Repair high-strength steel

Repair high-strength steel

Safety Precaution

Precautions of electric technician  who use Medical Electronic Equipment

Inspection of key points before the maintenance

Precautions of auxiliary restraint system "airbag" and "seat belt pretension"

Precautions of removing the 12V battery

Matters needing attention

Maintenance Precautions

 

 

 

 

 

 

 

 

 

 

 

Safety Precaution

Precautions of electric technician  who use Medical Electronic Equipment

Prohibit Operation

Warning:

●         Strong magnetic components have been assembled on this vehicle.

●         Technicians shouldn't operate electronic pacemaker or other medical electronic devices in this vehicle, or the functions of medical devices may be affected by strong magnetic components.

Precautions for normal charging

Warning:

●         If a technician uses a medical electric device such as an implantable cardiac pacemaker or a

heart pacemaker/defibrillator, the effects of the devices must be checked  before starting the charge operation.

●         If a technician using a medical electric device such as implantable cardiac

pacemaker or an implantable heart pacemaker defibrillator .he must not enter the vehicle compartment (including luggage room) during normal charge operation.

Communication equipment operation precautions

●         If the technician uses medical electronic devices such as  cardiac pacemaker, cardioverter or defibrillator and other medical electronic equipment, please keep enough distance with the communication devices.

●         The electromagnetic wave of the remote intelligent terminal may affect the function of the medical device such as cardiac pacemaker, cardioverter, defibrillator and other medical electronic devices.

●         If the technician uses the medical device such as  cardiac pacemaker, multiplexer, defibrillator and other medical electronic equipment, the electromagnetic wave of the remote intelligent terminal may affect the function of the device. The possible effect of the remote intelligent terminal on the medical electronic devices must be checked by the manufactures of the medical electronic devices  .

Inspection of key points before the maintenance

The high-voltage system may automatically operate. Please confirm the remote air conditioning and fixed-time charging haven’t been set before the maintenance.

Attention:

If remote air-conditioning or fixed-time charging is set, the high voltage system will run automatically even the switch is off.

Precautions of auxiliary restraint system "airbag" and "seat belt pretension"

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along

with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual front air bags. Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this Service Manual.

Warning:

Always observe the following items for preventing accidental activation:

●         To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized JAC dealer.

●         Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal

injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see “SRS AIR BAG”.

●         Do not use any electrical test devices to test any circuit of the auxiliary restraint system unless these tests are in the instructions described in the service manual. The wire harness and connectors of the auxiliary restraint system should adopt to yellow or orange color.

Precautions when using power tools(pneumatic or electric) and hammer

●         When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the power switch ON, never use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious

injury.

●         When using  power tools or a hammer, turn the key in the "LOCK" position, unplug the cathode of 12V lead-acid battery and wait at least 1 minute for maintenance.

Precautions of removing the 12V battery

When removing the 12V battery, turn the power switch to “ON”, and then to “OFF”.

Note:

●         The automatic 12V battery charge function may start even when the power switch is in “LOCK”state.

●         The automatic 12V battery charge control does not start within approximately one hour when the power switch is turned ON/OFF.

 

Matters needing attention

●         Before the repairing which no need the power: rotate the key to LOCK gear and disconnect the 12V battery negative.

●         After disconnect the 12V battery negative, the memory of radio and other control devices will be cleared.

●         Replace new oil seal, gasket,gasket ring,O-type ring,lock washer,cotter pins,self-locking nuts and other parts.

●         Place the removed parts in order and according to the positions as they are assembled .

●         If necessary, use approved binders, sealants or equivalent products.

●         For safe and efficient repair work, you should use hand tools, power tools (disassembly only) and special tools.

●         Before repairing the vehicle:

Cover the fender, interior and carpet with a suitable cover. Be careful do not scratch the paintwork with keys, buttons or something like this.

 

 

 

 

 

 

 

 

 

 

 

 

Maintenance Precautions

    It is not recommended to heat when repairing some steel framed structure, because heating will weaken its performance; when heating is inevitable, temperature of high strength steel part shall not exceed 550 ℃.

    When straightening car body, should be careful to pull high strength steel, because it is extremely strong, over pulling will make other parts that connect with steel deformed, in this case, increasing measuring numbers and careful pulling the steel panel is the only way.

             

    When cutting high strength steel, saw is a choice if can be replaced to avoid gas cutting, which can avoid surrounding panel wakening due to high temperature. If gas cutting is inevitable, be sure temperature influencing range is within 50mm.

 

    When welding high strength steel, spot welding is strongly recommended at any case,minimizing the influence to its surroundings due to welding heat; Rare gas shielded welding is the second choice when spot welding can’t proceed, do not use  gas welding due to its weak welding strength.

    The strength of spot welding position is higher than other places that don’t have welding position on high strength steel. When cutting welding spots of high strength steel, using drilling machine with low rpm and high torque(1,000 to 1,200 rpm) can increase its durability and operability.

Precautions of spot welding high strength steel

    This task should be carried out under the standard operation condition, following issues should be paid attention when spot welding high strength steel:

electrode tip diameter shall be chosen according to metal panel thickness.

   

 

Panel shall be stick to each other without sundries or intervals

    Restrain welding points intervals size according to the following instructions

 

Car body components：

Engine compartment groups:

 

Front floor part group:

 

 

Rear floor part group:

 

 

 

Front mold group:

 

 

Side skirt group:

 

 

Dispose parts of extra high strength steel

    Weaken or additional connecting is forbidden;

It is forbidden to weaken or additional connect extra high strength steel such as carling, if it is damaged, front floor assembly must be replaced.

Spray paint

    Operate according to battery protection standard during dry spray;

    When spray booth is used, keep the temperature in and out of threshold( lower  than 60℃) , minimizing damage to lithium battery.

Attention:

●         Install a non-contact thermometer;

●         If battery is covered, the cover shall be removed to measure inner temperature;

●         If the spray temperature exceeds 60℃ out of threshold, battery should be removed before spraying.

Car protection

Seat/glass/carpet all need to be removed or covered by appropriate material(Splash cover), so they will not be dirty or damaged by welding slag. Also, when cutting or welding part is close to high voltage part, this high voltage part shall be covered by insulating heatproof cover(Splash cover).