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    Service Training

    Self Study Program ******

    Volkswagen Collision

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    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.

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    iii

    Contents

    This Self-Study Program provides information

    regarding the design and function of new

    models.

    This Self-Study Program is not a Repair Manual.

    This information will not be updated.For maintenance and repair procedures,

    always refer to the latest electronic

    service information.

    Note Important!

    Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

    Steel Types and Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

    Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

    Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

    Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

    Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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    1

    Introduction

    S421_080

    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.

    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.

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    2

    Steel Types and Usage

    S421_092Steels

    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

    Cementite: Up to 215 MPa

    Bainite: 15 - 220 MPa

    Martensite: 170 - 250 MPa

    For more information regarding steel construction and treating methods, refer to SSP

    ******, Volkswagen *****

    MPa is the abbreviation for MegaPascals.

    MPA is a unit used to measure tensile

    strength. Tensile strength increases as

    the MPa number increases.

    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

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    3

    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

    Mechanical treatments

    Thermal treatments

    Thermochemical treatments

    Treatment

    Cold Forming

    Hot Forming

    Hardening

    Annealing

    Normalising

    Tampering

    Case Hardening

    Carbonitriding

    Nitrating

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    4

    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

    Conventional steels

    High-strength steels

    Higher-strength steels

    Ultra-high-strength steels

    Ultra-high-strengththermoformed steels

    Ultimatestrengthin MPa

    Up to approx. 300

    300-480

    350-730

    340-480

    500-600

    600-800

    >800

    >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.

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    5

    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.

    Darkening in color indicates an increase in sheet thicknessFront Longitudinal Member

    Front Floor

    S421_039

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    6

    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.

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    7

    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.

    Bonding+Spot Welds

    Laser Welds

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    8

    Welding

    S421_059

    Sheet Metal

    Welding Rod Feed

    Laser Nozzle

    Laser Beam

    Welding Rod

    S421_067

    Electrode

    Welding Spots

    Sheet Metal

    Electrode

    Laser Welding

    In laser welding, the heat to melt the materialsis 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:

    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

    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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    9

    Welding

    Adhesive

    Body PartS421_043

    Bonding

    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.

    Plasma Soldering

    Inert Gas NozzleSolder (wire)Wire Feed

    Soldering Seam

    Arc

    Sheet Metal

    Tungsten Electrode

    Wire Nozzle

    Plasma Nozzle

    S421_123

    Soldering

    In contrast to welding, the actual parts being joinedare 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

    The arc is constricted by a plasma nozzle . This allows a

    higher energy density and narrower seams. Also, higher

    soldering speeds are possible.

    Laser Soldering

    In LASER soldering, the soldering heat is produced by a

    laser beam.

    Laser Soldering

    Solder (wire)

    Wire Feed

    Soldering Seam

    Sheet Metal

    Wire Nozzle

    Laser Beam

    Laser Nozzle

    S421_072

    Bonding

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    11

    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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    12

    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 areused 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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    13

    Models

    220 - 260 MPa

    280 - 340 MPa

    360 - 420 MPa

    420 - 1000 MPa

    > MPa (form hardened)

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    14

    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 areused 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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    15

    Models

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    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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    17

    Models

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    18

    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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    19

    Models

    180 - 240 MPa

    260 - 320 MPa

    340 - 700 MPa

    > 1000 MPa (form hardened)

    Up to 140 MPa

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    20

    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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    21

    Models

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    22

    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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    23

    Models

    Hot Formed Steel

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    24

    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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    25

    Models

    420 MPa

    > 1000 MPa (form hardened)

    220 MPa

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    26

    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

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    30

    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

    Bonding+Spot Welds

    Laser Welds

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    Models

    180 - 240 MPa

    260 - 300 MPa

    300 - 420 MPa

    > 1000 MPa (form hardened)

    Up to 140 MPa

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    32

    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

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    Models

    420 MPa

    > 1000 MPa (form hardened)

    220 MPa

    High strength steels are used in the door assemblies

    to help prevent intrusion in a side impact.

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    34

    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

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    Models

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    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

    180 - 240 MPa

    260 - 300 MPa

    300 - 420 MPa

    > 1000 MPa (form hardened)

    Up to 140 MPa

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    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

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    Models

    180 - 240 MPa

    260 - 300 MPa

    340 - 700 MPa

    > 1000 MPa (form hardened)

    Up to 140 MPa

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    40

    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

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    Models

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    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

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    Models

    Up to 140 MPa

    180 - 240 MPa

    260 - 300 MPa

    300 - 420 MPa

    > 1000 MPa (form hardened)

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    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

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    45

    Models

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    Models

    2004 Touareg

    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

    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

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    49

    Models

    Panoramic Sunroof

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    50

    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

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    Models

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    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

    180 - 240 MPa

    260 - 300 MPa

    340 - 700 MPa

    Up to 140 MPa

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    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

    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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    57

    Special Tools

    VAS 6322A Spot Weld Breaker

    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.

    Design and features:

    Housing: Lightweight, polished aluminium

    Drive: Pneumatic

    Ejection: Pneumatic/mechanical

    Bar: Hardened and painted steel

    Technical data:

    Compressed air: 6 bar

    Motor speed: 1000

    Connection: 1/4"

    Contact pressure: approx. 240 kg

    Noise level: 82 dba

    Air consumption: 175 l/min, 6 CFM

    Items supplied:

    1 spot weld miller with small counterhold

    2 drill bits for standard sheet metal VAS 6322A/2

    1 drill bit for high tensile sheet metal VAS 6322A/3

    1 tool case with deep inlay

    Replacement parts:

    Drill bits (qty. 10)

    VAS 6322A/2 or ASE 329 007 00 000

    Drill bit (qty. 1)

    VAS 6322A/3 or ASE 329 008 00 000

    Recommended accessories:

    Counterhold, large VAS 6322A/1 or ASE 432 356 00 000

    Manufacturer

    Kamatec

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    Special Tools

    VAG 2001B Migatronic Flex 300 Welder

    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.

    Design and features:

    Current Range: 15-300 A On duration 100%: 220 A/25.0 V

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    Special Tools

    VAS 6388 Aluminum Shielded Arc Welder

    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

    Automatic free burn

    Gas test function

    Job operation

    Microprocessor control

    Multi-process MIG/MAG, WIG and e-hand

    Infinitely variable weld current adjustment via torch

    Synergic operation

    Temperature controlled fan

    Over-temperature protection

    Modes of operation:

    2 and 4 cycle operation with special 2 cycle

    operation

    Spot weld

    Aluminium weld start (special 4 cycle operation)

    Operating mode and process

    Panel thickness

    Dynamic, arc length and drop release correction

    Hold function, job number

    Manual operation

    Motor current

    Weld speed, weld current / voltage (actual value, guide

    value)

    Service codes

    Transition arc

    Adjustable parameters:

    Dynamics

    End crater current

    Free burn time

    Gas advanced and run-on time

    Hot start

    Arc length and drop release correction

    Welding output, infinitely variable

    Design and features:

    Current range: 3-270 A

    Idling voltage: 50 V

    Mains voltage: 3x400 V +/- 15% 50/60Hz

    Dimensions current source (mm):625 x 290 x 480

    Wire diameter: 0.8-2.0 mm

    Working voltage: 14.2-27.5 V

    Type of protection: IP23

    Weight: 27.5 kg / 60.63 lbs

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    Special Tools

    VAS 6530 Resistance Spot Welder

    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

    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 ball-

    head 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.

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    Special Tools

    VAS 6535 Resistance Spot Welder

    VAS 6535 Resistance Spot Welder

    The resistance spot welder VAS 6535 features a central

    connection and a tool detection function. An impedancemeasurement 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:

    Dimensions: 661mm (26") x 661mm (26") x 1372mm

    (54") Weight: 171 kg (376 lbs.)

    Power Supply Unit Mains connection: 208 - 240V

    3Phase

    Mains connection lead /length: 6mm2 / 10 m

    Fuse protection at least: 60 A delay

    Mains frequency: 60 Hz

    Mains connection output: 42 kVA

    Rated output at 50%

    ED: 60 KVA

    Idle voltage max.: 23 V DC

    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

    Includes:

    Mobile mains unit X tongs

    Welding gun

    Quick dent removal hammer

    Linear balancer

    Cooling Unit Heat Exchanger

    Special VAS Welding Programs

    Options:

    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

    VAS 6545 Resistance Spot Welder

    Setting the welding parameters is carried out using simple,

    self-explanatory symbols. The welding programs are forhigh 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 quickpositioning 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)

    Air pressure: 90 psi +/- 5%

    Refrigerant: water + anti corrosive

    Tank volume: 85 l / 22,5 gallons

    Dimensions: 810x560x750 mm

    Weight: 119 kg / 262 lbs.

    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

    Optional Accessory Packs :

    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 Dent Remover

    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)

    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

    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

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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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