Ford Kuga

 Service Manual

Body Repairs - General Information » Tools and Equipment for Body Repairs
Measuring systems

In order to exactly diagnose a damaged vehicle body, measuring systems are required. Depending on the measuring method, the systems vary in having mechanical, optical, acoustic and electronic measuring devices. In some cases, hybrid versions of particular systems are found.

NOTE: When working with each measuring system, the manufacturer's instructions provided in "the description of the measuring equipment must be followed.

Basically, the measuring systems must meet the following requirements:

• Universally applicable to all types of passenger car. Also can be used on light commercial and off-road vehicles.
• Suitable for all accident damage.
• Fast capture of body measurement points in the underfloor and external areas.
• Data catalog to record all measurement points (length, width and height) both with and without the aggregates being installed.

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

Beam compass

The beam compass is a very practical and straightforward aid for measuring bodywork and especially floor assemblies. The beam compass can be used to detect dimensional variations across the length and the width by means of comparison measurements and diagonal measurements.

As a basic principal, body reference points should be chosen which are shown in the body frame measurement data sheet.

NOTE: To be able to determine difference in measurements, the same reference points must always be chosen on both sides. For this purpose the beam compass must be positioned symmetrically.

Comparison measurements can also be made on the outside of the body. Depending on the damage, left/right measurements (symmetry measurements) and diagonal measurements can be made using the beam compass, telescopic rod or a measuring tape.

Laser measuring systems

These systems use laser beams which are projected in one or more planes.

By the use of two parallel laser heads which can be turned, symmetrical points of a vehicle body can be tested and compared. Using the linear scales which are attached to the measuring points, the measurement data is read off with the aid of the projected laser beams.

The integral inclination gauge also allows differences in height to be quickly checked.

Mechanical measuring system

The use of mechanical measuring equipment is an easy and effective way to check a vehicle frame and chassis assembly quickly, exactly and reliably.

In many cases an assessment of the damage can be made with the help of this system, without the need for elaborate setting up.

Because of its self-centering mount, measurement can be carried out by one person.

Further advantages:

• Fast deployment.
• Simple to use.
• Can be extended using adapters, measuring probes and measuring tubes.

Measuring systems which are firmly mounted on an aligning platform require more work in setting them up. They are used to constantly check measurements during alignment work.

This type of mechanical measuring system has measuring scales and measuring slides in three measuring axes. So that the body can be measured, the vehicle is secured on the aligning platform base frame using four universal chassis clamps. The exact fixing points are given in each respective data sheet.

Ultrasonic and mechanical-electronic measuring systems

These measuring systems can be combined with all current aligning platforms. In addition these measuring systems can be used independently of an aligning platform by using a vehicle lift or suitable support stands.

Des cript ion	Description
1	Ultrasound measuring instrument
2	Mechanical-electronic measuring system

Acoustic or ultrasonic measuring systems use ultrasonic emitters and sensors to survey a body.

To do this, ultrasonic emitters are mounted on the vehicle using special attachments. During the measuring process the ultrasonic emitters constantly send out signals which are received by sensors (microphones) and then passed to a computer. The measurements are displayed on the computer screen and are compared with the required values supplied by the vehicle manufacturer.

The ways in which mechanical-electronic measuring systems can be used are similar to those of the acoustic measuring systems. They can also be set up on a suitable understructure, without an alignment jig. After this system has been arranged under the vehicle floor and adjusted to three undamaged vehicle measuring points, the measuring arm is brought up to the required measuring points and the readings compared with the reference values. The data is transmitted to a computer where it is evaluated and the results displayed on a screen.

Alignment systems

Measuring systems

Welding gear