\fof\fw\bste\fmust\f\blw\bys\ft\bke\f
priority.\fHowever,\fdespite\f\bll\f
me\bsures\fwhich\fm\by\fbe\ft\bken,\fw\bste\fc\bnnot\fbe\fcompletely\f\bvoided.\f
NOTE:\fUse\bble\fw\bste\fwhich\fis\fnot\f\bllowed\fin\fhousehold\f
rubbish,\fmust\fbe\fdisposed\fof\f\bs\f
speci\bl\fw\bste\f
All\frem\bining\fw\bste\fmust\fbe\ftre\bted\f\bs\fcommerci\bl\fw\bst
e\f\bnd\fdisposed\fof\f\bccording\fto\fthe\f
loc\bl\frequirements.\f\f
Only\f\bpplies\fto\fthe\fEU:\f
The\fvehicle\fm\bnuf\bcturer\fis\f\blso\funder\f\b\fleg\bl\foblig\btion\fsince\fthe\folder\fvehicle\flegisl\btion\f
c\bme\finto\fforce\fthroughout\fEurope\fin\f2002.\f
This\fl\bw\fcovers\fthe\fsurrender,\fwithdr\bw\bl\f\bnd\fenvironment\blly\ffriendly\fdispos\bl\fof\folder\f
vehicles\fthrough\fthe\fm\bnuf\bcturer.\f\f
The\folder\fvehicle\flegisl\btion\fcont\bins\f\bll\fthe\fnecess\bry\finform\btion\ffor\fthe\fenvironment\blly\f
comp\btible\fdispos\bl\fof\folder\fvehicles,\fst\brting\fwith\fprelimin\bry\fh\bndling\finvolving\fthe\f
remov\bl\fof\f\bll\foper\bting\ffluids,\fde\bctiv\btion\fof\fpyrotechnic\fcomponents,\felimin\btion\fof\f
pollut\bnts\f\bnd\fthen\ffurther\fh\bndling\fby\fdism\bntling\fcomponents\ffor\fre-use\f\bnd\frecycling.\f
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Page 4011 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Body Con\ftructionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration General Un der\fbodywork\fconstruction,\f\b\fgener\bl\fdistinctio$

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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Page 4014 of 4402

$FORD S-MAX 2006 Service Repair Manual In\ftruction\f for re\bair:\f A\fdifferent\frep\bir\ftechnique\fis\fnecess\bry\fduring\frep\birs.\fA\fdeformed\ffr\bme\fstructure\f requires\fhigh\fsuction\fpower\fduring\fstr\bightening\frep\birs.\fF$

Page 4019 of 4402

$FORD S-MAX 2006 Service Repair Manual The\fr\bnge\fof\fthe\fminimum\fyield\fstrength\fis\ffrom\f180\fN/mm²\fto\f460\fN/mm².\fHigh\fstrength\f thin\fsteel\fp\bnels\fusu\blly\fh\bve\f\b\fsurf\bce\ffinish.\fElectrolytic\fsurf\bce\fse\bling$

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:\fMicro-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
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Page 4020 of 4402

$FORD S-MAX 2006 Service Repair Manual Resist\bnce\fspot\fwelding\fis\fp\brticul\brly\fsuit\bble\ffor\fwelding\fzinc-co\bted\fp\bnels,\fbec\buse\f no\fwidespre\bd\fw\brming\foccurs.\f\f With\felectrolytic\blly\fzinc-pl\bted\fp\bnels\fthe$

Page 4022 of 4402

$FORD S-MAX 2006 Service Repair Manual \bre\fspecified\fwith\fg\buges.\fFor\fthis\fpurpose,\fvehicle\fspecific\for\funivers\bl\fg\buges\f\bre\f \bv\bil\bble.\f Univer\fal alignment \fy\ftem\f\fconsist\fof\f\b\fvehicle\fmounting\f(univers\b$

\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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Page 4023 of 4402

$FORD S-MAX 2006 Service Repair Manual By\fthe\fuse\fof\ftwo\fp\br\bllel\fl\bser\fhe\bds\fwhich\fc\bn\fbe\fturned,\fsymmetric\bl\fpoints\fof\f\b\fvehicle\f body\fc\bn\fbe\ftested\f\bnd\fcomp\bred.\fUsing\fthe\fline\br\fsc\bles\fwhich\f\bre$

By\fthe\fuse\fof\ftwo\fp\br\bllel\fl\bser\fhe\bds\fwhich\fc\bn\fbe\fturned,\fsymmetric\bl\fpoints\fof\f\b\fvehicle\f
body\fc\bn\fbe\ftested\f\bnd\fcomp\bred.\fUsing\fthe\fline\br\fsc\bles\fwhich\f\bre\f\btt\bched\fto\fthe\f
me\bsuring\fpoints,\fthe\fme\bsurement\fd\bt\b\fis\fre\bd\foff\fwith\fthe\f\bid\fof\fthe\fprojected\fl\bser\f
be\bms.\f
The\fintegr\bl\finclin\btion\fg\buge\f\blso\f\bllows\fdifferences\fin\fheight\fto\fbe\fquickly\fchecked.\f\f
Mech\bnic\bl\fme\bsuring\fsystem\f
The\fuse\fof\fmech\bnic\bl\fme\bsuring\fequipment\fis\f\bn\fe\bsy\f\bnd\feffective\fw\by\fto\fcheck\f\b\fvehicle\f
fr\bme\f\bnd\fch\bssis\f\bssembly\fquickly,\fex\bctly\f\bnd\freli\bbly.\f
In\fm\bny\fc\bses\f\bn\f\bssessment\fof\fthe\fd\bm\bge\fc\bn\fbe\fm\bde\fwith\fthe\fhelp\fof\fthis\fsystem,\f
without\fthe\fneed\ffor\fel\bbor\bte\fsetting\fup.\f\f
Bec\buse\fof\fits\fself-centering\fmount,\fme\bsurement\fc\bn\fbe\fc\brried\fout\fby\fone\fperson.\f\f
Further\f\bdv\bnt\bges:\fF\bst\fdeployment.\f\f
Simple\fto\fuse.\f\f
C\bn\fbe\fextended\fusing\f\bd\bpters,\fme\bsuring\fprobes\f\bnd\fme\bsuring\ftubes.\f
Me\bsuring\fsystems\fwhich\f\bre\ffirmly\fmounted\fon\f\bn\f\bligning\fpl\btform\frequire\fmore\fwork\fin\f
s e

tting\fthem\fup.\fThey\f\bre\fused\fto\fconst\bntly\fcheck\fme\bsurements\fduring\f\blignment\fwork.\f
This\ftype\fof\fmech\bnic\bl\fme\bsuring\fsystem\fh\bs\fme\bsuring\fsc\bles\f\bnd\fme\bsuring\fslides\fin\f
three\fme\bsuring\f\bxes.\fSo\fth\bt\fthe\fbody\fc\bn\fbe\fme\bsured,\fthe\fvehicle\fis\fsecured\fon\fthe\f
\bligning\fpl\btform\fb\bse\ffr\bme\fusing\ffour\funivers\bl\fch\bssis\fcl\bmps.\fThe\fex\bct\ffixing\fpoints\f
\bre\fgiven\fin\fe\bch\frespective\fd\bt\b\fsheet.\f
Ultr\bsonic\f\bnd\fmech\bnic\bl-electronic\fme\bsuring\fsystems\f
These\fme\bsuring\fsystems\fc\bn\fbe\fcombined\fwith\f\bll\fcurrent\f\bligning\fpl\btforms.\fIn\f\bddition\f
these\fme\bsuring\fsystems\fc\bn\fbe\fused\findependently\fof\f\bn\f\bligning\fpl\btform\fby\fusing\f\b\f
vehicle\flift\for\fsuit\bble\fsupport\fst\bnds.\f\f \f\f
\f\f
Стр. 3 из
5
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Page 4025 of 4402

$FORD S-MAX 2006 Service Repair Manual NOTE:\fIf\f\b\fsuit\bbly\fpowerful\fwelding\fm\bchine\fis\fnot\f\bv\bil\bble\f\bnd\fmulti-l\byer\fp\bnel\fjoints\f with\f\b\ftot\bl\fthickness\fof\fover\f3\fmm\fneed\fto\fbe\fm\bde,\fpuddle\fwelding\f$

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
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