Reparacija Aluminijumskih Karoserija - alatistherm.in.rsalatistherm.in.rs/pdf.ws.eng/ALU.KAROSERIJE.BROSURA.pdf · Reparacija Aluminijumskih Karoserija ... Page 10 Alu Pull Kit AK

Reparacija Aluminijumskih Karoserija Alat i oprema , potrebni za opremanje radnog mesta tj. formiranje

radne stanice za reparaciju i popravku aluminijumskih karoserija

uvoznik : ALATISTHERM d.o.oKoče Kapetana 25 , 35230 Ćuprija , Srbijatel. / fax : +381 (0) 35 471-196mob : +381 (0) 65 8410651 / [email protected] - www.alatistherm.in.rs


U ovoj brosuri su prikazani svi potrebni alati koje preporucuje WIELANDERSCHILL a koji su potrebni i neophodni za poslove reparacije aluminijumskih karoserija. Uz svaki alat data je sifra tako da je snalazenje u brosuri veoma lako. Brosura je na Engleskom ali ce uskoro biti i na Srpskom.

Tel. +49 (0) 7720 8317 0 [email protected] Fax +49 (0) 7720 1255 www.wielanderschill.com2

Work station for aluminium car body repair

Tel. +49 (0) 7720 8317 0 [email protected] Fax +49 (0) 7720 1255 www.wielanderschill.com

Content

Page 3 Structure of aluminium car body - Special features in working with aluminium - Main rules in arrangement of working station for aluminium car body repairPage 4 Description of curtains, lighting and energy supply systemPage 5 Aspiration and dedusting system - Examples of aluminium work stationPage 6 Curtains, lighting and energy supply system - Mobile aspiration system - Tool trolleys Page 7 Stands for storage of car body elements - Industrial dust extractorPage 8 Pulse-arc welder InvertaPuls IP 6-2 - Adapter for second gas bottle - MIG/MAG IM-240i welder with inverter technologyPage 9 Welding helmet and gloves - Spesial pliers for welders - Protection blankets - Welding wiresPage 10 Alu Pull Kit AK 98 for stud welding - Maxilift puller - Universal stud clamping piece - Pull washers and rods - Studs amd rodsPage 11 Spot weld remover VarioDrill WS90 - Drill bits - Millers - Punches BTR / BOR / Variantic Starter kitPage 12 Rivet system XPress 800 - Tool box RS-06 version Jaguar Land Rover - Tool box RS-05 version Audi - Temporary fasteners Page 13 Body saw WPS 3000 - Saw blades - Drilling machine GTC-041B - Grinding machines Page 14 Grinders - Grinding pistol - Drill bits for rivets - Step drill bit - Punch setPage 15 Grinding and cutting discs - Grinding belt - Stainless steel round brushPage 16 Abrasive, grinding and cutting discs - Side milling cutter AluCut - Millers - Countersink - Drill bit setPage 17 Rivet head cutter - Body chisel - Body plane with blades - Files - Chisel set - Dolly planishig set WS93Page 18 Molding wedges - Files - Scraper - Deburring tool - Cartridge gun for Betamade - Sheet metal shearsPage 19 Brushes - Flexible magnet stick - Infrared thermometerPage 20 Vice gripsPage 21 Vice grips - Heavy spoons - Dolly wedgesPage 22 Aluminium dent removing set - HammersPage 23 Burners - Gas hose - Face and ear protector - Thickness measuring device Page 24 Ratchet key set - Key set 1/4“ - Key set 3/8“ - Screwdriver set - Nut set Torx 1/2“ - Universal pliers - Pliers with long jawsPage 25 Dent pulling system Line Puller 1250 - Manual hydraulic cylinder 10 t - Pyrosil flammable set - Acetylen burner setPage 26 Crack testing sprays - Aluminium filler - Scrapers for undercoating Dent pulling system for aluminium car body Carbon Miracle Alu Repair CMA-100

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Full set of tools and equipment

Structure of aluminium car body

Sheet aluminium

Extrusions

Node castings

partly repairable in case of small cracks and deformations

repairable only by cutting of the defec-ted fragment and its replacement by the insert of the same profile with using the strengthening inlays

non-repairable due to failure in the structure of metal

Special features of working with aluminiumAluminium cannot be brazed.Welding of aluminium must be carried out only in 100% argon shielding gas (MIG). The temperature range must be strictly observed while working with aluminium: by reaching the melting temperature of 650°С the metal begins flowing without bearing any marks.Aluminium is very heat-conducting, from whence welding processes have high influence on the neightbor working areas.Always use thermal strips while heating the aluminium.Aluminium has no magnetic susceptibility, hereupon you cannot fix on it any magnetized auxiliary accessories.In comparison with steel aluminium has limited plastic properties. The excessive pulling of the metal may cause the increased tendency to crack formation.

Main rules in arrangement of working station for aluminium car body repairThe working place for aluminium must be fenced from the one for steel repairs.All electrical devices used in working area for aluminium repairs must have the proper level of ex-plosion protection. Aluminium dust is highly explosive and injurious to health. The aluminium working station must be equipped with the explosion-proof aspiration and dedusting system.The tools for aluminium repair must be marked and used only for aluminium. Using the steel repair tools for aluminium is strictly prohibited.Aluminium body parts must be stored in dry place separate from steel body parts.




Construcion type: 4 columnsThe working station consists of the following constructive components: aluminium four-sided bea-ring lacing construction FD 34, 7,50 m x 5,50 m x 3,50 m, 26 module traverse beams for guide rails, curtains and lighting. LightingFour-sided lighting, 20 x 80 W = 1,6 kW, luminous power over 1.500 lux, daylight lamps with evol-vent reflectors for optimal lighting of vertical surfaces.

Curtains2 curtains made from fire-resistant glas fiber fabric, U-formed closing, opening in the middle where car drives in.Outside color: aluminium-greyInside color: silver sprayingViewing windows: antidazzle filterDimensions, L x W: 2 pcs., 12,0 m x 3,00 mEdging strips from all sides, with inlays from aramid fiber.

Version CLM with single energy supply moduleThe module moves along the U-formed trajectory around the car.

The module consists of:2 pcs pneumatic coil ¼“2 pcs electrical coil 230 V / 16 A1 pcs air preparation unit with pressure gauge, air-dryer and oiler2 pcs safety connection of pneumatic system1 pcs electricity box with 5 sockets 230 V / 16 А and 2 sockets CEE 400 V / 16 A, each socket with separate fuze4 pcs holder for pneumatic tools1 pcs tool storage place with rubber pad2 pcs wall panel with holes for tools storage1 pcs locking ring1 set of flexible cables and guide rails for movement along the U-formed trajectorty, length 22 mSpecial features: color aluminium-grey RAL 9007 with structural surface. All connections and quick-lock.

Version CLE with double energy supply modulesThe modules move laterally along the car on the upper guide rails. Each module consists of:2 pcs socket CEE 400 V / 16 A3 pcs socket Schuko 230 V / 16 A2 pcs pneumatic connector ¼“1 pcs holder1 suspension spring2 set of flexible cables and line guide rails, length of each set is 7,5 mSpecial features: color aluminium-grey RAL 9007 with structural surface. All connections and quick-lock.

Curtains, lighting and energy supply

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Dedusting system for aluminium:Mobile industrial dust extractor D1 for area 22, power 2,2 kW, explosi-on-proof according to ATEX II 3 D for aluminium dust capture. The ext-

aera gnol m 5 deggulp dna noitcetorp gnikraps htiw deppiuqe si rotcarand includes the set of adapters and accessories for different types of cars. Approved by TÜV Sachsen-Anhalt e.V. Germany.

Dedusting system for aluminium and carbon:Mobile industrial dust extractor D1 for area 22, identical to the versi-on for aluminium dust capture, additionally equipped with the class „H“ fine filter for man-made materials dust capture, which cause can-cerous diseases.

Remark: the current legislation strictly prescribes, that the working areas with escape of man-made materials‘ particles must be equipped with the proper dedusting system. In case if the existing de-

dust extractor for man-made materials‘ dust is not needed. Therewith you may capture dust of all types of light construction materials (except steel).

Telescopic arm from stainless steelExtension 2 m with absorbing, swing arm and installation kit for mounting onto the dust extractor, connecting hose and antistatic-coated inlet funnel.

Remark: using the dedusting system with the telescopic arm you may also at the same time capture welding fumes which escape during the aluminium welding. Unlike the aluminium dust, the alumini-um welding fumes don‘t require the ATEX explosion-proof. In case if the welding fumes exctractor already exists (for example for steel), it can also be used for aluminium welding fumes extraction.

Aspiration

Example of aluminium working station





881201 Tool trolley R230, 1000 x 620 x 890 mm

881205 Tool trolley with additional cabinet

881093 Curtains, lighting and energy supply system, 4х7х3,5 m., double energy supply modules (special version, on request)

881094 Curtains, lighting and energy supply system, 6х8х3,5 m., double energy supply modules

881095 Curtains, lighting and energy supply system, 6х8х3,5 m., single energy supply module

881090 Mobile extraction system for aluminium dust capture

881091 Mobile extraction system for aluminium and carbon dust capture

881092 Telescopic arm for mobile extraction system

Art. Description



881101 Body shop manager CLASSIC881102 Body shop manager PROFESSIONAL

881107 Bumper Stand Mobile deposit system for bumpers ( max. 8 pcs.)

881105 X-Stand Rack for storage and carrying of bumpers, spoilers, front and rear valance and car glas

932464 Mobile industrial dust extractor, class B1

Art. Description




Art. Description331007 Inverta Puls IP 6-2 3x400 В Pulse-arc welder for aluminium and steel welding

341290 MIG/MAG IM-240i 230V Welder with inverter technology

311045 Adapter for second gas bottle for Inverta Puls IP6-2



Art. Description

311076 Welding wire AlMg5 Ø1,0 mm, 2 kg, coil D-200 Ø200 mm311077 Welding wire AlMg5 Ø1,2 mm, 2 kg, coil D-200 Ø200 mm311078 Welding wire AlSi5 Ø1,0 mm, 2 kg, coil D-200 Ø200 mm311079 Welding wire AlSi5 Ø1,2 mm, 2 kg, coil D-200 Ø200 mm311080 Welding wire AlSi12 Ø1,0 mm, 2 kg, coil D-200 Ø200 mm311081 Welding wire AlSi12 Ø1,2 mm, 2 kg, coil D-200 Ø200 mm311083 Welding wire AlMg3 Ø1,2 mm, 2 kg, coil D-200 Ø200 mm

881047 Welding helmet WS07

311041 Special pliers for welders, 4 functions

882001 Set of protection blankets, 3 pcs. Consists of: blanket 2500х1250 blanket 2000х1500 blanket 1000х1000

881036 Welding gloves

881001 Grinding protection blanket 3000х2500 mm

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Art. Description361000 Alu Pull Kit AK 98 for stud welding

351060 Maxilift with triple pulling claws

368060 Universal stud clamping piece

368040 Pull washers М4, 10 pcs.368043 Pull washers М4, 3 pcs.

368050 Pulling rod, 160 mm.

367015 Stud Alu, М4х15 mm, 100 pcs367016 Stud Alu, М4х15 mm, 1000 pcs367030 Stud Alu, Т5х10,5 mm, 100 pcs367035 Stud Alu, Т5х15,5 mm, 100 pcs367040 Stud Alu, Т5х25 mm, 100 pcs367045 Stud Alu, М6х12 mm, 100 pcs367050 Stud Alu, М6х16,5 mm, 100 pcs367080 Pulling rod, steel, 4х35 mm, 200 pcs367081 Pulling rod, steel, 4х35 mm, 500 pcs367085 Pulling rod V2A, 4х35 mm, 200 pcs




Art. Description

627005 Hard metal drill bit VHM for rivets Ø 5,0 x 49 mm, 3 edges, piston 8 mm

627001 Two-level drill bit W+S NK-2F for rivets, Ø 6,7x44 mm

622003 BTR/BOR/Variantic Starter Kit Consisting of: 3 Variantic drill bits, 3 edges, Ø 8х44mm 1 BTR/BOR drill bit, 3 edges, Ø 8х44mm 1 centering punch BTR/BOR fluid, 125ml, cutting oil for drill bits

620205 Drill bit Variantic, Ø 8х44 mm, set 5 pcs.

607101 Special cap miller, 3 caps

628005 UHSS centering punch

601001 Vario Drill WS 90 spot weld remover

628006 W+S special centering punch, two functions, for rivets




Art. Description

700002 Rivet system XPress 800 Full Set Consists of: basic unit power cylinder SSC35/25 С-arm GC 80/40 С-arm GC 80/120 С-arm GC 140/240 blind rivet adapter BR20 (20kN) blind rivet adapter BR50 (50kN) blind rivet nuts adapter BRN20 (50kN) tool set RS-03 tool set RS-04

700203 Tool box RS-06 version Jaguar Land Rover

700202 Tool set RS-05 version Audi

577104 Temporary fastener, Ø4,1 mm, 20 pcs





Art. Description

120030 Body saw WPS 3000

197003 Saw blades 32 tpi, 10 pcs

197004 Saw blades 28 tpi, 10 pcs

611122 Pneumatic Drill GTC-041B 450 rpm

611123 Pneumatic grinder GTC-082A/SW 20210 rpm, 400 W

611126 Angle grinder GTC-986 A2.0 pneumatic rpm 20 000, power 190 W

611120 Belt grinder FX-8309B

661001 Rotary sander RAS 115.04E, 230 V




Art. Description611121 Angle grinder GTC-412S, 4500 rpm

611124 Pistol grinder 19286-S 371 5“

611125 Angle grinder FX-8125 LA

617220 Drill bit for rivets TIN, Ø4,1 mm, 70 mm



617301 Step drill-bit 4 - 30 mm

628010 Punch set, 6 pcs



Art. Description667017 Grinding discs set for grinder RAS 115.04E Consists of: 25 x STF D115 P36 25 x STF D115 P50 25 x STF D115 P80 50 x STF D115 P120

637039 Supporting disc for sanding disc М14 Ø115 mm

637055 Grinding and cutting kit, Ø 50 мм637056 Grinding and cutting kit, Ø 115 мм

677001 Grinding belt P80

541202 Round brush, Ø75 mm, stainless steel

637036 Aluminium cutting disc, 25 pcs

637037 Aluminium roughing disc, 10 pcs

637038 Fiber grinding disc, grain 60, 25 pcs





Art. Description

612010 Abrasive discs (2 pcs) with clamping unit

637025 Set cutting and grinding discs with tool holder Consists of: 1 х clamp 10 х discs 30 mm 10 х discs 50 mm

637010 Cylindrical miller

637011 Round miller

637012 Conical miller

637113 Side milling cutter AluCut 40x4,4 mm Consists of: 2 х 637111 - side milling AluCut 1 х 637112 - shaft AluCut, Ø 6 mm

617240 Countersink 120°

637004 Drill bit set from 1,0 mm to 10,0 mm grade 0,5 mm



Art. Description

531110 Rivet head cutter

512001 Body chisel with handle

523222 Set of 6 files in curling bag

521210 Body blade with holder

521211 Body blade diagonal Z-2521212 Body blade radial Z-1

541015 Chisel set, 6 pcs

582001 Dolly planishing set WS93, 4 pcs




Art. Description

581100 Set molding wedges, 5 pcs

521201 File with handle, fine

521203 File with handle, coarse

541001 Hard metal scraper, 24 mm, 3 edges547001 Blade for scraper 541001

541030 Manual deburring tool

547030 Blades for deburring tool

831100 Cartridge gun MR50 for Betamade glue 2096, 50 ml

531100 Sheet metal shear, left, 260 mm

531101 Sheet metal shear, right, 260 mm



Art. Description

541101 Round brush with long bristles, G10

541103 Flat brush, G5

541250 Flat brush, nylon

541290 Round brush, size 2

541211 Stainless steel wire brush

541212 Stainless steel wire brush, INOX, V-formed

881320 Flexible magnetic stick

801150 Infrared thermometer 2 point laser

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Art. Description

561150 Vice grip 112, straight jaws 5“

561151 Vice grip 145, U-shape 12“

561152 Vice grip 144

561153 Vice grip 224

561154 Vice grip 111, curved jaws 10“

561181 Vice grip Axial DW

561182 Vice grip Axial DS

561183 Vice grip Axial D

561184 Vice grip Axial T

561185 Vice grip Axial WS




Art. Description

561230 Vice clamp 30 см

561156 Vice grip, straight jaws

561157 Vice grip, long nose

511222 Heavy spoon, 170x60x30 mm

511220 Heavy spoon, 150x50 mm

511201 Pry bar and pumping spoon, 200 mm long / 60 and 40 mm wide

511113 Dolly wedge, half round

511100 Dolly wedge, comma shape

511110 Dolly wedge, toe shape

511112 Dolly wedge, universal




511028 Plastic hammer, rebound free

511029 Soft face hammer, rebound free, 400 g511022 Soft face hammer, rebound free, 500 g

511030 Aluminium hammer

511031 Soft face hammer, elastonal

511039 Bumping hammer

511040 Locksmith hammer, 300 g

512002 Aluminium planishing hammer set, 4 pcs

512004 Aluminium dent removing dolly set, 11 pcs

Art. Description



Art. Description

808001 Burner handle with piezoelectric element

808003 Needle point burner

808004 Hot air burner

808005 Cyclone burner

808004 Gas hose, 3 m

881030 Face and ear protector

871025 Thickness measuring device




Art. Description

561032 Pliers with long jaws

561031 Universal pliers, 200 mm

881381 Key set 1/4“ 16 pcs

881382 Key set 3/8“ 17 pcs

881384 Nut set Torx, 1/2“ 10 pcs

881383 Screwdriver set, 7 pcs

881385 Ratchet key set



Art. Description

821102 Line Puller 1250dent pulling systemConsists of:1 x aluminium traverse1 x pulling hook 3 claws1 x pulling hook 2 claws1 x pulling rods set, 4 pcs, Ø8 mm2 x suction holder1 x gauging unit

511305 Manual hydraulic cylinder 10tincl. wedge, enlarger and extension pieces

341003 Pyrosil flammable set

802020 Acetylen burner set






311050 Penetration test fluid Ardrox 9VF2, 500 ml, red

311051 Penetration test cleaner, 500 ml

311052 Developer fluid Ardrox 9D1B, 500 ml

542050 W+S 2C aluminium filler, two components

821103 Carbon Miracle Alu Repair CMA-100 dent pulling system for aluminium car body

Art. Description

541010 Scraper for undercoating

541020 Scraper set for undercoating, 4 pcs



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Development Production Sales Service Trainig Technical support Guarantee

Wieländer+SchillMV Marketing und Vertriebs-GmbH & Co.KG

Professionelle Karosserie-SpezialwerkzeugeSiederstraße 50 D-78054 Villingen-SchwenningenTel. +49 (0) 7720/8317-0 · Fax +49 (0)7720/[email protected] · www.wielanderschill.com


Documents

Reparacija Aluminijumskih Karoserija - alatistherm.in.rsalatistherm.in.rs/pdf.ws.eng/ALU.KAROSERIJE.BROSURA.pdf · Reparacija Aluminijumskih Karoserija ... Page 10 Alu Pull Kit AK