Perform stone chipping repair on windshield

AR67.10-P-1601-01LF

Perform stone chipping repair on windshield

Model

all (CAR)

except code Z04 (Light armoring)

except code Z05 (B5 armoring on special protection version)

except code Z06 (B6 armoring)

except code Z07 (B7 armoring on special protection version)

Repair materials

Number

Designation

Order number

BR00.45-Z-1025-08A

TEROSON VR 1500, Glass repair kit

Henkel AG & Co. KGaA
[email protected]

Preparation

1

Clean windshield (FS) in area of stone chipping using a cleaning cloth (11).

 Do not rub impact point.
The effect of the repair resin (2r) will otherwise be reduced.

2

Remove loose glass splinters and contamination using stone chipping probe (5).

 Do not unnecessarily enlarge impact point.
Larger visual residues will otherwise arise after the stone chipping repair.

3

Coat suction cup of inspection mirror (13) with vacuum gel (3).

 The vacuum gel (3) increases the adhesion of the inspection mirror (13) to the windshield (FS) and the inspection mirror (13) can be moved.

4

Secure inspection mirror (13) from inside onto windshield (FS) at center under stone chipping.

5

Coat suction cup of tool jig (12) with vacuum gel (3).

 The vacuum gel (3) increases the adhesion of the tool jig (12) on the windshield (FS) and the tool jig (12) can be moved.

6

Position tool jig (12) vertically on windshield (FS) so that the bore (12b) is located at the center over stone chipping.

 Transverse positions of tool jig (12) have a negative effect on repair result.

7

Turn lever (12h).

8

Open a repair resin package (2), remove injector (2i) and repair resin (2r).

9

Unscrew plunger (2k) 5 mm from barrel (2z).

10

Completely fill working chamber of injector (2d) with repair resin (2r), resin must be bubble-free.

Perform stone chipping repair

11

Screw injector (2i) into tool jig (12) until injector (2i) is firmly in place and flush with windshield (FS).
Check contact pressure in inspection mirror (13).

 Do not screw injector (2i) too tightly onto windshield (FS).
This will otherwise lead to an enlargement of the stone chipping.

12

Check position of injector (2i).

 The center of the injector tip (2d) must be located in center of stone chipping.

If center of injector tip (2d) is not in center of stone chipping,



repeat operation steps 6 and 7.

13

While holding barrel (2z), screw in plunger (2k) until diameter of injector tip (2d) increases by approx. 1 mm.

 Ensure that working pressure is not too high.
This will otherwise lead to an enlargement of the stone chipping.

 Maintain this pressure phase for the defined waiting time.

 The individual waiting times of the pressure and vacuum phases are as follows:
The waiting time starts with a duration of approx. 10 s.
The waiting time increases with every additional pass by approx. 50 % of the previous pass. (1st pass: 10 s, 2nd pass: 15 s, 3rd pass: 20 s, 4th pass: 30 s etc.)

14

While holding barrel (2z), unscrew plunger (2k) from barrel (2z) until threaded end of plunger has been reached and is visible.

 Do not remove plunger (2k) from barrel (2z).
Vacuum will otherwise be lost.

 Maintain the vacuum phase for the defined waiting time.

 Slightly heat the damaged area to accelerate the filling of persistent air pockets and small cracks.

 The individual waiting times of the pressure and vacuum phases are as follows:
The waiting time starts with a duration of approx. 10 s.
The waiting time increases with every additional pass by approx. 50 % of the previous pass. (1st pass: 10 s, 2nd pass: 15 s, 3rd pass: 20 s, 4th pass: 30 s etc.)

15

Repeat pressure and vacuum phases until stone chipping is clear and without air pockets.

 The repair can only be evaluated in the vacuum phase.

16

Remove tool jig (12) with injector (2i) from windshield (FS).

Curing

17

Apply a strip of curing film (7) to the repair point immediately after the removal of the tool jig (12) and slightly press on using your fingers.

18

Remove curing film (7) from repair point and remove excess repair resin (2r).

19

Apply a drop of finishing resin (9) to the repair point and apply a new strip of curing film (7) without applying pressure.

 The finishing resin (9) must be visible bubble-free under the curing film (7).

20

Coat suction cups of UV lamp (14) with vacuum gel (3).

21

Position UV lamp (14) from outside at center over damaged area and attach to windshield (FS).

22

Switch on UV lamp (14) and leave switched on for 10 min.

23

Remove UV lamp (14) from windshield (FS).

24

Remove curing film (7) from windshield (FS).

Aftertreatment

25

Insert a scraper blade (6) into scraper blade holder (8).

 Only use undamaged scraper blades (6).

26

Using scraper blade holder (8), scrape off excess finishing resin ( 9) with scraper blade ( 6) at an angle of 90° to windshield (FS).

 Do not strip or plane off (avoid a scraper blade (6) work angle to windshield (FS) < 90°) the finishing resin ( 9).
Finishing resin (9) will otherwise be pulled out of the damaged area.

 The scraped off finishing resin (9) is matt.

If high-gloss spots exist,



repeat operation steps 19 to 26 again.

27

Apply some finishing polish (4) to windshield (FS) in area of repair point.

28

Using a polishing cloth ( 10), polish windshield (FS) in area of repair point while exercising slight pressure.

 Matt points may not be visible.