Ford Galaxy / Ford S-MAX. Manual — part 1003

The refrigeration system is filled with refrigerant R134a. This can cause frostbite if it

contacts the skin. Pay attention to the corresponding warning notices and instructions in
the chapter Air Conditioning Systems.
NOTE: Work on the refrigerant circuit may only be performed by persons who have a
relevant certificate of competence.

Vehicles with a refrigerated compartment are often used to transport foodstuffs. For this
reason, additional hygiene regulations must be complied with during repair work.

Aluminum and plastic are used to construct the two different types of compartment found
on refrigerated vehicles.

The aluminum conversion is a very stable and technically perfect variant. However, against
this the relatively high production costs and a lower payload must be taken into account,
because of the weight of the aluminum conversion itself.

NOTE: Basic and in-depth training is offered on the following topics. You will find an
overview of the complete range listed in the Training brochure published by the Ford
Service Organization.

The plastic conversion has developed into a light, clean and economical alternative because
of constant further development of materials and working techniques.

NOTE: The material combinations, the workmanship and the working methods must
comply with the current food hygiene regulations. For this reason, service and repair work
on the refrigerated conversion may only be performed by authorized and specially trained
technicians.

Refrigerated compartment constructions are often made using both materials. The floor pan
is made of structured, slip-proof aluminum panels and the wall and ceiling cladding is made
of smooth surfaced plastic elements.

CAUTION: PUR hard foam is flammable. If PUR hard foam is overheated, it will burn

on its own with a brilliant yellowish flame. It produces unpleasant choking and toxic
fumes. Special measures must be taken when welding the vehicle body.

Polyurethane wall and ceiling elements are manufactured using a sandwich principle. An
insulating polyurethane core is coated with food grade ABS plastic on one side.

PUR hard foam does not decompose, is rot resistant and is odorless. These properties make
it suitable for use as insulation.

Because of its closed cell structure, water uptake by PUR hard foam is for the most part
only a problem at edges. Cut edges or other mechanically worked surfaces must however
be sealed with the greatest care.

The conversion to a refrigerated vehicle is performed as made-to-order production. The
large surfaces of the wall and ceiling cladding can be changed and are particularly easy to
repair.

If access to the back of a body panel section is needed because of body straightening work,
in some circumstances it is cheaper to perform a cut-out repair instead of removing an
element.

The repair process is fully described in the Student Information booklet Refrigeration
System Technology, Transit 2000.5 Freshline.

Body Repairs - General Information -
Environmental Regulations

S-MAX/Galaxy 2006.5 (02/2006-)

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Description and Operation

Orderly and responsible waste management is not only very important for the protection of
health and the environment, but it also has great importance where saving natural
resources is concerned.

In body repair shops, since the introduction of the EU directives on the avoidance of vehicle
waste and the promotion of return, re-use and recycling of vehicles and their components
(2000/53/EU), more rigorous attention than before is also paid to avoidance and recycling
of waste materials.

NOTE: The organization of disposal in the operation must comply with the country specific
waste regulations:

In this respect, body repair shops must take into account and comply with the following
requirements:

Separate waste according to its recycling and disposal methods.
Produce evidence for the correct transport and disposal of waste.

NOTE: The organization of disposal in the plant must comply with the requirements of the
Waste Avoidance and Management Act.

The avoidance and recycling of waste must always take priority. However, despite all
measures which may be taken, waste cannot be completely avoided.

NOTE: Useable waste which is not allowed in household rubbish, must be disposed of as
special waste

All remaining waste must be treated as commercial waste and disposed of according to the
local requirements.

Only applies to the EU:

The vehicle manufacturer is also under a legal obligation since the older vehicle legislation
came into force throughout Europe in 2002.

This law covers the surrender, withdrawal and environmentally friendly disposal of older
vehicles through the manufacturer.

The older vehicle legislation contains all the necessary information for the environmentally
compatible disposal of older vehicles, starting with preliminary handling involving the
removal of all operating fluids, deactivation of pyrotechnic components, elimination of
pollutants and then further handling by dismantling components for re-use and recycling.

Body Repairs - General Information -
Body Construction

S-MAX/Galaxy 2006.5 (02/2006-)

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Description and Operation

General

Under bodywork construction, a general distinction is made between monocoque and non-
monocoque bodywork. The safety of the occupants is the main consideration for all types of
bodywork construction. The front and rear sections are designed so that they absorb the
energy of the impact via crumple zones. The use of modern design and manufacturing
methods and the use of newly developed body panels (relating to their deformation and
strength properties) mean that, despite the continuous weight-savings, all safety-related
requirements made of the construction can be met.

Integral body-frame

In this method of construction, coverings, reinforcements, retaining panels and profiles are
permanently joined together using a variety of joining techniques (gluing, spot welding,
laser welding, soft soldering or brazing). The load-bearing function of the structure must
always be achieved in each case.

There is no distinction made between components which are purely subject to
bending/torsion or thrust loads and parts which perform sealing/covering functions (as in
non-monocoque bodywork for example). In modern passenger vehicles, monocoque
bodywork is very widespread and offers the advantages of a lightweight and low-cost
construction.

The rigidity of the bodywork is achieved by a panel skin and panel cross-section with the
largest possible profile and therefore the largest resisting torque (such as for instance the
rocker panel). Swage lines in the outer area of the bodywork increase the stiffness and the
natural vibration frequency, to prevent possible drumming noises. The mounting points for
ancillary components such as doors and wings are permanently built into the monocoque
bodywork.

High rigidity of the bodywork is vitally important to keep the elastic deformations low at the
joins to the ancillary components and to prevent noise when driving. Small gap dimensions
are therefore only possible on vehicles with very stiff bodywork. With high bodywork
stiffness, the construction can exert an influence on the handling of the vehicle (e.g. on

poor road surfaces).

Advantages of monocoque bodywork:

Weight reduction.
Economical manufacturing technology.
High torsional rigidity and high flexural strength.
Defined deformation behavior at the front and rear.
Maximum passive safety due to the strong passenger compartment

The protected passenger compartment with strong pillars, rocker panels and doors with
integral side impact protection increase occupant protection. Opening of the doors is
ensured, even if there is extreme deformation.

NOTE: Repair work must always be performed according to the established workshop
literature. All the safety requirements must be guaranteed after any repair work has been
performed !

Convertible

The body of a convertible differs from the principle of the integral body-frame of a saloon
due to the lack of a roof construction. The body has a high degree of torsional stiffness.
This is achieved by using high, super-high and maximum-strength sheet steel and body
reinforcements in specifically-targeted areas.

These reinforcements can be installed in the area of the doors (diagonal braces etc.) or on
the underfloor. In contrast to the saloon (or other non-convertibles) with square-section
side members (closed profile), these reinforcements have a profile which is open on the
underside (U-section).

Description

Description

1

Body components adopted from the Focus 2004.75 (07/2004-)

2

Conventional bodywork construction steel

3

High-strength sheet steel

4

Super-high strength sheet steel

5

Maximum-strength sheet steel

6

Aluminium, can be subjected to high stresses