SAE J 2376-2011 New-Vehicle Collision Repair Information《新汽车碰撞维修信息》.pdf

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1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref

2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication ma

3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside US

4、A) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2376_201105SURFACEVEHICLERECOMMENDEDPRACTICEJ2376 MAY2011 Issued 1997-12 Revised 2011-05Supers

5、eding J2376 MAR2005 New-Vehicle Collision Repair Information RATIONALEThis document was revised to specify the latest repair information, based on materials and methods developed during the past five years. Additions also include repair procedures and safety precautions applicable to hybrid and elec

6、trically powered vehicles.TABLE OF CONTENTS 1. SCOPE 31.1 Purpose . 32. REFERENCES 32.1 Applicable Document 32.1.1 SAE Publication 32.2 Related Publications . 32.2.1 SAE Publications . 32.2.2 Uniform Procedures for Collision Repair 42.2.3 Tech-Cor Research Bulletins 42.2.4 Research Council for Autom

7、otive Repairs (RCAR) Design Guide . 43. DEFINITIONS . 43.1 DRIVE-AWAY TIME 43.2 STRUCTURAL PARTS . 43.3 TRACKING OFFSET 44. PUBLICATION REQUIREMENTS 44.1 Delivery Format . 44.2 Timeliness . 44.3 Content Level 44.4 Industry Segments 55. TECHNICAL CONTENTS . 55.1 Safety Precautions 55.1.1 Personal Pro

8、tection . 55.1.2 Hazardous Materials, including high-voltage battery packs for hybrid and electrically powered vehicles . 55.1.3 Air-Bag and Explosive Pretensioner Handling 55.1.4 Pulling Precautions . 55.2 Restraint Systems . 55.3 Materials Identification and Repair Processes . 6SAE J2376 Revised M

9、AY2011 Page 2 of 11 5.3.1 Steel 65.3.2 Aluminum 65.3.3 Magnesium 65.3.4 Plastics and Composites . 65.3.5 Structural Foam . 65.3.6 Energy-Absorbing Foam . 65.3.7 Acoustic Foam 65.3.8 Special Coatings . 65.4 Structural Straightening 65.4.1 Vehicle Dimension Specifications . 65.4.2 Vehicle Clamping and

10、 Pulling . 65.4.3 Stress-Relieving 65.5 Structural Sectioning. 75.6 Glass Replacement . 75.6.1 Stationary Glass 75.6.2 Movable Glass 75.6.3 Specialty Glass . 85.7 Refinishing 85.7.1 Surface Preparation 85.7.2 Finish Application 85.7.3 Special Applications 85.8 Wheel-Alignment Specifications . 95.8.1

11、 Front Wheels. 95.8.2 Rear Wheels . 95.8.3 Thrust Angle 95.8.4 Tracking Offset 95.9 Steering, Suspension, and Brakes . 95.9.1 Four-Wheel Steering . 95.9.2 Anti-Lock Brakes . 95.9.3 Traction- and Stability-Control Systems . 95.9.4 Collapsible Steering Column . 95.10 Electrical and Electronic Systems

12、. 95.10.1 Entertainment, Climate Control, Safety and Convenience Systems 95.10.2 Electrical and Electronic Parts 105.11 Miscellaneous Information 105.11.1 Fastener Information . 105.11.2 Special Parts Availability . 105.11.3 Warranty Information 115.11.4 Service Parts Information 115.11.5 Energy-Abs

13、orbing Bumper Systems . 115.11.6 Vehicle Lifting and Transporting Procedures 116. NOTES 116.1 Marginal Indicia . 11SAE J2376 Revised MAY2011 Page 3 of 11 1. SCOPE This SAE Recommended Practice defines the various types of information required by the collision repair industry to properly restore ligh

14、t-duty, highway vehicles to their pre-accident condition. Procedures and specifications are defined for damage-related repairs to body, mechanical, electrical, steering, suspension, and safety systems. The distribution method and publication timeliness are also considered. 1.1 Purpose The purpose of

15、 this document is to assist vehicle and equipment manufacturers, and information providers in providing timely information, in user-friendly formats, to facilitate economical, high-quality repair of collision-damaged, light-duty, highway vehicles by dealer-owned and independently owned collision rep

16、air shops. 2. REFERENCES 2.1 Applicable Document The following publication forms a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publication Available from SAE International, 400 Commonwealth Drive,

17、Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J1828 Uniform Reference and Dimensional Guidelines for Collision Repair 2.2 Related Publications The following publications are provided for information purposes only and are not a req

18、uired part of this SAE Technical Report.2.2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J1142 Towability Design Criteria and Equipment UsePassenger Car

19、s, Vans, and Light-Duty Trucks SAE J1344 Marking of Plastic Parts SAE J1555 Recommended Practice for Optimizing Automobile Damageability and Repairability SAE J1556 Stationary Safety Glazing Replacement SAE J2184 Vehicle Lift Points for Service Garage Lifting SAE J2235 Paint and Trim Code Location S

20、AE J2621 Qualifying Aftermarket Two-Component Structural Foams SAE J2376 Revised MAY2011 Page 4 of 11 2.2.2 Uniform Procedures for Collision Repair Available from I-CAR International, 5125 Trillium Blvd., Hoffman Estates, IL 60192, Tel: 847-590-1198, http:/www.i-.2.2.3 Tech-Cor Research Bulletins Av

21、ailable from Tech-Cor, Applied Research, 110 E. Palatine Road, Wheeling, IL 60090, http:/www.tech-.2.2.4 Research Council for Automotive Repairs (RCAR) Design Guide Available on the RCAR web site (http:/www.rcar.org/Papers/Papers.htm) as a downloadable .pdf file. 3. DEFINITIONS 3.1 DRIVE-AWAY TIME T

22、he minimum time required for an adhesive system to reach the vehicle makers specified strength following replacement of a glass part. 3.2 STRUCTURAL PARTS Parts that support vehicle weight and absorb road shock, while maintaining the vehicle shape. Structural parts also absorb and manage collision e

23、nergy. 3.3 TRACKING OFFSET The separation between the track of the rear wheels and the track of the front wheels of a vehicle, with zero thrust angle, as it travels in a straight line. 4. PUBLICATION REQUIREMENTS 4.1 Delivery Format Collision repair information can be published in print form, such a

24、s repair manuals, technical service bulletins (field bulletins), towing manuals, etc., but the use of electronic formats, such as DVDs and the Internet, is encouraged. Coined or other permanent symbols, applied to specific parts, may be used if referenced in repair instructions. 4.2 Timeliness To be

25、 most effective, collision repair information should be made available, to all repair facilities who request it, no later than the introduction date of each new vehicle platform. Information should be updated on a timely basis, whenever significant changes occur in areas such as procedures, specific

26、ations, prices, etc. 4.3 Content Level The contents should describe the necessary vehicle-specific repair processes and specifications that will enable trained, experienced repair technicians to restore the vehicle to its pre-accident condition. Common repair practices should not be included. Descri

27、ptions of new or unique designs, materials, tools, processes, fasteners, and hazardous materials must be included, as well as unusual safety hazards. SAE J2376 Revised MAY2011 Page 5 of 11 4.4 Industry Segments The affected industry segments include vehicle manufacturers, repair facilities, insurers

28、, information providers, training organizations, and manufacturers of products and equipment in the following areas: a. Body repair b. Refinishing c. Structural parts straightening and replacement d. Wheel alignment e. Mechanical and electrical repairs f. Hydraulic repair 5. TECHNICAL CONTENTS 5.1 S

29、afety Precautions Include special warnings and procedures, related to the vehicle repair, to avoid personal injury and property damage. It is not necessary to include standard industrial safety practices. 5.1.1 Personal Protection Safety equipment and precautions. 5.1.2 Hazardous Materials (includin

30、g high-voltage battery packs for hybrid and electrically powered vehicles) Handling and disposal. 5.1.3 Air-Bag and Explosive Pretensioner Handling Manual deployment, shipping, and disposal. 5.1.4 Pulling Precautions Recommended anchoring locations. 5.2 Restraint Systems Include information on disar

31、ming, post deployment service, diagnostics, repairs, replacement, and operational verification for the following items, whether mechanically or electronically controlled: a. Air-bag system, including occupancy sensors b. Seat-belt system, including pretensioners c. Knee bolsters d. Integrated child-

32、safety seat e. Side-impact airbags SAE J2376 Revised MAY2011 Page 6 of 11 5.3 Materials Identification and Repair Processes Include methods of identification, special procedures for repairing, joining and attaching (including adhesive bonding), and requirements for corrosion protection for the vario

33、us materials in the vehicle. Include heat limitations where applicable. 5.3.1 Steel Include coated steels, special alloys, and the use of weld-through primers and weld-bond adhesives. 5.3.2 Aluminum Include special alloys, the use of structural adhesives and special rivets. 5.3.3 Magnesium 5.3.4 Pla

34、stics and Composites Include the use of plastic welding and structural adhesives. 5.3.5 Structural Foam 5.3.6 Energy-Absorbing Foam 5.3.7 Acoustic Foam 5.3.8 Special Coatings 5.4 Structural Straightening 5.4.1 Vehicle Dimension Specifications Specify the locations and measurement tolerances, in thre

35、e dimensions, of frame, underbody, upperbody, and engine compartment control and reference points, in mm (inches). Use an equipment-specific coordinate system when appropriate. See SAE J1828. 5.4.2 Vehicle Clamping and Pulling Identify the anchoring locations and methods. 5.4.3 Stress-Relieving Spec

36、ify the maximum heating temperature and heating time for the various types of materials used in vehicle structures, including the following: a. Mild steels b. High-strength steels (including boron alloys, stainless steels, etc.) c. Aluminum alloys SAE J2376 Revised MAY2011 Page 7 of 11 5.5 Structura

37、l Sectioning Identify crush zones, cross members and reinforcements, and define cut locations, joint configurations, and partial-panel availability, for all structural items including the following: a. Front and rear unibody rails b. Front and rear frame rails c. A, B, C, and D pillars d. Rocker pan

38、els and floorpans e. Quarter panels and wheelhouses 5.6 Glass Replacement Specify special replacement procedures, including fasteners, modular glass, integral moldings, bonding adhesives, drive-away times, etc. Include procedures for adjusting the “anti-pinch” feature of electrically powered regulat

39、ors. 5.6.1 Stationary Glass Include the following types: a. Windshield b. Backlite c. Quarter window d. Side or door window e. Roof window 5.6.2 Movable Glass Include the following types: a. Door b. Roof c. Quarter d. Hatch e. Backlite f. Vent window g. Rear slider SAE J2376 Revised MAY2011 Page 8 o

40、f 11 5.6.3 Specialty Glass Include the following types: a. Heated (including full-view and wiper-parking areas) b. Integral antenna systems c. Glass-mounted antennas, mirrors, auto-brake sensors, etc. d. Outside rear-view mirrors e. Insulated glass f. Any other type of specialty glass, including hea

41、d-up display, heat- or rain-sensing, etc. 5.7 Refinishing Include paint codes and special application information. 5.7.1 Surface Preparation Include requirements for application of the following: a. Corrosion protectionInclude procedures for new replacement parts. b. Primer and sealer c. Adhesion pr

42、omoter 5.7.2 Finish Application Include special color-matching procedures for the following finishes: a. Single-stage b. Multi-stage 5.7.3 Special Applications Include special requirements for applying the following: a. Stone-guard coating b. Stripes c. Decals d. Color-compatible primer e. Chip-resi

43、stant primer SAE J2376 Revised MAY2011 Page 9 of 11 5.8 Wheel-Alignment Specifications Include standard conditions of loading, ride-height, etc. (see SAE J1555). Describe methods of adjustment and special parts such as cam bolts. 5.8.1 Front Wheels Camber, caster, SAI, included angle and toe, in deg

44、rees 5.8.2 Rear Wheels Camber and toe, in degrees 5.8.3 Thrust Angle Maximum allowable, in degrees 5.8.4 Tracking Offset Maximum allowable, in mm (inches) 5.9 Steering, Suspension, and Brakes Include diagnostic, repair, and operational verification information. Include diagnostic dimensions for whee

45、lbase and lower ball-joint locations, and information on electronically controlled systems.5.9.1 Four-Wheel Steering 5.9.2 Anti-Lock Brakes Include proportioning systems for brake force distribution. 5.9.3 Traction- and Stability-Control Systems Include active skid and yaw control. 5.9.4 Collapsible

46、 Steering Column 5.10 Electrical and Electronic Systems 5.10.1 Entertainment, Climate Control, Safety and Convenience Systems Include basic operating instructions and procedures for maintaining the owners settings for the following systems: a. Entertainment systems, including radio, television, soun

47、d system, DVD player, hard drives, MP3 interfaces, etc. b. Climate control system, including heated and cooled seats c. Powered seats, mirrors, etc. d. Security system, including remote-controlled starting and keyless entry e. Navigation system SAE J2376 Revised MAY2011 Page 10 of 11 f. Active skid-

48、 and steering-control systems g. Ignition- and fuel-immobilizing (anti-theft) systems h. Hands-free telecommunication i. Automatic vehicle location and tracking systems 5.10.2 Electrical and Electronic Parts Include wiring diagrams, locations, ratings, operating instructions, safe-handling procedures, and replacement specifications (including wire splicing), as applicable to the following items: a. Fuses and circuit breakers b. Electronic mod