Sika Technicians` Handbook for Passenger Car Glass Replacement

Transcription

Sika Technicians' Handbook
for Passenger Car
Glass Replacement
Version 1 / 2010
Copyright © 2010 Sika Services AG. All Rights Reserved.
This handbook is intended only for Sika professionals. The information contained
herein is the property of Sika AG and is supplied without liability for errors or
omissions. No part of this handbook may be reproduced, stored in a retrieval
system, or transmitted in any form whatsoever, without the prior written consent
of the Vice President of Automotive Aftermarket, Sika Services AG.
Due to the ongoing development of Sika products, the information contained
herein is subject to change without notice. No part of this publication shall be
deemed a warranty; implied or expressed.
Sika refers to Sika AG in Switzerland and to all other members of the worldwide
Sika organization.
Sika Services AG, Tüffenwies 16, 8048 Zürich, Switzerland
Tel +41 58 436 40 40
Fax +41 58 436 45 30
www.sika.com
2_Sika Automotive Aftermarket
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Introduction
Sika is a tier-one supplier and development partner to the automotive OEM
industry. The knowledge Sika has acquired from this partnership is also beneficial
to the product range for the automotive aftermarket.
Since entering into this market in the early 1980s, Sika has continuously
developed products that have provided added value for customers. Understanding
benefits and their impact on the system have lead to concepts like the Sika®
All-in-One Modulus, the perfect adhesive for every car. At Sika, we strive to keep
things simple.
Sika has been working diligently for over 20 years to become the leader in
adhesive systems for the automotive glass replacement (AGR) industry. Innovation,
performance and automotive OEM competence, coupled with proven safety,
reliability and ease of use, make the Sika System the number one choice of direct
glazing professionals all around the world.
Customer Safety is our Mission
The auto glass replacement technician’s profession is a very important one. The
use of inadequate products and poor workmanship has resulted in fatal accidents
that have cost the glass replacement industry millions. Pride in workmanship and
attention to detail are key to providing 100% installations 100% of the time.
The variety of cars available is growing every day. The increasing complexity of
new designs, changing components and windshields puts an ever-increasing
demand on AGR technicians. For Sika, the safety of all occupants of cars with Sika
bonded replacement windshields is paramount. For this reason the Technicians’
Handbook and Certification Program has been introduced specifically to support
the professional AGR technician.
Sika’s Technician Handbook for Passenger Car Glass Replacement describes the
procedures for safe and durable glass installation. This ensures that the vehicle
is restored to the OEM design specification for structural integrity and aesthetic
appearance.
Sika Automotive Aftermarket_3
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The scope of this manual is to provide instructions for the replacement
of bonded windows with direct glazing adhesives. This means that
glass which was originally fixed mechanically with gaskets must be
re-installed using the same fixing technology again.
Always refer to the most recent local Product Data Sheet for each Sika
product.
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About Sika
Sika is one of the world’s foremost manufacturers of specialty chemicals. Today,
Sika Industry is one of the leading suppliers of process materials for the
Automotive OEM, Automotive Aftermarket, Transportation and Appliances and
Components customer groups. As a producer of specialty chemicals, Sika
relies on a strong and independent R&D and operates on the principle that the
company bears responsibility for safety and the environment at every stage of the
production and marketing cycle. Sika is committed to a comprehensive quality and
service culture. Sika Management System conforms to international standards
ISO 9001, ISO 14001 and QS 9000.
Disclamer:
The information contained herein and any other advice are given in good faith based on Sika's current knowledge and
experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika's
recommendations. The information only applies to the application(s) and product(s) expressly referred to herein. In case
of changes in the parameters of the application, such as changes in substrates etc., or in case of a different application,
consult Sika's Technical Service prior to using Sika products. The information contained herein does not relieve the user
of the products from testing them for the intended application and purpose. All orders are accepted subject to our current
terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product
concerned, copies of which will be supplied on request.
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Contents
Introduction............................................................................................... 3
Contents.................................................................................................... 7
Important................................................................................................... 9
Step-by-Step Guide
1 Inspect the Vehicle................................................................................ 13
2 Always Start with the Glass................................................................... 15
3 Protect Vulnerable Areas of the Vehicle.................................................. 17
4 Remove Trim, Wipers and Rear-View Mirrors . ...................................... 18
5 Cut Out the Windshield......................................................................... 19
6 Preparation of the Pinchweld (Full Cut Method)..................................... 21
7 Dry-Fit the New Windshield................................................................... 25
8 Preparation of the Windshield .............................................................. 27
9 Installation of the Windshield................................................................ 31
10 Post Inspection................................................................................... 35
Detailed Sections
Identification of Butyl, Silicone and Polyurethane...................................... 39
Complete Removal Procedure.................................................................. 41
Corrosion Treatment................................................................................ 45
Freshly Painted Vehicles........................................................................... 49
Removal of Contamination....................................................................... 51
Special Windshields................................................................................. 55
Special Weather Procedures.................................................................... 59
Appendix Section
Sika Products.......................................................................................... 63
Sika Application Gun................................................................................ 77
Glossary of Terms.................................................................................... 88
FAQ......................................................................................................... 91
Technician Training Test........................................................................... 96
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Important
The work that a glass technician does is critically important to the safety and
welfare of the customer and the integrity of the vehicle. Use of the wrong products
and poor workmanship has resulted in fatal accidents that have cost the glass
industry significant financial losses. Every step described in the handbook is
important and must be followed, in keeping with the training provided by Sika
personnel. Always refer to the latest edition of the Product Data Sheets and
Material Safety Data Sheets for all Sika products before use.
It is important to note that some of the instructions in the Product Data Sheets are
different from those given in this manual, e.g. flash-off times/drying times. The
reason is that the Product Data Sheets are made for the general user, whereas
this handbook is intended specifically for professional technicians trained by Sika
specialists. Technicians using this handbook are expected to work to the highest
standards of their profession by delivering a safe and quality-proven installation
100% of the time. Anything less may be fatal!
Safety Instructions
Pre-treatment products and adhesives are chemical products.
Please follow safety instructions:
Wear chemical-resistant gloves and safety glasses. Material Safety Data
Sheets and instructions for use (Product Data Sheet) must be strictly
adhered to.
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Step-by-Step Guide
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1 Inspect the Vehicle
Before working on any vehicle, conduct an inspection. Look for existing damage
such as scratches or dents in the areas around where work is to be carried out.
This step can save thousands in damage claims and is a professional courtesy
that the insurance industry respects.
It is equally important to inspect for any conditions that may compromise the safe
retention of the glass. Such conditions include, but are not limited to, corrosion,
vehicle body damage, paint system failure, missing parts, improper workmanship
from previous glass repair or replacement work and use of improper products.
It is also advisable to check for the operability of all mechanical and electrical
parts and devices related to auto glass systems. All conditions discovered prior to
and during the auto glass replacement process should be recorded and the owner/
operator of the vehicle notified. Any conditions discovered that would compromise
the retention system must be fully remedied prior to the installation of the glass.
 Inspect for pre-existing damage
 Inspect any rain and light sensors
Sika Vehicle Inspection Sheet
Pre-Inspection
Interior
Exterior
Headliner
Seats
Dashboard
Door panels
Floor front
Floor rear
Rain sensor
Tears Stains Area
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
* checked
Mark all damages as follows: S = Scratched, P = Peeled paint, D = Dented, C = Chipped, M = Missing part, R = Rusted spots, O = Others _____________________________
Post-Inspection
Before Returning to Customer
Vacuumed
Trim secure
Glass cleaned
Air condition runs
Radio
Rain sensor
*
done
*
checked
*
done
*
checked
*
checked
*
checked
Customer name ________________________ Date ____________________________________
Phone no. ____________________________ Color vehicle ______________________________
Type vehicle___________________________ VIN (Vehicle Identification) no. __________________
Glass DOT no. _________________________ Glass part no. _____________________________
Urethane system used ___________________ Car inspection by ___________________________
Urethane batch no.______________________ SikaAktivator® PRO batch no.___________________
SikaPrimer®-206 batch no. ________________
Safe drive-away Time job finished at_______ Your car will be safe to drive at _______________
I hereby have read the inspection sheet, authorization and agreement, before affixing my signature below,
and warrant that I fully understand the contents thereof.
Customers signature ____________________ Date ____________________________________
Our most current General Sales Conditions shall apply. Please consult the
most current local Product Data Sheet prior to any use.
www.sika.com
Template is available from your local Sika Organisation.
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2 Always Start with the Glass
Never begin work on the vehicle before cleaning and inspecting the glass to be
installed. Inspect both the quality and the suitability of the selected glass for
installation on the target vehicle. There have been occasions, especially in mobile
work, where the glass had a small scratch or blemish that went undetected in the
shop and was not discovered until after the new glass was installed on the vehicle.
There have been other incidents where the technician did not realize he had the
wrong part; he prepared the glass and applied the adhesive, and only when he
tried to install it in the vehicle, did he realise his mistake. Pre-inspection and
cleaning of the glass helps to avoid these two time-consuming errors.
Is the glass free of scratches or blemishes?
Is it the correct glass for the vehicle?
Is it the right color?
Is there a rain sensor?
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3 Protect Vulnerable Areas
of the Vehicle
It is advisable to use bonnet and wing covers as well as some form of seat
covering before working on a vehicle.
Taping vulnerable paint areas to protect them from becoming scratched is
also a good idea. Never leave tools or equipment on painted surfaces, seats or
dashboards. Such mistakes result in many needless damage claims.
Cover parts to be protected.
Use seat covers.
Mask adjacent surfaces prior to
any activating/priming/bonding
operation.
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4 Remove Trim, Wipers and
Rear-View Mirrors
Check the specific vehicle information for trim and accessories before starting to
dismantle.
Gaskets must be reinstalled on the new glass immediately after glass preparation
or after removal of trims. Always wear nitrile rubber gloves during installation to
avoid leaving any fingerprints on the bonding area.
When removing cowls, wipers and other equipment from the vehicle, store them in
a safe area to eliminate the risk of damage from inadvertent contact.
Check for specific vehicle
information for trims and
accessories.
Ensure availability of all necessary
spares and accessories.
Carefully remove all fitted trims and
accessories and store them in a
safe area.
Where possible, use new trims.
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5 Cut Out the Windshield
Always wear safety glasses and cut-resistant gloves during windshield
removal. Use tools appropriate to the type of windshield to be removed.
Sika recommends the use of either cold knife or cheese wire, as these tools allow
cutting out a windshield with minimal damage to the vehicle. Also oscillating
knifes can be used but here care must be taken to avoid damage to the car body.
Wear personal protective equipment.
Cut out glass.
Remove debris with vacuum cleaner
or brush.
Clean the bonding area with
Sika® CleanGlass.
Remove the damaged windshield.
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These are two methods for preparing the pinchweld:
Full Cut Removal Method
Complete Removal Method
Use the full-cut removal method when:
The old adhesive is a polyurethane.
The existing bead of cured
adhesive is well bonded to the
flange and is in good condition.
There are no signs of corrosion
There was no damage during the
removal procedure.
In all other cases, use the complete
removal method. Please see the
indicated tab section:
For instructions on detection of other
materials such as butyl and silicone
please refer to:
Corrosion Treatment
Complete Removal Method
If the surface is rusty, please refer to:
Identification of Butyl, Silicone
and Polyurethane
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6 Preparation of the Pinchweld
(Full Cut Method)
Use the full-cut method only if the existing adhesive is well bonded to
the aperture and is in excellent condition, the aperture shows no signs
of corrosion or rust and the correct procedures and were used on a
suitable polyurethane adhesive (NOT silicone or butyl).
For detection of silicones and butyls, etc., please refer to:
Identification of Butyl,
Silicone and Polyurethane
If rust or surface corrosion is detected please refer to:
Corrosion Treatment
Remove debris with vacuum cleaner
or brush.
Clean the entire aperture using
Sika® CleanGlass, making sure the
surface is completely dry and no
moisture remains.
Short cuts like lightly trimming the existing urethane beads and using
minimal amounts of new urethane are unacceptable and potentially
very DANGEROUS. Short cuts taken to replace a windshield will void all
Safe Drive-Away Time (SDAT) guidelines and can cause possible loss of
glass adhesion and serious personal injury. Since too little space would
remain to accommodate an adequate depth of urethane between the
new windshield and the old bead of urethane, the application will not
comply with all applicable FMVSS regulations, and may also fail during
normal day-to-day use to the vehicle.
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Trim back the remaining PUR bead
and try to cause as little damage as
possible. The remaining PUR must
be between 0.5 and 2 mm before it
is safe to apply fresh adhesive.
0.5 - 2 mm
Using a dry, clean, lint-free cloth,
wipe Sika® Aktivator PRO on the
entire base section of the aperture.
Use strokes in one direction only.
Allow Sika® Aktivator PRO to
flash- off for at least 3 minutes.
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Scratches and Fresh Rubs <5 cm2
For treatment of fresh scratches or bright metal rubs and scrapes that are
5 cm2 in area or less, Sika recommends that these areas be covered with
Sika® Primer-206 G+P.
3 min
Apply a thin but complete
and homogeneous layer of
Sika® Primer-206 G+P into the
scratch using a small brush or
dauber. Ensure that there is an
overlap of 5 mm between the
damaged area and the undamaged
area to provide adequate protection.
Allow to flash-off for at least
3 minutes or until touch dry.
One coat of Sika® Primer-206 G+P will provide a good level of corrosion
protection if the area is also covered by adhesive. Sika recommends
that a second coat of Sika® Primer-206 G+P should be applied for even
better performance.
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Scratches and fresh rubs 5 cm2 – 150 cm2
For fresh scuffs and scrapes that are greater than 5 cm2 but less than 150 cm2,
two coats of Sika® Primer-206 G+P are required for sufficient corrosion protection.
3 min
10 min
Apply a thin but complete and
homogeneous layer of
Sika® Primer-206 G+P into the
scratch, using a small brush or
dauber. Make sure you have an
overlap of 5 mm between the
damaged area and the undamaged
area to ensure adequate protection.
Allow to flash-off for at least
3 minutes or until touch dry.
Apply a second coat of
Sika® Primer-206 G+P and allow
to flash-off for 10 minutes or until
touch dry.
Do not use Sika® Primer-206 G+P on the surface of fresh-cut PUR
as it considerably reduces the strength of the bond.
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7 Dry-Fit the New Windshield
It is recommended that the glass be dry-fitted in order to verify correct positioning
and to establish fitting marks. An added advantage of this is that it allows a fast
and precise operation once the adhesive is applied to the glass.
Dry-fit the windshield.
To ensure a quick and precise
installation of the windshield once
the adhesive is applied, first dry-fit
the glass and add fitting marks.
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8 Preparation of the Windshield
Each time a windshield installation is performed, a key component of the vehicle’s
structural system is put in place. An essential part of this component is the bond
between the adhesive and the glass. This critical area can experience leaks and
problems if there are contaminants between the adhesive and the glass.
Most new cars have a ceramic frit or band near or along the edge of the glass,
which also needs to be cleaned. Care must be taken to prevent contaminants
coming into contact with the edge of the glass, leaving behind solvents, grease,
oily fingerprints and other substances. These can adversely affect the performance
of the adhesives with potentially serious consequences!
Cleaning the glass with Sika's recommended products is vital for safe and leakfree installations.
Clean the new windshield with
Sika® CleanGlass.
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Unnatural contamination can
be detected by spraying the
Sika® CleanGlass onto the
ceramic frit.
If contamination similar to the
picture is detected, please refer to:
Removal of Contamination
Sika® Aktivator PRO must be used on every windshield before
applying the adhesive.
Windshields installed without the use of Sika® Aktivator PRO may
be subject to leaks, stress cracks and retention problems. The
loss of windshield retention can cause serious injuries. Therefore,
the use of Sika® Aktivator PRO cannot be over- emphasized. After
the application of Sika® Aktivator PRO, the windshield installation
must be completed within 8 hours or the Sika® Aktivator PRO must
be re-applied.
Make sure the windshield is stored in a clean, dry place. Do not
touch the activated area.
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Activate the bonding area with
Sika® Aktivator PRO by wetting a
clean lint-free cloth and wiping the
surface in one direction only.
3 min
Allow to dry for at least 3 minutes.
Sika® Aktivator PRO can be used on glass with a ceramic frit as bonding
surface, glass with a float glass surface, glass with a Pre-Applied
Adhesive System (PAAS) and glass with factory pre-applied black
primer. Sika® Aktivator PRO also works on encapsulated quarter- and
backlights.
Sika® Aktivator PRO can be used to reactivate pre-applied black primer that has
been put onto the windshield in a controlled factory setting. This ensures that
there is sufficient adhesion between the factory-applied black primer and the
bond area of the glass, and consistent application between the two. Under no
other circumstances should primers be interchanged, nor glass activators, nor
adhesives from different adhesive suppliers. If the installation technician is unable
to determine if the primer has been applied by an automotive OEM, then Sika
recommends that the glass is not installed and that it is returned to the distributor.
For plastic windshields and windshields without a ceramic frit, please refer to:
Special Windshields
If Sika® Aktivator PRO is applied to the clear area of the window it will
be visible and the customer will be justified to complain.
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9 Installation of the Windshield
Sika adhesives are supplied with a pre-cut triangular V-notched nozzle. This is the
recommended nozzle tip that must be used in order to apply the proper bead size.
A round bead can trap air when compressed between the glass and pinchweld.
Make sure that the depth of the V-notched nozzle is the same height or up to
3 mm greater than the space between the aperture mounting surface and the roof
of the car. This can be checked by simply placing the nozzle on the aperture near
the roofline. If it is too short, cut the V in the nozzle deeper and wider. When applying
Sika adhesives, it is imperative for the fresh adhesive to match the location and
profile (height and width) of the trimmed OEM bead on the aperture. This will ensure
that there is a sufficient amount of new adhesive available to meet FMVSS standards
for safety.
The best bonding surface for Sikaflex® and SikaTack® Adhesives is a freshly cut,
uncontaminated bead of original urethane. It is recommended that the newly
extruded urethane make contact with the original bead.
The Sikaflex® and SikaTack® Adhesives can be applied to the windshield or to the
aperture. However, application to the glass offers benefits such as easier control
of the bead dimension during application, which can help to prevent water leaks.
However, if it is not possible to accurately determine where the new bead will
make contact with the original bead of urethane, it is recommended to apply the
adhesive to the trimmed bead or the pinchweld instead.
Independently of the place the
application occurs, it is important
that the adhesive matches both to
the activated surface of the glass
and to the freshly cut bead of
urethane.
Set the gun at an 80 - 90° angle to
the surface.
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Position the glass. Depending on
the dimensions and weight of the
windshield, tape might be required
to keep it in the exact position until
the adhesive has developed enough
strength.
Remount trim and moldings so
that they fit properly. Ensure that
all dismantled parts are installed
correctly.
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After a windshield replacement, a vehicle must meet the FMVSS 212/208
standards to be safe to operate. This requires that the adhesive system is
adequate to hold the windshield in place in the event of an accident occurring
while the vehicle is being driven. The two key tips to ensure a safe auto glass
installation is to follow the written instructions provided within this manual and to
allow adequate time for the adhesive to set fully before driving off.
The Save Drive-Away Time (SDAT) for each Sika AGR adhesive can be identified
through use of either the Sika SDAT chart, located in the product section of this
manual or the Sika Product Data Sheet, available for each Sika AGR adhesive
available on www.sika.com.
The vehicle must remain out of service and NOT be operated until the appropriate
SDAT has been reached; the owner/operator of the vehicle must be notified of this
time restriction.
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10 Post Inspection
After installation is complete, inspect and clean all areas affected by the work.
Glass, carpets, seats, dashes and all painted surfaces around new windows
must be cleaned and vacuumed. Air ducts must be blown out and cleared of any
glass fragments. Check to see that all parts that have been removed have been
replaced again. Test their operation where applicable. Check operation of wipers
and windshield fluid hose dispenser. Test the operation of all applicable electrical
devices. Conduct a glass-leak-check if possible. Complete and maintain a record
of all post inspection procedures. As a courtesy, provide the owner/operator of the
vehicle with a copy. The technician should also wear appropriate eye protection
while clearing the heater vents to avoid injury. All airbags and safety belts must be
in place and functional.
To finish the job, also clean the windshield on the outside to remove
finger marks and any marks made by the suction pads.
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Detailed Sections
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When installing a replacement windshield, it is essential to ensure that the
residual material on the pinchweld is polyurethane. SikaTack® and Sikaflex®
polyurethane direct glazing adhesives develop very strong adhesion to many
different brands of polyurethanes and also to some of the newer MS Polymer
direct glazing adhesives. However, if the residual material on the pinchweld
is a butyl or silicone, it must be completely removed. SikaTack® or Sikaflex®
polyurethane direct glazing adhesives do not adhere to butyls or silicones. If left
on the surface, these materials could interfere with the adhesion of the ceramic
coating or paint.
How can it be determined if it is a polyurethane adhesive bead?
Press very firmly with the fingernail into the existing material.
If it is a polyurethane or a direct glazing MS Polymer, it should hardly be
possible to make an indentation into the material.
If it is a butyl or silicone, it should be possible to press half way into the
material or possibly all the way through to the pinchweld.
If it is a butyl, there should be an indentation at the point of depression. The
butyl should retain a finger mark in it, where it does not regain its original
shape.
If it is still unidentified:
Cut out a long piece of the material and pull it apart.
If it is polyurethane, a great amount of force will need to be applied in order to
pull the material apart and break it.
If it is a silicone, it will stretch a great distance, without exerting too much
force. It will also be “snappy”, where it will stretch back and forth rather easily.
If it is a butyl, it should pull apart very easily.
If it remains unidentified:
Completely remove the old adhesive and follow the procedures as indicated in
the following section.
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If the technician discovers that either inappropriate procedures or products (such
as butyl or silicone) were used on previous glass replacements or that the existing
aperture and urethane conditions would compromise the retention system, they
are NOT to use the full cut method.
Instead, it is recommended to fully correct any adverse glass installation related
conditions, providing a clean and sound substrate for bonding. A complete
adhesive removal requires the total removal of existing material down to the
frame. During a complete removal, the aperture must be cleaned of all products
and materials other than the clean weld area and the original paint. This method
must be used when:
 The aperture has been repainted for any reason (e.g. body shop corrosion
treatment).
 The aperture is damaged and will be repainted.
 The existing urethane adhesive is loose or has deteriorated.
 An improper product was previously used (e.g. – butyl, silicone).
 After exposing the original paint,
carefully scuff the paint on the
aperture to remove the clear coat.
Care must be taken so that the
e-coat and phosphate coatings,
which lie beneath the OEM primer,
are not removed. The e-coat and
phosphate coatings are essential
part of the OEM corrosion inhibiting
system and it is not possible to
replace these in the after market.
Complete Removal
Procedure
Complete Removal Procedure
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Clean the area using
Sika® CleanGlass.
Before continuing, ensure that the
surface is dry and clean.
Activate the bonding surface with
Sika® Aktivator PRO. Let it dry for at
least 3 minutes.
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3 min
 Apply Sika® Primer-206 G+P using a
brush or dauber, making sure the primer
overlaps onto the surrounding
intact paint by a minimum of 5 mm.
Respect a flash-off time of 3 minutes
and wait until the surface is touch dry.
10 min
 Apply a second coat of
Sika® Primer-206 G+P over the first
coat using a brush or dauber. Allow
a flash-off time of at least 10 minutes
before proceeding to the next step.
220.107 mm
For further information please refer to:
Corrosion Treatment
220.107 mm
Freshly Painted Vehicles
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Corrosion Treatment
Corrosion around the aperture is very serious and must be corrected properly.
Automotive OEMs have issued guidelines for addressing this problem and these
have been incorporated into the recommendations that follow. To properly treat
around an aperture that is corroded, it is important to first identify the nature and
the extent of corrosion present. The following defines these characteristics:
Description
1
Light
Light metal discoloration; typically orange
2
Moderate
Moderate corrosion typically has some red spots.
3
Severe
This can be identified by deep “pitting”, dark red spots
and raised edges.
4
Perforation
This level can vary from microscopic holes to loss of
metal.
Sika recommends that treatment of level 4 corrosion, or perforation,
only be performed by a body shop that is trained in metal restoration!
Also, if corrosion around the aperture is greater than an overall total of
150 cm2, it is recommened that this treatment should only be performed
by a body shop skilled in metal restoration. Any corrosion greater than
this is very severe and potentially dangerous and should only be
corrected by reputable professionals.
Perforation corrosion in the window frame of a vehicle, just like perforation
corrosion located in any other structural area, requires replacement of the entire
section of metal. Filling these types of areas with body filler is not acceptable.
Do not apply body filler in areas where glass bonding adhesive will
be applied.
Corrosion Treatment
Level
Version 1 / 2010
Corrosion Removal
 Remove corrosion to obtain a bright
and corrosion-free metal surface.
Ideally this should be done prior to
trimming the remaining well-bonded
adhesive bead.
 Abrade the intact paint for a further
5 mm beyond the paint edges
surrounding the fresh bright metal
areas where corrosion has been
removed. Use a sia or 3M Scotch
Brite abrasive pad for this purpose.
Level
Recommended Procedure
1
Light
Remove corrosion with 80 grit sand paper, wire wheel
or Dremel® and a grinding stone.
2
Moderate
Remove corrosion with wire wheel or chemical rust
remover.
3
Severe
Remove corrosion with media blast or chemical rust
remover.
4
Perforation
The panel must be replaced and treated by a body
shop.
Version 1 / 2010
Corrosion Treatment
 Clean the entire area using
Sika® CleanGlass, to remove dust
and dirt.
 Wipe the bright metal using
Sika® Aktivator PRO.
 If the adhesive bead was trimmed
prior to removal of the corrosion,
clean the contaminated areas of the
trimmed original bead by wiping
with Sika® Aktivator PRO. Allow a
flash-off time of 3 minutes.
3 min
 Apply Sika® Primer-206 G+P
using a brush or dauber, making
sure the primer overlaps onto the
surrounding intact paint by at least
5 mm. Allow a flash-off time of
3 minutes and wait until the surface
is touch dry.
Version 1 / 2010
10 min
 Apply a second coat of
Sika® Primer-206 G+P over the first
coat using a brush or dauber. Allow
a flash-off time of at least 10 minutes
before proceeding to the next step.
220.107 mm
Version 1 / 2010
If the bond is to be made to a freshly painted vehicle and it is uncertain which paint
or paint drying system was used or the correct paint drying times are unknown,
allow the paint to dry for 24 hours first before treating the aperture. If the drying
times are known, use the paint shop recommandations and proceed as follows:
 Clean the aperture with
Sika® CleanGlass.
 Abrade the bonding area with a
suitable scouring pad or very fine
grade sandpaper (grade 120).
Version 1 / 2010
 Activate the bonding area with
Sika® Aktivator PRO and let it dry for
a minimum of 3 minutes.
10 min
 Using a brush or dauber, paint a
thin coat of Sika® Primer-206 G+P
and let it dry for a minimum of
10 minutes.
220.107 mm
Version 1 / 2010
Prior to applying Sika® Aktivator PRO, Sika® CleanGlass can be used to remove
traditional forms of contaminants such as dirt, dust and skin oils, which are
commonly found on auto glass parts.
However, as there are many new glass suppliers on the scene, installation
technicians have seen increased occurrences of uncommon contaminants on
windshield frits that can adversely affect adhesion. It has been Sika’s experience
that the nature and quantity of uncommon contamination can vary significantly.
Generally, the source of this contamination is from the manufacturing process
itself.
Silicone residue from a vacuum tube
laminating process which is used for
the lamination process of laminated
safety glass.
Mould release agents associated
with encapsulated parts (where trim
is bonded to the part).
Version 1 / 2010
While many incidents of contamination are clearly visible to the naked eye, some
contaminants are not as easy to see without introducing additional tests. To verify
the presence of contaminants, the auto glass Technician should be trained to
inspect the bond areas of each part for inconsistent areas of surface tension. After
it has been applied to the frit, the Technician should be able to see whether the
glass cleaner migrates or changes appearance along the contaminated areas.
Recommended Treatment for Contamination
Once it has been determined that the bond area of a window has been
contaminated, the following universal treatment procedure should be followed:
Apply small dots of Sika® Cleaner S (II)
on the contaminated area.
Alternatively Sika® Cleaner S (II) can
be applied onto a paper towel, cloth
or Abrasive Pad (as available from
sia or 3M Scotchbrite).
Scrub the Sika® Cleaner S (II) into
the contaminated area.
Apply adequate pressure with a
clean, dry paper rag to wipe it off.
Clean the glass with
Sika® CleanGlass.
Version 1 / 2010
Alternative Method for Removing Silicone Residue Contamination from the
Lamination Process.
Although the Sika® Cleaner S (II) method given above will treat all known types of
windshield contamination, a procedure specifically designed for treating silicone
oil residue derived from a vacuum tube lamination process should be followed.
A contaminant can be identified as a silicone residue if the glass cleaner reveals
an area of low surface tension in a relatively straight line that runs parallel to the
edge of the glass (see photo page 51). If the glass cleaner migrates or changes
appearance and the technician suspects silicone contamination, then the area can
be treated using the Sika® Cleaner S (II) method above or using the glass cleaner
“wet scrub” methods given below. If the technician finds contamination but is
unsure whether it is silicone, then it is recommended that the universal method be
followed:
Apply glass cleaner to the frit and lightly “wet-scrub” the affected area with a
fine weave abrasive pad (e.g. sia or 3M Scotch-briteTM) using small circular
motions.
Care should be taken not to scratch the glass or frit.
After the “wet-scrub” has been completed, clean the frit area with
Sika® CleanGlass and a clean paper towel.
Check the performance by spraying Sika® CleanGlass over the contaminated
area. It should now wet the glass uniformly with no reaction.
Allow the surface to completely dry before applying Sika® Aktivator PRO.
This method is only recommended for removing silicone residue
resulting from the glass manufacturer’s laminating process and is NOT
to be used to remove silicone contamination that originated from a
glass manufacturer’s encapsulation process.
Version 1 / 2010
Version 1 / 2010
Special Windshields
Bonding Plastic Windshields (PMMA and PC)
Plastic windshields can be found on vehicles such as:
Building machines.
Special-purpose vehicles (BGS, Police).
Light-weight construction vehicles.
Typical materials are PMMA (Polymethylmethacrylate) and PC (Polycarbonate). In
the manufacturing process, many polycarbonate sheets are coated with a scratch
resistant surface. Unlike standard float glass, plastic windshields have a much
higher coefficient of thermal expansion, resulting in greater movement (expansion
and contraction of the window).
In addition, plastic windshields do not have the ceramic coating that glass
windshields have that provides UV-protection for the adhesive bond-line. For
these reasons, the following procedures must be followed when bonding plastic
windshields.
Permanent Glazing
Step 1
Abrade bonding area with Scotch Brite or
sia abrasive pad.
Remove scratch resistant
coating.
Step 2
Remove dust (Note: Use only oil free
compressed air or wipe with a clean
paper towel).
Clean surface of dust.
Step 3
Apply Sika® Aktivator PRO. Flash-off for
3 minutes.
Clean and activate the surface.
Step 4
Apply Sika® Primer-206 G+P. Flash-off for
10 minutes.
Create a suitable surface for
bonding. (Note: Primerless
bonding is not possible).
Step 5
Application of Sikaflex®-222 UV. Layer
thickness according to Table below.
Bonding.
Sika® Primer-206 G+P must be used for bonding plastic windshields.
Black-primerless bonding is not possible.
Special Windshields
Pre-Treatment PC or PMMA Windshield
If there is an unknown coating, it is recommended that the surface is tested before
bonding (contact Sika); otherwise, use the following procedure:
Version 1 / 2010
Adhesive Thickness
Largest Windshield length
Triangular Bead Required
H
L
Adhesive Bead
Dimension*
D
B
B
L [m]
H [mm]
B [mm]
D [mm]
B [mm]
0.5
8
6
3
8
1.0
8
8
4
8
1.5
12
10
6
10
2.0
16
12
8
Over 2.0 Meter
12
contact Sika
*Important: Conform to minimal adhesive thickness, D.
UV-Protection
To ensure a durable bond, transparent windshields must be surface protected
against UV.
Possible solutions are:
Suitable print color.
Protective metal or opaque plastic trim.
Sika UV Shielding Tape*.
Without this protection, Sika® Primer-206 G+P will eventually detach
from the plastic windshield. The exact period until failure depends
largely on the weather, the synthetic material quality and the general
load.
* Availability depends on the local Sika Organisation.
Version 1 / 2010
Surrounding Conditions and Safe Drive-Away Time
It is recommended that plastic windshield bonding is carried out at temperatures
between +10 °C to +35 °C. It is important to comply with the recommended
flash-off times (see pre-treatment). The vehicle must not be moved for 16 hours
after the replacement.
Remarks
Sikaflex®-222 UV is recommended for the durable bonding of plastic windshields.
This adhesive has a low modulus (soft) and can handle the thermal expension of
the windshield without resulting in mechanical over-load. PMMA is particularly
sensitive to stress cracks. For this reason, windshields should remain flat during
the bonding process. If there are larger than specified dimensions of PC or PMMA
to be bonded, please contact Sika before commencing work.
Temporary Glazing of PC or PMMA Windshields
This procedure is used when a short-term application is required for plastic
windshields. Temporary glazing is carried out if the original glass windshield is not
available at the time of the repair. At the most, this temporary glazing is only to be
used for two weeks until the correct glass windshield can be installed.
Temporary Glazing: Pre-Treatment PC or PMMA Windshields
Step 1
Step 2
Step 3
Step 4
Step 5
Abrade bonding area with Scotch Brite or
sia abrasive pad.
Remove dust (Note: Use only oil free
compressed air or wipe with a clean
paper towel).
Wipe on with Sika® Aktivator PRO.
Flash-off for 3 minutes.
Apply Sika® Primer-206 G+P. Flash-off
time 10 minutes.
Bond the part using standard direct
glazing adhesive and refer to the indicated
drive-away times.
Remove scratch resistant
coating.
Clean surface of dust.
Clean and activate the surface.
Create a suitable surface for
bonding. Note: Primerless
bonding is not possible.
Bonding.
Sika® Primer-206 G+P must be used for bonding plastic windshields.
Black-primerless bonding is not possible.
Version 1 / 2010
Gasket Set Windshields
While some vehicles will come from the factory having used both a gasket and
polyurethane set process, some may have come with only the gasket and some
form of sealant compound. Other than for egress rated windows, antique or
classic vehicles not licensed for highway use or in cases where the introduction
of urethane conflicts with current OEM specifications, polyurethane must be
used. When using polyurethane on gasket set windshields, Sika recommends the
following procedure:
Use appropriate personal protective equipment when performing the following
tasks.
Remove original windshield and gasket.
Use a new gasket if the original has been damaged.
Clean the glass with Sika® CleanGlass.
Remove contaminants from around the aperture, and the inside of the gasket
where the edge of the aperture and glass locate using a clean towel and water.
Sika® CleanGlass may be used to clean these areas if necessary.
Allow water and glass cleaner to thoroughly dry before proceeding.
Prepare all areas of the glass that will sit in the gasket with Sika® Aktivator PRO
Apply Sika® Aktivator PRO to the aperture, where the gasket will sit, and to the
inside of the channels of the gasket. A total flash time of 15 minutes is required
for all gasket set installations as Sika® Aktivator PRO will react slower due to
the porosity and geometry of the rubber gasket.
Set the windshield, making sure that the gasket is fully seated on the aperture,
and be sure to apply the desired Sika AGR adhesive into the channels of the
gasket at the appropriate time.
Clean up uncured urethane using Sika® Remover-208 or Sika® HandClean.
When sealing air or water leaks within a gasket set windshield, make
sure to identify whether or not a polyurethane product is required and
then use only a compatible sealant system.
Version 1 / 2010
Special Weather Procedures
General Precautions
Store all chemical products in an area above +5 °C for an adequate period
before use.
Bear in mind that push-in trims will be more difficult to fit at low temperatures
because the adhesive is stiffer.
Use extra care when removing and replacing scuttles and trim pieces as they
become more brittle below freezing point.
As bonding cannot take place in air temperatures below -10 °C, the vehicle
should be stored somewhere with a higher air temperature or the job
postponed.
Cold Temperature
Additional measures must be taken when bonding glass at temperatures between
-10 °C and +5 °C so that the glass can be bonded safely by all methods.
Sika® CleanGlass
If air temperature is below -5 °C the glass cleaner will freeze when it comes in
contact with the glass and will malfunction. In such a case move the glass and
the vehicle to a warmer environment.
Sika® Cleaner S (II)
If air temperature is below -5 °C the Sika® Cleaner S (II) will freeze when it
comes in contact with the glass and it will malfunction. In such a case move
the glass to a warmer environment.
Sika® Aktivator PRO
Condensation on the glass does not inhibit Sika® Aktivator PRO.
Below -10 °C at least 10 minutes flash-off time must be allowed for instead of
the standard 3 minutes.
®
Adhesives
It is recommended that the adhesives are temperature soaked to above +5 °C
prior to application. With products approaching their expiry date, the higher
viscosity combined with the low temperature can cause unsatisfactory decking
or fitment, resulting in poor adhesion.
Special Weather Procedures
Sika® Primer-206 G+P
Below -10 °C at least 20 minutes flash-off time must be allowed if it is used
for bonding purposes. Tip: Warming up the primer surface with a hot air gun
until it is “touch” dry will save considerable time.
Version 1 / 2010
Hot Temperature
To avoid bubble formation in the adhesive bead, it is recommended that when
replacing the glass at air temperatures greater than +35 °C, the glass components
and vehicle’s aperture are not exposed to direct sunlight during and until the Save
Drive-Away Time have passed the process.
Another important fact is, that at higher temperatures chemical
reactions work faster, and the open times can be reduced down to
less than 5 minutes.
It is therefore essential that the windshield be installed within this
period in order to ensure a good bond between the polyurethane
adhesive and the aperture/glass. This is necessary to prevent leaks
and to guarantee customer safety.
Appendix Section
Version 1 / 2010
Version 1 / 2010
Sika Products
Sika® CleanGlass
Sika® CleanGlass has been designed for the cleaning of glass surfaces. It can also
be used for cleaning other hard, non-porous materials. Surfaces must be allowed
to dry completely before the next step in surface preparation (e.g. application of
Sika® Aktivator PRO).
Application
 Moisten a dry, clean paper tissue with the product
and wipe the entire surface until it is dry.
Or spray the product onto the surface and wipe
until it is dry using a clean paper tissue.
Dispose the paper tissue properly after each use.
If air temperature is below -5 °C, Sika® CleanGlass will freeze when
it comes in contact with the glass and it will malfunction. In such
temperatures, allow the glass to warm up in a warmer environment.
Version 1 / 2010
Sika® Cleaner S (II)
Sika® Cleaner S (II) is a cleaning paste for heavily soiled bonding substrates,
especially for windshields and glass. Sika® Cleaner S (II) can either be generally
used or applied specifically to the soiled areas only.
Application
 Apply small dots of Sika® Cleaner S (II) around the
perimeter of the bonding area.
 Use a clean, dry paper tissue and moderate
pressure to scrub Sika® Cleaner S (II) into the
contaminated area.
 Use a fresh clean, dry paper tissue to remove any
excess Sika® Cleaner S (II).
 Spray Sika® CleanGlass onto the part and wipe it
dry and clean.
After using Sika® Cleaner S (II) the part must be cleaned with
Sika® CleanGlass to remove any remaining contaminants.
Do NOT use Sika® Cleaner S (II) on porous substrates, lite foam,
tapes etc.
Version 1 / 2010
Sika® Aktivator PRO is used to give improved adhesion on glass, ceramic coated
glass, freshly cut surface of old polyurethane adhesive beads, polyurethane coated
window glass and paints. Sika® Aktivator PRO is an important process step in
the Sikaflex® and SikaTack® System, because it has been designed to ensure a
strong, durable bond between the polyurethane direct glazing adhesive and the
windshield.
Application
 Moisten a dry, clean and lint-free paper tissue or
cloth with Sika® Aktivator PRO.
 Apply the Sika® Aktivator PRO by dragging the
cloth in one direction around the perimeter of the
bonding area.
 When the cloth requires re-wetting, always
expose a clean portion of the cloth to the
Sika® Aktivator PRO can.
 Dispose off cloth properly after each use.
 Always close the Sika® Aktivator PRO can
immediately after use.
 The flash-off time for Sika® Aktivator PRO is
3 minutes at temperature between -10 °C and
+45 °C.
Sika® Aktivator PRO must NEVER be applied with a brush or dauber. Do
not use Sika® Aktivator PRO on porous substrates like foam, tapes, etc.
Used correctly, Sika® Aktivator PRO will remove small quantities of dust, oil and
other contaminants, which could cause a bond to fail. Unlike some glass cleaners
and primers, Sika® Aktivator PRO will not harm the topcoat of car finishes.
Unopened, properly-stored Sika® Aktivator PRO bottles have a 12-month shelf
life; opened bottles must be used within one month of opening or before if
contaminated.
Version 1 / 2010
Sika® Primer-206 G+P
Sika® Primer-206 G+P is a one-component, black, moisture-curing liquid primer
specifically formulated for the treatment of bond faces in direct glazing work.
It is used to give improved adhesion to glass, ceramic coated glass, paints and
other substrates such as plastics and metals and can be used to inhibit corrosion
where scratches on bare metal of the window frames become visible during the
installation process. Sika® Primer-206 G+P can also be applied on poor quality
ceramic coatings (non-uniform glass and continuous opaque, mineral-based
ceramic frit) to provide supplemental UV protection or if the ceramic frit is not
applied correctly, (no frit on the glass edges) to provide a uniform aspect to the
glass.
Application
 Before opening, shake the can vigorously until the
ball-bearing rattles and then continue for a further
10 seconds.
 Apply Sika® Primer-206 G+P, using a clean brush,
into the scratches wherever bare metal or glassreinforced plastic is visible on the window frames.
 Apply Sika® Primer-206 G+P on the glass or
window frames, when used as the bonding surface,
with a dauber in a thin even coat.
 Close both the inner liner and outer cap of the can
immediately after each use.
 Sika® Primer-206 G+P requires a longer flash of
time below +5 °C. Wait until the surface is touch
dry before proceeding to the next step.
Sika® Primer-206 G+P must NOT be used on the old polyurethane
bead as it reduces the bonding strength as compared to non-primed
interfacial adhesion. Do not dilute primers with solvents.
Unopened, properly-stored Sika® Primer-206 G+P bottles have a 9-month
shelf life; opened bottles must be used within one month of opening or before if
contaminated.
Version 1 / 2010
SikaTack® MOVEIT
SikaTack® MOVEIT is a moisture curing high performance polyurethane adhesive
designed for use in replacing bonded windshields. SikaTack® MOVEIT is best
applied with the Sika Application Gun or with a heavy duty adhesive application
gun.
®
SikaTack MOVEIT
One Component Adhesive
✓
High Initial Strength
✓
Very short cut-off string
✓
Black-primerless bonding with
✓
No heating required
✓
Open Time (at +23 °C / 50% r.h.)
8 min
Antenna Suitability
✓
Non Conductive
✓
Sika All-in One Modulus
✓
Availability
Cartridge 300 ml, Unipack
400 ml, 600 ml
Shelf Life
9 months
Recommended Safe Drive-Away Time for Passenger Car
Windshields up to 29 kg
Relative Humidity
Temperature
>-10 °C > 0 °C
>+10 °C >+20 °C >+30 °C <+45 °C
Cars without Airbags and Backlights (minutes)
> 90%
30
30
30
30
30
30
> 75%
30
30
30
30
30
30
> 50%
30
30
30
30
30
30
> 25%
30
30
30
30
30
30
> 0%
30
30
30
30
30
30
Cars with Passenger Airbag (minutes)
> 90%
60
60
60
60
60
60
> 75%
60
60
60
60
60
60
> 50%
60
60
60
60
60
60
> 25%
60
60
60
60
60
60
> 0%
60
60
60
60
60
60
Version 1 / 2010
Version 1 / 2010
SikaTack® Drive
SikaTack® Drive is a moisture curing high performance polyurethane adhesive
designed for use in replacing bonded windshields. SikaTack® Drive is best applied
with the Sika Application Gun, standard battery or air powered application gun or
hand application tool.
®
SikaTack Drive
✓
✓
✓
✓
No heating required
✓
10 min
Antenna Suitability
✓
Non Conductive
✓
✓
Availability
400 ml, 600 ml
Shelf Life
9 months
Relative Humidity
Temperature
>-10 °C > 0 °C
>+10 °C >+20 °C >+30 °C <+45 °C
> 90%
30
30
30
30
30
30
> 75%
30
30
30
30
30
30
> 50%
30
30
30
30
30
30
> 25%
30
30
30
30
30
30
> 0%
120
120
120
120
120
120
Cars with Passenger Airbag (hours)
> 90%
2
2
2
2
2
2
> 75%
2
2
2
2
2
2
> 50%
2
3
3
2
2
2
> 25%
3
4
4
3
2
2
> 0%
5
5
5
5
5
5
Version 1 / 2010
Version 1 / 2010
SikaTack® Go!
SikaTack® Go! is a moisture-curing high-performance polyurethane adhesive
designed for use in replacing bonded windshields. SikaTack® Go! is best applied
with a standard battery or air powered application gun or hand application tool.
SikaTack® Go! Offers longer open time and improved gunnability.
SikaTack® Go!
✓
✓
✓
✓
No heating required
✓
15 min
Antenna Suitability
✓
Non Conductive
✓
✓
Availability
400 ml, 600 ml
Shelf Life
9 months
Relative Humidity
Temperature
>-10 °C > 0 °C
>+10 °C >+20 °C >+30 °C <+45 °C
> 90%
60
60
60
30
30
30
> 75 %
60
60
60
30
30
30
> 50 %
60
60
60
30
30
30
> 25 %
60
60
60
60
60
60
>0%
120
120
120
120
120
120
> 90%
4
4
2
2
2
2
> 75 %
4
4
2
2
2
2
> 50 %
4
4
3
2
2
2
> 25 %
4
4
4
3
2
2
>0%
5
5
5
5
5
5
Version 1 / 2010
Version 1 / 2010
SikaTack® Go4it!
SikaTack® Go4it! is an easy to gun 4-hour windshield adhesive. It is designed to be
applied using manual handguns.
SikaTack® Go4it!
✓
✓
✓
✓
No heating required
✓
15 min
Antenna Suitability
-
Non Conductive
-
✓
Availability
400 ml, 600 ml
Shelf Life
9 months
Relative Humidity
Temperature
>-10 °C > 0 °C
>+10 °C >+20 °C >+30 °C <+45 °C
Cars without Airbags and Backlights (hours)
> 90%
NR
1
1
1
1
1
> 75%
NR
1
1
1
1
1
> 50%
NR
1
1
1
1
1
> 25%
NR
1
1
1
1
1
> 0%
NR
2
2
2
2
2
> 90%
6
6
4
4
4
4
> 75%
6
6
4
4
4
4
> 50%
6
6
4
4
4
4
> 25%
6
6
4
4
4
4
> 0%
6
6
6
6
6
6
Version 1 / 2010
Version 1 / 2010
Sikaflex®-256
Sikaflex®-256 is a moisture-curing high-performance polyurethane adhesive
designed for use in replacing bonded windshields. Sikaflex®-256 is best applied
using a standard battery or air powered application gun or hand application tool.
®
Sikaflex -S256
✓
✓
✓
✓
No heating required
✓
20 min
Antenna Suitability
✓
Non Conductive
✓
✓
Availability
400 ml, 600 ml
Shelf Life
12 months
Relative Humidity
Temperature
>-10 °C > 0 °C
>+10 °C >+20 °C >+30 °C <+45 °C
Cars without Airbags and Backlights (hours)
> 90%
NR
NR
2
1
1
1
> 75 %
NR
NR
3
1
1
1
> 50 %
NR
NR
4
2
1
1
> 25 %
NR
NR
NR
4
2
2
>0%
NR
NR
NR
6
4
4
> 90%
NR
NR
8
6
3
3
> 75 %
NR
NR
12
6
4
4
> 50 %
NR
NR
16
6
4
4
> 25 %
NR
NR
NR
8
6
6
>0%
NR
NR
NR
16
12
8
Version 1 / 2010
Version 1 / 2010
Sika Application Gun
Auto shut-off,
Auto reverse
Transparent barrel to see
material remaining
Patented reversible
plunger for best economy
(”zero waste”)
All metal gear transmission
360° rotating carriage
Powerful 2800 N
pushing force
Manual clutch release
Variable speed trigger
Trigger lock off
Speed dial to
adjust extrusion
speed
Milwaukee exclusive
reversible battery pack
Gun Configuration for Unipack and Cartridge
For Unipacks
For Cartridges
Plunger installation for unipacks is
described on following pages.
Plunger installation for
cartridges is not described in
detail in this manual.
Version 1 / 2010
Plunger Installation for Unipack
Mount supporting socket on plunger rod.
Mount steel plunger on plunger rod.
Mount blue plastic plunger with black ring
on the new combination.
Screw dome attachment on plunger rod as
shown.
Version 1 / 2010
Tighten dome attachment to 1 mm gap
between steel and plastic plunger.
This step is very important!
Insert 5/16“ screw.
Tighten inserted screw well using spanner and hex wrench.
The complete plunger for unipack should
now look like this.
Version 1 / 2010
Operation of Sika® Application Gun
Remove the Sika® Application Gun and the
Battery from the box.
fro
remove
nt
Install the battery as desired.
Press the gray button to remove
the battery.
rea
r
Push the clutch release trigger and
simultaneously pull the plunger rod hook
backwards to its extreme.
Pull back
Push
Version 1 / 2010
Insert the new unipack into the gun.
Insert
the un
ipack
Cut-off the clip that is facing the front of
the gun.
Assemble the gun by installing the
unipack adapter and nozzle, and the
sleeve nut onto the transparent barrel. In
the example the unipack adapter and the
nozzle were already mounted together.
Version 1 / 2010
Press the clutch release trigger and move
the plunger rod hook forward until the
unipack fits tightly between the plunger
and the unipack adapter. The nozzle
outlet can still be adjusted by turning the
transparent barrel.
Push
Push
Press the gun switch until the adhesive
reaches the nozzle outlet.
Version 1 / 2010
To achieve best wetting of the adhesive,
always apply the adhesive with the gun
perpendicular to the substrate.
If the bead is applied as shown in this
picture, the adhesive bead will not have the
correct geometry (height) nor good contact
between the adhesive and the substrate
and cannot be guaranteed.
Version 1 / 2010
Procedure to Change a Unipack
2
1
Press the clutch release trigger (1)
and simultaneously pull the plunger
rod hook (2) backwards. The empty
unipack will be detached from the
plunger and cap.
First remove the sleeve nut and then
force the plunger rod fast forward
to push out the adapter and the
empty unipack (adapter and empty
unipack pop off). Remove the empty
unipack and dispose off it according
to national regulations. Both the
unipack adapter and the nozzle may
be used several times.
Version 1 / 2010
Maintenance and Cleaning
The blue plastic plunger (part no. 10, page 87) needs to be regularly replaced. Different
factors (friction between plunger and barrel, viscosity of material, etc.) determine
how often this is necessary.
Sika® Lube reduces friction between the barrel and the blue plastic plunger. The life
of the plastic plunger can be dramatically prolonged by using Sika® Lube. Apply one
spray shot of Sika® Lube to the inside of the barrel each week. Press and release the
trigger quickly. For further information refer to the Sika® Lube Product Data Sheet.
Do not use alcohol or other solvents to clean the transparent barrel.
Use only Sika® Remover-208.
Once per week for a higher extrusion rate
1 SHOT ONLY!
Never use silicone-based materials, like silicone spray or oils.
This could adversely affect the adhesion as well as other properties
of the adhesive.
Battery and Charger - Use and Lifetime
The use of the battery and charger are described in detail in the Operations Manual
which comes with each Sika® Application Gun Set. Use only original batteries.
The battery life can be increased if used in alternate mode. Use one battery
completely, and then use another one while charging the first. The battery life is
expected to be approximately 1000 charging cycles, subject to compliance with
operating instructions.
Version 1 / 2010
Spare parts / Service addresses
Service and spare parts can only be obtained and purchased through Atlas
Copco/Milwaukee Service Centers (see service addresses supplied with
Sika® Application Gun Set). In order to obtain the correct repair, spare parts or
service, it is necessary to call the nearest Atlas Copco/Milwaukee Service Center.
Sika must be informed if a concentration of similar problems to those of the
Sika® Application Gun Set occur. Please send this information directly to the
following email address:
[email protected].
For a proper and smooth operation, only original spare parts must be used.
Modifications to the Sika® Application Gun that do not use Atlas Copco/Milwaukee
will invalidate the warranty.
For further details consult the following documents (provided with
Sika® Application Gun Set):
Spare part list
Atlas Copco/Milwaukee Service addresses
It is highly recommend that the following spares be kept with each
Sika® Application Gun Set at all times:
1 Spare parts kit
2 Blue plastic plungers
1 Sleeve nut
Version 1 / 2010
Legend
3
4
5
7
8
6
1
2
1
9
+ for cartridge only
*
1
2
3
4
5
6
7
10
7
11
for unipack only
12
Sleeve nut
Flange screw
Screw
Rod handle
Plunger rod
Transparent barrel
Plunger cap
8
9
10
11
12
13
13
Nozzle for cartridges
Nozzle for unipacks
Steel plunger
Plastic plunger
Screw
Unipack adapter
The plunger cap (part no. 7) is a patented Sika part. This plunger cap reduces
adhesive waste by approximately 80%.
Version 1 / 2010
Glossary of Terms
Activated Surface
A surface that has been wiped with
Sika® Aktivator PRO, where deposits of adhesion
promoters remain and which is ready for adhesiv
e bonding or a primer application. (I.e. A ceramic
coat that is wiped with Sika® Aktivator PRO,
remains activated for 8 hours).
Antenna Suitability
Automotive OEM standards specify that the
impedance of an adhesive must fall within a
specific range of values (epsilon ε). Impedance
is a compound product of the resistance,
capacitance, and frequency, and is measured
using an alternating current. When an antenna
compatible adhesive is used, it will not interfere
with radio reception on windshields with
integrated antennas.
Ceramic Coating
A black, ceramic composite applied to the
perimeter of the windshield glass for cosmetic
and protective purposes. This ceramic
composition protects the polyurethane adhesive
against harmful ultraviolet (UV) rays.
Compression
Pressure exerted on a sealant or adhesive in a
joint.
Cure Time
The time required to effect a complete cure at a
given temperature and relative humidity.
Curing conditions
The factors that influence the curing of
adhesives, e.g. temperature, relative humidity,
etc.
Direct Glazing
Where a window is bonded directly to the body
or structure of the vehicle, vessel, or building.
Encapsulated Windshields
Windshields which contain a polyurethane
profile moulding around the edges.
EPDM
A rubber material that is commonly used for
framing plastic side windows.
Version 1 / 2010
FMVSS 212/208
The Federal Motor Vehicle Safety Standard
which states that, when a vehicle travelling at
48 km per hour crashes, more than 75% of the
adhesive bond-line must be retained, whereas
no more than 50% on any one side can be lost.
Fresh-cut PUR
A cured polyurethane bead that has been freshly
cut.
Modulus
The ratio of stress to strain.
Non-Conductive Adhesive
Automotive OEM standards specify an adhesive
as non-conductive when the electrical
resistance, measured according to DIN 53482,
is greater than 108 Ω/cm for aluminium
body vehicles and greater than 109 Ω/cm for
magnesium body vehicles.
Nozzle
The plastic tip of the applicator gun from which
the bead of adhesive is extruded.
One-component
Polyurethane Adhesive
A polyurethane adhesive supplied as a single
premixed compound, which cures on exposure
to moisture.
Open Time
The maximum period of time that may elapse
between application of the adhesive and
assembly of the joint, depending on the adhesive
and environmental conditions.
Pre-Applied Adhesive
System (PAAS)
A polyurethane adhesive applied in a specific
shape by the glass manufacturer to the edge of
the glass. This can be used as a moulding and
decorative trim for flush-mounted auto glass.
Plunger
The disc-shaped component at the end of
the rod, within the Sika® Application Gun, that
pushes the material along the tubular body.
Version 1 / 2010
Polyurethane
A family of polymers, ranging from rubbery
to brittle, usually formed by the reaction of
diisocyanate with a hydroxylic compound.
Primer
A special paint coating designed to inhibit
corrosion as well as improve adhesion between
adhesives and some substrates. The contribution
made to corrosion inhibition will depend on
composition and paint thickness.
Tack-free or Skinning Time
The time between the application of the
adhesive and the formation of a skin on its
surface, after which point bonding can no longer
take place.
Tackiness
The stickiness of the surface of the sealant or
adhesive.
Ultraviolet Light
Part of the light spectrum. Ultraviolet rays cause
chemical changes in rubbery materials.
Version 1 / 2010
FAQ
A Can SikaTack® polyurethane adhesives be applied to wet surfaces?
No. Polyurethane can not be applied onto wet surfaces because a reaction with
water can cause the polyurethane to lift from the surface. All surfaces must be
dry.
B Can Sika® Aktivator PRO be used in damp conditions?
Yes, Sika® Aktivator PRO can be used in damp conditions, e.g. on windshields
with a light misting of condensation. (In this application, ‘damp’ refers to any
humid condition where larger water droplets are NOT visible, either as pooled
condensation or as spots of rain). However, it is better if the part is dried first.
C How long will primers and cleaners last after they have been opened?
All Sika cleaners and primers have a reduced shelf life when opened. With
proper storage conditions, they will remain usable up to 1 month after opening,
or until the expiration date, whichever comes first. Always tightly reseal both
the inner liner and outer cap after each use. If the product becomes thick or
cloudy, or inhomogeneous, immediately discard according to the information
provided in the Material Safety Data Sheet.
D If the open time of Sika® Aktivator PRO has passed, is it ok to perform the
activation step again?
Yes. It is OK to apply Sika® Aktivator PRO up to three times onto the bonding
surface. It is important that the surface is clean and activated. You can tell if
the surface has been activated when it has a shimmery aspect to it. If you are
uncertain it is better to re-apply Sika® Aktivator PRO.
If Sika® Aktivator PRO is applied a second time without following through with
the bonding, the activated surfaces must be cleaned with a solvent such as
Isopropanol or a glass cleaner. After that, pre-treatment of the surfaces can
start again.
Version 1 / 2010
E Why is the use of daubers with Sika® Aktivator PRO not recommended?
1. Sika® Aktivator PRO performs a cleaning function, as well as an activating
function. Application with a dauber simply moves dirt around and does not
clean it off.
2. Daubers apply too much product, which is unnecessary and wasteful.
3. They can become dirty and contaminate the activator if they are dipped in the
bottle several times.
4. It is difficult to cover the required area using daubers.
F Why is the use of daubers recommended for Sika® Primer-206 G+P, when
applied to clear glass, but only brushes recommended for scratches on
the flange?
Many prefer using the daubers for Sika® Primer-206 G+P when it is applied
as the bonding surface, because of the smooth uniform application. It is
recommended that a brush is used when covering scratches, because it is
important that the product is applied INTO the scratch. Some installers find
that the use of cotton buds sticks or Q-tips is also effective to apply Sika®
Primer-206 G+P to the scratches in the flange.
G Why does Sika® Primer-206 G+P need to be shaken?
Shaking primers mixes the solids that may have settled at the bottom of the
bottle and ensures a thin, uniform mixture and coverage. All manufacturer's
primers containing solids should be shaken before use.
H Why is it not recommended to apply Sika® Primer-206 G+P onto the old
PUR bead?
Cured Sika® Primer-206 G+P forms a rigid layer, which if incorporated between
two soft layers (the old PUR bead and the new PUR) reduces the strength of the
bond. If performing scratch treatment, it is acceptable if a small area of the old
PUR bead comes into contact with Sika® Primer-206 G+P, but it must never be
applied to large areas of old PUR bead.
Version 1 / 2010
I What happens if the recommended flash-off time of the pre-treatment
products is not adhered to?
In addition to bonding products, pre-treatment products also require time to
react. For example, a primer is like a diluted adhesive that also requires
moisture for curing to occur. If the pre-treatment product is not allowed to
fully react, it can reduce the bond strength of the system and in the worst
case, the bond may fail. Lower temperatures increase the flash-off time of
Sika® Primer-206 G+P.
J Cutting out a windshield has revealed that the old PUR bead contained
a bubble between the adhesive and the windshield. How can this be
prevented?
This is known as ‘Tunneling’ which, in most cases, is caused by errors by the
technician. When the adhesive is applied, ensure that the nozzle is at a right
angle to and is in contact with the substrate. Always apply a triangular bead so
that when compressed no air is trapped.
K Having cut out a windshield, the old PUR bead contained lots of small
bubbles in the adhesive bead. How can this be prevented?
The PUR adhesive releases carbon dioxide while curing. If the adhesive bead
is heated during curing, the gas is released more quickly which can result in
small bubbles dispersed throughout the bead. This can happen if the car is
parked with the windshield exposed to sunlight on a warm day. Parking the car
in the shade will prevent this problem.
L Are there any aggressive components in Sika® Aktivator PRO or
Sika® Primer-206 G+P that could attack surfaces?
Sika® Aktivator PRO and Sika® Primer-206 G+P contain reactive components
which react chemically with glass, paint and other materials. Once cured, they
can only be removed mechanically and the upper layer of the substrate is
damaged in the process. Care must be taken to apply Sika® Aktivator PRO only
to the required areas. If the product is applied to the transparent area of the
glass, it will be visible and the customer will have cause for complaint.
Version 1 / 2010
M What happens if too thick a layer of Sika® Primer-206 G+P is applied?
Applying a thick layer of Sika® Primer-206 G+P results in a longer flash-off
time. But if applied as corrosion protection on bare metal it is recommended
that two thick layers of Sika® Primer-206 G+P be applied for long lasting
protection.
N Is there a product for cleaning Sika® Primer-206 G+P from Interior parts?
Sika® Primer-206 G+P can be cleaned using Sika® Remover-208 or
Sika® HandClean Tissues as long as it has not cured completely. Once cured, it
must be removed mechanically.
O What is the minimum temperature to perform a replacement job?
Sika’s products are intended for use at temperatures between +5 °C and
+35 °C. For all other conditions Sika has special hot and cold weather
recommendations. While a job can be carried out at -10 °C, there is a question
of adequate dexterity with cold hands. It may be too cold to carry out the job to
a suitable professional standard. In this case, the job should be deferred.
Version 1 / 2010
Version 1 / 2010
Technician Training Test
Please indicate whether each statement is true or false
1 When preparing the glass using Sika® Aktivator PRO (orange cap) at a
temperature of -5 °C, there are special low temperature requirements to
be considered.
❒ true
❒ false
2 A complete adhesive removal is required if the bonded window was
installed using a non-urethane adhesive.
❒ true
❒ false
3 There is no reason to worry about scratching the paint of a vehicle
because Sika® Primer-206 G+P (black cap) can be used to restore the
corrosion protection system back to OEM level.
❒ true
❒ false
4 It is acceptable to apply Sika® Primer-206 G+P over rust.
❒ true
❒ false
5 SikaTack® Drive is rated non-conductive and antenna compatible.
❒ true
❒ false
6 A bonded window that was previously installed using a silicone adhesive
can be reinstalled if properly prepared using Sika® Aktivator PRO.
❒ true
❒ false
7 Glass that has been prepared properly using Sika® Aktivator PRO (orange
cap) can be installed 8 hours after the Sika® Aktivator PRO’s application.
❒ true
❒ false
8 A higher modulus urethane may be considered to be stiffer than a
conventional urethane with normal modulus.
❒ true
❒ false
Version 1 / 2010
9 If a 250 ml can of Sika® Aktivator PRO (orange cap) expires 8 months
from today but the can is opened today, it can be used for the intervening
months or until it becomes cloudy.
❒ true
❒ false
10 The full-cut method requires trimming the existing bead of urethane to a
height of:
❒ 0.5 to 1.2 cm.
❒ 0.5 to 2 mm.
❒ 1 to 2 cm.
11 The factors affecting safe drive-away time are
❒ when the customer wants their car put back into service.
❒ temperature, humidity and presence of passenger side airbag.
❒ following the proper application procedure specified by the adhesive
manufacturer.
12 One reason to apply Sika® Primer-206 G+P (black-cap) around the
aperture of a vehicle is to:
❒ Provide a UV barrier for the paint of the vehicle.
❒ Provide coverage for bare metal in order to reduce future corrosion.
❒ To cover the existing urethane bead for improved adhesion.
13 When installing a gasket set windshield the preparation of the gasket
requires
❒ removal of contaminants from within both slots of the gasket using
Sika® Primer-206 G+P and allow to dry for 10 minutes. Then apply
Sika® Aktivator PRO per normal application procedure and allow to cure
for 15 minutes.
❒ removal of contaminants from within both slots of the gasket using a towel,
water or an approved glass cleaner for additional cleaning power. After drying
completely, apply Sika® Aktivator PRO to both slots and allow a minimum of
15 minutes before proceeding.
❒ removal of contaminants from within both sides of the gasket using
compressed air. Do not apply any form of liquid in case of rubber
contamination.
Version 1 / 2010
14 When applying Sika® Aktivator PRO (orange cap) to the windshield it is
critical to
❒ apply in one direction to avoid spreading contaminants.
❒ apply Sika® Aktivator PRO only to the ceramic band or bonding area as it will
leave a visible residue on the glass.
❒ only use the product between +5 °C and +35 °C and do a wipe off step after
the application.
15Any glass cleaner is acceptable to use as long as
❒ there is no alcohol or ammonia within the product.
❒ the glass cleaner has no odor or fragrance.
❒ the glass cleaner does not contain anti-static ingredients.
16Which of the following Sika products are not rated non-conductive and
antenna compatible?
❒ SikaTack® Drive ❒ SikaTack® MOVEIT
❒ Sikaflex®-256
17The shelf life of a 250 ml can of Sika® Aktivator PRO is
❒ 9 months.
❒ 6 months.
❒12 months.
18The reason for applying a triangular bead using a V cut nozzle is
❒ to prevent air from being trapped between the adhesive bead and the glass.
❒ to prevent adhesive from skinning over too quickly.
❒ to provide OEM appearance.
19The shortcut method of removing existing urethane should not be used
because
❒ it won’t allow enough time for the new urethane system to reach its SDAT
strength.
❒ it doesn’t provide a bondable surface for the new urethane.
❒ it doesn’t provide enough space for the proper amount of new urethane to be
applied which is required for a safe installation.
Version 1 / 2010
20The proper procedure for cleaning around a dirty aperture is to
❒ remove loose debris using a towel and water or glass cleaner or oil-free
compressed air if necessary. For heavy cleaning Sika® Aktivator PRO can be
used. Then trim the existing urethane bead.
❒ blow out loose debris after trimming urethane to ensure all contaminants are
removed. If additional cleaning is required use Sika® Aktivator PRO.
❒ remove loose debris prior to trimming the bead. After trimming the existing
urethane bead, clean the opening with any type of solvent.
21The procedure to use when installing a window with a Pre-Applied
Adhesive System (PAAS) is to
❒ apply Sika® Primer-206 G+P to the bonding surfaces of the pre-applied
adhesive following normal application procedures.
❒ just clean the surface with the glass cleaner and apply the adhesive.
❒ apply Sika® Aktivator PRO to the bonding surfaces of the pre-applied adhesive
following normal application procedures as for other glass parts.
22To maximize shelf life, Sika urethanes should be stored
❒ at temperature above +25 °C.
❒ at temperature below +25 °C.
❒ it doesn’t matter, Sika urethanes are usable for 9 months no matter what the
storage conditions are.
23The shelf life of Sika® Primer-206 G+P (black cap) in 250 ml cans is
❒ 6 months.
❒ 9 months. ❒ 12 months.
24When applying Sika® Primer-206 G+P (black cap) at temperatures
below +5 °C
❒ confirm the dryness of the primer by touching a non-bonding area with a clean
nitrile-glove. It may take up to 25 minutes to dry.
❒ dry the primer with a heat gun and test with a nitrile glove to assure that it is
dry.
❒ Lightly spray wet primer surfaces with warm water to speed up the crosslinking of the urethane polymer that is in the primer.
Version 1 / 2010
25When applying the V bead to the aperture or glass, the height of the bead
should
❒ exceed the roofline by 1 cm.
❒ not exceed the pre-cut dimensions of the provided Sika nozzle.
❒ match the height of the vehicle’s roofline.
26Level 3 corrosion can best be characterized by which of the following
descriptions:
❒ Moderate corrosion which typically has some red spots.
❒ Identified by deep pitting, dark red spots and raised edges.
❒ Varies from microscopic holes to loss of metal.
27It is acceptable to treat up to 150 cm2 of corrosion around the aperture
using the following procedures, assuming that the corrosion has not
perforated the metal.
❒ Remove all corrosion, abrade the paint edges, apply Sika® Aktivator PRO
and then one coat of Sika® Primer-206 G+P (black cap) according the
recommended application procedure.
❒ Remove all corrosion, abrade the paint edges, apply Sika® Aktivator PRO and
then one coat of Sika® Primer-215 according the recommended application
procedure.
❒ Remove all corrosion, abrade the paint edges, apply Sika® Aktivator PRO
and then two coats of Sika® Primer-206 G+P according the recommended
application procedure.
28Under which of the following circumstances may a removed window be
reinstalled using Sika’ AGR adhesive system?
❒ The adhesive that remains on the glass is polyurethane and does not have
good adhesion around the entire perimeter.
❒ The adhesive that remains on the glass has good adhesion around the
perimeter, but it cannot be confirmed that it is a polyurethane.
❒ The adhesive that remains on the glass is a polyurethane that has good
adhesion to the entire perimeter.
Version 1 / 2010
29The reason for using a paper towel and rotating it to the clean side when
re-applying Sika® Aktivator PRO from a can is
❒ to guarantee proper coverage and thickness of application that only a paper
towel can provide.
❒ to avoid allowing contaminants from the towel to mix with the contents of the
can.
❒ to avoid over usage of product through use of daubers.
30Windshields that are supplied pre-primed with a factory applied blackprimer can be installed
❒ if prepared with an additional coat of Sika® Primer-206 G+P.
❒ by removing the primer down from the frit and applying Sika® Aktivator PRO.
❒ by preparing with glass cleaner and Sika® Aktivator PRO just as if the part was
not pre-primed.
31The installation of used glass is not allowed when using any Sika AGR
adhesive system because
❒ the part is of unknown origin and the age and brand of the glass may not be
identifiable, voiding its acceptability.
❒ the part is of unknown origin and the conditions of the glass edge cannot be
determined to assure a bondable surface.
❒ the part is of unknown origin and only glass parts that are new and provided
through approved AGR distributors are considered eligible for use with Sika
AGR adhesive systems.
32In order to validate that any of the Sika re-sealable cans of activators and
primers are being used within their defined open shelf-life of 1 month,
technicians should:
❒ Make sure that purchase orders and invoices are available to review the dates
when the products were purchased.
❒ Make sure they understand and are able to identify the shelf life listed on the
label of the product.
❒ Make sure that the date opened is marked either on the bottom of the can or
on the label.
Version 1 / 2010
Version 1 / 2010
Notes
Version 1 / 2010
Notes
Version 1 / 2010
Notes
Sika
Worldwide
Sika is a globally active company supplying the specialty chemical markets. It is a leader in processing materials used in sealing,
bonding, damping, reinforcing and protecting load-bearing structures in construction (buildings and infrastructure construction) and
in industry (vehicle, building component and equipment production).
/1010
Sika’s product lines feature high-quality concrete admixtures, specialty mortars, sealants and adhesives, damping and reinforcing
materials, structural strengthening systems, industrial flooring and membranes. Subsidiaries in more than 70 countries worldwide
and approximately 12,900 employees link customers directly to Sika.
Our most current General Sales Conditions shall apply. Please consult the
most current local Product Data Sheet prior to any use.
www.sika.com

Sika Technicians` Handbook for Passenger Car Glass Replacement

Transcription

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