Service Training
Self Study Program ******
Volkswagen Collision
Volkswagen Group of America, Inc. Volkswagen Academy Printed in U.S.A. Printed 1/2012 Course Number ******
©2011 Volkswagen Group of America, Inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. All requests for permission to copy and redistribute information should be referred to Volkswagen Group of America, Inc. Always check Technical Bulletins and the latest electronic repair information for information that may supersede any information included in this booklet. Trademarks: All brand names and product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Steel Types and Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Note
This Self-Study Program provides information regarding the design and function of new models. This Self-Study Program is not a Repair Manual.
Important!
This information will not be updated. For maintenance and repair procedures, always refer to the latest electronic service information.
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Introduction
The use of steels in current vehicles is essential due to its availability, low cost and high strength. Steel has one of the highest strengths of all metals, and allows for different levels of flexibility depending on how it is processed. It is possible to produce vehicles without steel. However, using other materials to achieve the same strengths increases cost. Aluminum, magnesium, titanium and carbon fiber are all materials that can be used to make a vehicle. Some of these materials are actually used in Volkswagen vehicles, but the primary material for the body components is steel.
S421_080
This SSP will cover the steels used in Volkswagen vehicles, where they are used and general repair information. There are variations in the types and colors of steels used in the graphics. Please refer to the legend for each model . Do not assume that a particular color indicates the same strength steel for all vehicles.
1
Steel Types and Usage Steels
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Special steels are created for use in different parts of the vehicle. These steels may have different hardnesses and flexibility depending on the composition and treatment processes. The use of these different steels increases the strength of the occupant cell and allows for high chassis stiffness, while reducing vehicle weight.
Basic Steel Types • Ferrite: Up to 28 MPa • Pearlite: 55 - 70 MPa • Austenite: 88 - 105 MPa
MPa is the abbreviation for MegaPascals. MPA is a unit used to measure tensile strength. Tensile strength increases as the MPa number increases.
• Cementite: Up to 215 MPa • Bainite: 15 - 220 MPa • Martensite: 170 - 250 MPa
Alloying One way to increase the strength of steels is to alloy, or add other elements to the steel mixture while it is molten. Elements commonly added to steel for alloying are: • Chrome • Manganese • Molybdenum • Nickel • Niobium • Phosphor • Silicon • Nitrogen • Titanium
For more information regarding steel construction and treating methods, refer to SSP ******, Volkswagen *****
2
Steel Types and Usage Treatments In order to further increase the strength of steels or alloys, there are many treatments. These treatments are broken down into three main categories:
Treatment Type
Treatment
Mechanical treatments
Cold Forming Hot Forming
Thermal treatments
Hardening Annealing Normalising Tampering
Thermochemical treatments
Case Hardening Carbonitriding Nitrating
3
Steel Types and Usage Classification After all alloying and hardening processes are applied to steel, the steel must be classified according to its characteristics.
Classification according to strength
Ultimate strength in MPa
Conventional steels
Up to approx. 300
High-strength steels
300-480 350-730 340-480
Higher-strength steels
500-600 600-800
4
Ultra-high-strength steels
>800
Ultra-high-strength thermoformed steels
>1,000
Need help creating comparison to other steels to identify what types of repairs and heat ranges can be performed. Chart below is what most OEMs supply.
Steel Types and Usage Applications When designing a vehicle, the strength and characteristics of steel are used in the computer modeling process. Specific steels and thicknesses of these steels are used in different areas to make the vehicle stiff and safe. In addition, multiple sheets can be assembled with other steels to create parts with specific characteristics.
Tailored Blanks Tailored blanks are different steel grades and thicknesses to be joined together in a single part. Tailored blanks allow for better and more precise adjustment of the body structure to the loading of certain body sections. This allows parts with complex shapes and precisely fitting designs to be produced. The individual parts of the tailored blanks are joined together by welding. After welding the blank can then be shaped.
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Front Floor
Front Longitudinal Member
Darkening in color indicates an increase in sheet thickness
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Steel Types and Usage Ultra High Strength Hot Formed Sheet Metal This type of metal is formed using special treatments that may include boron. Although some aftermarket companies provide products and state that this material can be worked with, Volkswagen requires that these parts be replaced if damaged. Also, these parts should not be welded. They are to be replaced according to the repair information. These parts are usually used in the A-pillar, B-Pillar, some floor sections and the front and rear bumpers. ErWin and ElsaWeb repair information both provide images of where these steels are located in General Information, Hot Formed Body Panels.
6
Welding Welding and Bonding Methods There are many different types of methods used to hold the body together. • Spot Welding
• Laser Welding • Laser Soldering • Plasma Soldering • Bonding
Each of the above techniques may be used depending on whether the parts are for crash safety, chassis strength, deformation reduction, surface finish and many other reasons. In order to determine the correct repair for any type of welding or bonding, always refer to the repair information.
Laser Welds Bonding+Spot Welds
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Welding Laser Welding Laser Nozzle
In laser welding, the heat to melt the materials is produced by a laser beam. Laser welding was first used to produce tailored blanks for body construction. It is becoming more commonly used in the assembly of vehicles due to:
Welding Rod Feed
Laser Beam
Welding Rod • Laser welding allows an “almost seamless” connection of parts - this is particularly advantageous for connecting higher-strength sheets • Complicated seams such as single-sided welds, are possible • A very good surface quality is achieved even at high working speeds • The surface of a laser weld seam is already so good that reworking for a good paint finish only requires a minimum amount of time
Sheet Metal S421_059
Electrode
Spot Welding This method allows electrically conductive materials to be welded. An electrical current flowing through the welding joint melts the material and the parts are welded together - without additional material. In modern body construction, adhesive is also added to the joining level to improve the structural behavior and stiffness of the joint and increase the vibration resistance. The adhesive layer also prevents penetration of substances such as water or other liquids, preventing crevice corrosion.
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Welding Spots
Sheet Metal
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Electrode
Welding Soldering
Plasma Nozzle Tungsten Electrode
In contrast to welding, the actual parts being joined are not melted at the joint during the soldering process. The solder material is bronze. The melted solder fills the space at the joint and connects the parts being joined with a high strength. Due to the low temperatures used for soldering, the zinc coating on galvanized sheet metal is less affected and substantial hardening is avoided in the join area. Join gaps can be bridged better by the solder. The lower process temperatures allow less heat distortion.
Plasma Soldering
Solder (wire)
Inert Gas Nozzle
Wire Feed
Sheet Metal
Soldering Seam Wire Nozzle
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Arc
Plasma Soldering
Laser Nozzle Laser Beam
The arc is constricted by a plasma nozzle . This allows a higher energy density and narrower seams. Also, higher soldering speeds are possible. Solder (wire)
Laser Soldering
Sheet Metal Wire Feed
In LASER soldering, the soldering heat is produced by a laser beam. Soldering Seam S421_072
Wire Nozzle
Laser Soldering
Bonding Adhesive
Bonding is a method for the permanent connection of components using an adhesive. Depending on the type of adhesive, the hardening process can be reinforced by heating the bond slightly. Due to the continued development of new, more efficient adhesives that are tailored to the applications, adhesives and bonding processes are becoming increasingly important in body construction. Bonded joints can even be STRONGER than welding points.
Body Part
S421_043
Bonding
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Repair What Steels Cannot be Welded or Repaired? Volkswagen does not authorize welding or repair of high-strength hot formed steels. These are the steels normally found in the A- and B-Pillars as well as in some floorboard components. They are clearly called out in the repair information. In this SSP, these steels are referred to as form hardened. These parts must be completely cut out in the areas specified in the repair information. Welding or repairing these parts may reduce the crash safety of the occupant cell.
All other steels on the vehicle can be welded or repaired, unless otherwise indicated in the repair information.
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Repair Warnings and Cautions The warnings and cautions listed below are only a partial list. Always follow the warnings and cautions in the repair information, as well as common sense.
Both battery terminals must be disconnected and covered before any welding takes place Be sure to locate the radio code before disconnecting the battery. If any sparks from welding or grinding processes will get anywhere near the battery, the battery must be removed form the vehicle. Batteries produce hydrogen gas, which is explosive. Before reconnecting the battery, turn the ignition to the ON position. This assures that nobody is in the vehicle with the airbag system is re-armed. Airbag components must never be exposed to temperatures over 100C (212F) for even a brief period of time. Airbag pyrotechnic components are or may be located (depending on vehicle model and options): • In the steering wheel • In the passenger front dash • In the sides of the front seats as side airbags • In the A, B and C-Pillar upper areas as a curtain airbag • In the rear side seats as side airbags • At the base of each outboard seat belt as a pyrotechnic seat belt tensioner
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Models 2012 Beetle The 2012 Beetle uses the latest in high strength materials. Although the softer steels are still used in many parts of the chassis, hot formed steels are used in the front inner side panel, B-pillar and the rear of the passenger compartment floor. High strength steels are also used in the doors to reduce side impact intrusion.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
220 - 260 MPa 280 - 340 MPa 360 - 420 MPa 420 - 1000 MPa > MPa (form hardened)
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Models 2012 Beetle The 2012 Beetle uses the latest in high strength materials. Although the softer steels are still used in many parts of the chassis, hot formed steels are used in the front inner side panel, B-pillar and the rear of the passenger compartment floor. High strength steels are also used in the doors to reduce side impact intrusion.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
15
Models A5 Golf The A5 Golf and Jetta were the first to use the hot formed steels. These were used in the areas of front inner side panel and the B-pillar.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
17
Models A6 Golf Hot formed high strength steels are used in the front inner side panel and the B-pillar.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
Up to 140 MPa 180 - 240 MPa 260 - 320 MPa 340 - 700 MPa > 1000 MPa (form hardened)
19
Models A6 Golf Hot formed high strength steels are used in the front inner side panel and the B-pillar.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
21
Models A5 Jetta The A5 Golf and Jetta were the first to use the hot formed steels. These were used in the areas of front inner side panel and the B-pillar.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
Hot Formed Steel
23
Models A6 Jetta Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
≤ 220 MPa ≤ 420 MPa > 1000 MPa (form hardened)
25
Models A6 Jetta Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
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Models Jetta SportWagen Hot formed high strength steels are used in the front inner side panel and B-pillar.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
29
Models B6 Passat Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
Laser Welds Bonding+Spot Welds
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Models
Up to 140 MPa 180 - 240 MPa 260 - 300 MPa 300 - 420 MPa > 1000 MPa (form hardened)
31
Models B7 Passat Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
32
Models
High strength steels are used in the door assemblies to help prevent intrusion in a side impact.
≤ 220 MPa ≤ 420 MPa > 1000 MPa (form hardened)
33
Models B7 Passat Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
34
Models
35
Models Passat Wagon Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
Up to 140 MPa 180 - 240 MPa 260 - 300 MPa 300 - 420 MPa > 1000 MPa (form hardened)
37
Models CC Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
38
Models
Up to 140 MPa 180 - 240 MPa 260 - 300 MPa 340 - 700 MPa > 1000 MPa (form hardened)
39
Models CC Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
40
Models
41
Models Eos Hot formed high strength steels are used in the front inner side pane and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
42
Models
Up to 140 MPa 180 - 240 MPa 260 - 300 MPa 300 - 420 MPa > 1000 MPa (form hardened)
43
Models Eos Hot formed high strength steels are used in the front inner side pane and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
44
Models
45
Models 2004 Touareg Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
46
Models
47
Models 2011 Touareg Hot formed high strength steels are used in the front inner side panel, the roof crossmember and B-pillar. For vehicles with a panoramic sunroof, the section surrounding the sunroof is also hot formed high strength steel.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
48
Models
Panoramic Sunroof
49
Models 2011 Touareg Hot formed high strength steels are used in the front inner side panel, the roof crossmember and B-pillar.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
50
Models
51
Models Tiguan Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
Up to 140 MPa 180 - 240 MPa 260 - 300 MPa 340 - 700 MPa
53
Models Tiguan Hot formed high strength steels are used in the front inner side panel, B-pillar and parts of the floorpan.
Welds: • Laser brazing used on roof area • Laser welding used in various areas throughout the body
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Models
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Special Tools VAG 1731 Spot Weld Breaker Pneumatic tool for removing spot welds during body repairs. By exact positioning of the milling tool on the weld, material weakening and damage to the paint is avoided, which is unavoidable when grinding. External spot-welds on edges, tapers and folds can be removed in conjunction with the centering device, which allows precise centering. For the removal of internal, concealed and spot welds with poor accessibility, the handgrip must be used. An adjustment ring provides infinitely variable adjustment for the milling depth. This prevents the back panel from being drilled through and prevents contact with the centering device.
Design and features: Pneumatic spot-weld breaker with air-flow valve for individual speed adjustment. • Recommended speed: approx. 1200 rpm. • Compressed air: 6 - 8 bar • Speed (without load): 2200 rpm • Weight: 1.8 kg
Items supplied: • Plastic case • Spot-weld breaker with centering device and high-grade alloy milling cutter • 8 mm dia. air-flow reduction valve • Hexagon key • 5 replacement cutters
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VAG 1731 Spot Weld Breaker
Special Tools VAS 6322A Spot Weld Breaker Pneumatic tool for removing spot welds during body repairs. By exact positioning of the milling tool on the weld, material weakening and damage to the paint is avoided, which is unavoidable when grinding. The spot weld miller VAS 6322A has a mechanically supported pneumatic ejector. This enables ergonomic working without exertion. When the drill bit is deployed, the ejection speed can be set individually by the user depending on the spot weld in question. The use of relevant drill bits enables conventional and higher tensile steels to be drilled. A lower speed prevents the drill from overheating, improves the cutting properties and increases service life.
VAS 6322A Spot Weld Breaker
Design and features: • Housing: Lightweight, polished aluminium • Drive: Pneumatic • Ejection: Pneumatic/mechanical • Bar: Hardened and painted steel
Replacement parts: Technical data: • Compressed air: 6 bar
• Drill bits (qty. 10) • VAS 6322A/2 or ASE 329 007 00 000
• Motor speed: 1000 • Connection: 1/4" • Contact pressure: approx. 240 kg
Drill bit (qty. 1) • VAS 6322A/3 or ASE 329 008 00 000
• Noise level: 82 dba • Air consumption: 175 l/min, 6 CFM
Items supplied: • 1 spot weld miller with small counterhold
Recommended accessories: • Counterhold, large VAS 6322A/1 or ASE 432 356 00 000
Manufacturer
• 2 drill bits for standard sheet metal VAS 6322A/2 • 1 drill bit for high tensile sheet metal VAS 6322A/3
• Kamatec
• 1 tool case with deep inlay
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Special Tools VAG 2001B Welder This fully digital aluminum shielded arc welding unit VAG2001B has been designed specifically for repairs to vehicles with aluminum bodies. Operation is simple and convenient. Different welding parameters can be set on a storage card system and called up at the press of a button. Changes to the parameters or updates to the equipment software can be carried out via a new storage card system. Good welding finishes can be achieved at lower heat thanks to the quattro pulse function. All the important equipment functions can be called up without having to change the working position from the handle.
VAG 2001B Migatronic Flex 300 Welder Design and features: Current Range: 15-300 A On duration 100%: 220 A/25.0 V
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Special Tools VAS 6388 Arc Welder This fully digital aluminium shielde arc welding equipment VAS 6388 has been designed specifically for repairs to vehicles with aluminium bodies. Operation is simple and convenient.
Technical data: • 4 roller drive Burn-off pulse • Automatic cooler unit shutoff • Digital welding process control • Wire advance and speed • Wire feed without gas and current • Ground failure monitoring
VAS 6388 Aluminum Shielded Arc Welder
• Automatic free burn • Gas test function • Job operation • Microprocessor control • Multi-process MIG/MAG, WIG and e-hand
• Adjustable parameters:
• Infinitely variable weld current adjustment via torch
–
Dynamics
• Synergic operation
–
End crater current
• Temperature controlled fan
–
Free burn time
• Over-temperature protection
–
Gas advanced and run-on time
• Modes of operation:
–
Hot start
–
Arc length and drop release correction
–
Welding output, infinitely variable
–
2 and 4 cycle operation with special 2 cycle operation
–
Spot weld
–
Aluminium weld start (special 4 cycle operation)
Design and features:
• Operating mode and process • Panel thickness • Dynamic, arc length and drop release correction
• Current range: 3-270 A
• Hold function, job number
• Idling voltage: 50 V
• Manual operation
• Mains voltage: 3x400 V +/- 15% 50/60Hz
• Motor current
• Dimensions current source (mm):625 x 290 x 480
• Weld speed, weld current / voltage (actual value, guide
• Wire diameter: 0.8-2.0 mm
value)
• Working voltage: 14.2-27.5 V
• Service codes
• Type of protection: IP23
• Transition arc
• Weight: 27.5 kg / 60.63 lbs
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Special Tools VAS 6530 Resistance Spot Welder The VAS 6530 Resistance Spot Welder is recommended for general body repairs on vehicles with high and ultra high tensile strength steel panels, especially for workshops with critical mains power supply. The inverter technology in conjunction with adaptive smart control makes quality spot weld joints possible. Variations in joint structure are detected and compensated for if possible. If a weld is not possible, a text warning message will be issued by the unit. Operation is by touch screen via three different welding modes: manual, smart/automatic or manufacturer-specific programs. With a USB interface, new welding programs can be uploaded or recorded; welding results can be copied for further processing on a PC. The water-cooled C-transgun delivers equal electrode contact force with electrode arms up to 635mm in length.
Specifications: • Mains connection: 230 V 3 Phase 60 Hz Breaker protection: 60A delayed • Mains connection lead: 17 KVA Welding current max.: 14000 A DC Electrode contact force max.: 450 daN (1011 lbs.) • Dimensions: 600mm (24")x 680mm(27.2") x 1220mm(48.8") Weight: 130 kg (286 lbs.)
Includes: • 1 Main unit with inverter and touchscreen • 1 Inverter C-transgun, pneumatic with short electrode • 1 C-arm, length 85mm with electrode, water-cooled • 1 Cart with rear large wheels and front braked castors • 1 C-Transgun holder and swivel arm with adjustable balancer • 1 Water cooler module for transformer, transgun, arms and electrodes • 1 Rubber mains power cord, 8m retractable • 1 Electrode cap key for electrodes up to DN 21 Resistance Spot Welder
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VAS 6530 Resistance Spot Welder
VAS 6530/1 Accessory Package for VAS 6530 Includes: • 1 C-arm, long, 505mm with angled electrodes, short (water-cooled) • 1 C-arm, small, air-cooled for wheel housings with ballhead electrode • 1 Ball-head electrode, water-cooled with mushroom head insert • 1 Long angled electrode. Water-cooled VAS6530/2 Accessory Package for VAS6530 Includes: • 1 C-arm, medium, 355mm with angled electrodes, short (water-cooled) • 1 Support, long for offset electrodes • 1 Offset electrode, water-cooled • 1 Electrode, long straight, water-cooled on arm side. Manufactured by: TECNA S.p.A.
Special Tools VAS 6535 Resistance Spot Welder The resistance spot welder VAS 6535 features a central connection and a tool detection function. An impedance measurement is used to regulate the welding parameters automatically. In this way, a constant level of quality of the weld points is assured. Weld processes can be stored and and to documented. Disturbance variables such as dirt, adhesive etc. are detected and compensated for. A compact flash memory card allows the software of the unit to be updated at any time. Mobile resistance spot welder with inverter technology, can be updated, features impedance measurement and welding parameter regulation.
Specifications: VAS 6535 Resistance Spot Welder • Dimensions: 661mm (26") x 661mm (26") x 1372mm (54") Weight: 171 kg (376 lbs.)
Includes:
• Power Supply Unit Mains connection: 208 - 240V 3Phase
• Mobile mains unit X tongs
• Mains connection lead ø/length: 6mm2 / 10 m
• Welding gun
• Fuse protection at least: 60 A delay
• Quick dent removal hammer
• Mains frequency: 60 Hz
• Linear balancer
• Mains connection output: 42 kVA
• Cooling Unit Heat Exchanger
• Rated output at 50%
• Special VAS Welding Programs
• ED: 60 KVA • Idle voltage max.: 23 V DC
Options:
• Welding current regulated: max. 12,000 A DC • Water tank volume: approx. 32 l • Ambient temperature: 40 C° • Type of protection: IP21 X tongs • Cable length: 2.5 m • Welding current: max. 12,000 A DC • Weight of tongs without cables: 8 kg
VAS6535/1 Resistance Spot Welder Accessory Pack • Electrode set 02/06/415 MX coded • Electrode set 05 MX coded • Electrode set 11/280 MX coded • Abrasive sponge fine • Multi purpose electrode SB8 for planishing work • Electrode caps A 13 R 25 (6 pcs.) • Electrode caps A 13 R 15 (6 pcs.)
Manufactured by: Elektron, Bremen, Germany
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Special Tools VAS 6545 Resistance Spot Welder Setting the welding parameters is carried out using simple, self-explanatory symbols. The welding programs are for high and higher tensile panels, for spot weld bonded connections and for galvanized panels. Individual storage of welding parameters is possible. In addition, the system is suitable for documentation and administration of work order details on A4 paper. Software updates can be carried out using an SD card (upload). The material recognition function is performed with a material test program. Current control and pressure monitoring is provided. The welding process is monitored and the actual values are shown in the display. The C-arms can be exchanged by means of a quick positioning feature. The C-arms can be opened via a folding catch, enabling access to the body behind profile sections.
Specifications: • Power supply 3 x 190-240 Volt 50-60 Hz. • Setting range 0-13 kA • Welding current: DC • Continuous duty 100 %ED 2,8 kA • Open circuit voltage 12 V DC • Max.Power with 5% ED: 156 KVA • Fuse (slow blow): 63 A • Connector cable (Cu): 5m / 4 x 0,157sqinch)
VAS 6545 Resistance Spot Welder
Includes: • Current source • 1 CS transformer tongs • 1 control unit with water tank 80 l • 1 CS transformer tongs with integrated C-arm size 1 • 1 balancer with spring-loaded cable • 1 mounting set for C-arms
• Air pressure: 90 psi +/- 5% • Refrigerant: water + anti corrosive
Optional Accessory Packs :
• Tank volume: 85 l / 22,5 gallons • Dimensions: 810x560x750 mm • Weight: 119 kg / 262 lbs.
• VAS 6545-1 transformer x-gun with watercooling up to the tips • 3 x 200-240 Volt / 50-60Hz , 13.000 A / 65 A breaker. • VAS 6545-2 single sided gun for c-trafo aircooled, with earth cable and accessory box • VAS 6545-3 single sided gun for x-trafo aircooled, with ground cable and accessory box
Manufactured by: Wielander & Schill KG
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Special Tools VAS 6378 The dent removal tool VAS 6378 is an independent unit for removing dents, pulling in sheet metal and tacking. In addition, it also allows connection of an air puller as well as welding on studs, pins, corrugated wire and U plates. The tools included in the items supplied with VAS 6378/1 can be used as well with all other units of the system thanks to the central connector. The tool coding means the unit is given the correct functional setting automatically.
Technical data: • Resistance welding unit WST 2000 • Mains connection: Single phase 230 V (205 - 250 V)
VAS 6378 Dent Remover
• Mains protection: Delay 16 A • Mains frequency 50/60 Hz • Mains connection output: 3.3 kVA • Welding output: 11 kVA • Idle voltage: 8 V AC • Welding current: Max. 3000 A • Ambient temperature: 40 °C • Type of protection: IP 21 • Dimensions H/W/D: 285 x 220 x 415 mm • Weight: 21 kg
Items supplied: • Dent remover • Main connection lead
Recommended accessories: • Accessory pack VAS 6378/1, ASE 435 167 00 000 • Equipment trolley VAS 6378/2, ASE 435 168 00 000 Manufacturer Elektron, Bremen
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Special Tools VAS 6378/1 Accessory Package Items supplied: • Welding gun 4 m with central connector • Panel beater's hammer • Puller tool • Contact piece U/B • 100 discs B8 DIN 125 • Carbon electrode diameter 10 mm • Ground clamp bar Manufacturer: Elektron, Bremen
VAS 6378/1 Accessory Package
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Knowledge Assessment An on-line Knowledge Assessment (exam) is available for this Self-Study Program. The Knowledge Assessment may or may not be required for Certification. You can find this Knowledge Assessment at: www.vwwebsource.com
For Assistance, please call: Volkswagen Academy Certification Program Headquarters 1-877-791-4838 (8:00 a.m. to 8:00 p.m. EST)
Or, E-mail:
[email protected]
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Volkswagen Group of America 2200 Ferdinand Porsche Drive Herndon, VA 20171 October 2011
