HAIMA M3 Series Istruzioni operative
Body Repair Manual
M3 Series
Warning
Warning
The repair works of the vehicle are dangerous. The repair personnel not receiving the related vehicle
repair training will probably cause repair failure or even loss of properties and personal injuries. Only the
technical personnel receiving the related vehicle repair training and having actual repair experiences are
allowed for repair works.
The repair procedures contained in this manual, including parts “Warning” and “Caution”, are prepared
by technical training personnel of Haima Automobile Co., Ltd. Before the repair operations, the repair
personnel shall carefully read this manual to understand general safety procedures. The technical personnel
shall abide by the “Warnings” and “Cautions” to reduce the injury hazard and the possibility of vehicle
damage and potential safety problems arising from the improper repairs and services. It’s of equal importance
that it should be understood that the “Warnings” and “Cautions” do not include everything and are impossible
to warn all hazardous consequences arising from the violations of the operation procedures.
The repair recommendations and related procedures contained in this manual are the effective service
and repair methods. Some repair operations require the use of special tools. The personnel using the
procedures or tools not recommended by HaimaAutomobile must take cautions to guarantee the safety of
personnel and vehicle.
The genuine Haima Automobile parts or the parts designated by HaimaAutomobile shall be used during
replacement of parts. Haima Automobile will not be liable for any problem arising from the following factors:
Insufficient training, improper use of tools, use of non-genuine HaimaAutomobile parts or parts other than
those designated by Haima Automobile, and the negligence of revisions to this manual. The factors are not
limited to the above mentioned ones.
Haima Automobile reserves the right to change the design of the vehicle and contents of this manual
without prior notice to the users and will not be liable for any consequence thereof.
Overview I-1
Preface
This repair manual is intended for the use of technical personnel of Haima Automobile authorized
dealers, in order to help their repairs and maintenances of Haima M3 series vehicles. For the owner and driver
of Haima vehicles, this manual is also helpful for the vehicle repair and maintenance works within own
competency.
Understanding this manual is of great importance for correct repairs and maintenances of the vehicle.
Please always carry this manual with you to obtain reference information in a fast and convenient manner.
The contents contained in this manual, including graphs and technical specifications, are the latest data
available at the preparation of this manual. When the changes in some contents influence the repairs and
maintenances of the vehicle, please obtain the supplemental data of related parts from the dealers of Haima
Automobile. This manual shall be kept updated frequently.
Haima Automobile reserves the right to change the technical specifications and contents of this manual
without prior notice and will not be liable for any consequence thereof.
The copyright of this manual is reserved. Without prior written consent, no part of this manual can be
duplicated or used in any form, including photocopy, recording, and information storage and searching
system.
HAIMA CAR CO., LTD.
Henan, China
Contents
Name Chapter
Overview Ⅰ
Sizes Ⅱ
Structure Ⅲ
Replacement of Panels Ⅳ
Water-Proof and Rust-Proof Treatment Ⅴ
Overview I-2
Chapter 1 Overview
How to use this manual
Effective replacement of body sheet metal parts
The contents of this chapter include the welding
type, number of welds, and shearing-cutting
locations for the body sheet metal parts. This
information is of great importance for the
disassembly and installation of the sheet metal
parts.
The welding types and locations are indicated by
symbols.
The relevant operation precautions are given in
some sections. Please carefully read and
understand these precautions before any operation
procedure.
Note
The number of welds at asterisk (A) varies depending on different shearing-connecting locations.
When the drilling is required during the installation of new parts, take cautions not to completely drill
through the sheet metal parts.
Symbol
The following 6 symbols are used to indicate the welding types during the replacement of body sheet metal
parts.
Symbol Meaning Symbol Meaning
Spot welding Continuous MIG welding
(shearing-connecting location)
CO2 gas shielded arc welding (plug
welding) Braze welding
CO2 spot welding Rough shearing location
Overview I-2
Body sizes
Planar sizes
The planer sizes refer to the sizes measured from certain reference points projected onto certain plane.
The standard points and sizes are symmetric with respect to the body center, unless otherwise explicitly
specified.
The imaginary lines are different for different vehicle models.
Example:
Z=0 plane is the plane that passes through the rotation center of rear suspension torsion beam (under no-load
condition) and parallels with the lower plane of floor longitudinal beam.
Point symbol Name Hole diameter or nut size mm (in)
A Front anti-collision beam datum hole Ø15(0.59)
B Front body main datum hole Ø25(0.98)
C Front suspension mounting hole Ø86.6(3.41)
D Front beam mounting hole M14(0.55)
E Front beam mounting hole M14(0.55)
F Front body secondary datum hole Ø20(0.79)
G Rear longitudinal beam main datum hole Ø13(0.51)
H Rear longitudinal beam secondary datum hole Ø25(0.98)
I Rear beam datum hole Ø20(0.79)
Overview I-3
Linear Sizes
The linear sizes refer to the actual sizes between
two standard points.
The standard points and sizes are symmetric with
respect to the center of the vehicle, unless
otherwise specified.
Example:
The sizes are different between left and
right sides with respect to center of vehicle.
Symbol
The following 8 symbols are used to indicate standard points.
Symbol Meaning Symbol Meaning
Center of round hole Port and gap of steel plates
Center of elliptical hole Bolt pin
Edge of hole Center of rectangular hole
Groove Edge of rectangular hole
Overview I-4
Repair Precautions
Layout of workshop
The layout of workshop is of great importance to
the safety and working efficiency.
Protection of vehicle
Use the seat and floor covers.
Use the insulation shield, in order to prevent the
heat and spark from damaging the glasses and
seats during welding.
Protect the accessories including trims and
insertion strips during welding.
Use of Traction Apparatus
When a traction apparatus is used, the working
personnel shall keep away from the working zone
and take cautions in suing the safety cable.
Precautions
During working, wear safety helmet and safety
protective shoes to prevent injuries. Wear protective
articles depending on the working characteristics,
including gloves, protective goggles, earplugs, and
mask.
Welding
goggles
Dust-proof
mask
Earplug
Safety goggles
Welding gloves
Mask
Cotton gloves
Protective shoes
Guard against short-circuit
While disassembling the wires or electric
apparatus, disconnect the negative cable of
battery.
Removal of hazardous articles
Within the area using open fire, move away the
fuel tank and plug the connecting pipes of the
fuel tank, in order to prevent fuel leakage.
Overview I-5
Efficient Replacement of Body Panels
Efficient disassembly of body panels
Measurement of body
Before the disassembly or rough cutting, firstly
measure the damaged body portions and their
surroundings as per the standard reference sizes.
Upon detection of deformation, conduct initial
correction with frame repair device.
Guard against body deformation
Disassemble with fixtures or jack and reinforce
the portions to be roughly cut and their
surroundings, in order to prevent body
deformation.
Selection of cutting and welding portions
For the parts impossible for complete
replacement, adopt the cutting and welding
methods and operate with cautions. To cut the
portions without reinforcement ribs, select the
locations yielding to minimum welding
deformation for cutting.
Disassembly of connected parts
While disassembling the connected parts, protect
the insertion strips, trims, and parts with pipes.
Rough cutting of damaged panels
Ensure that there is no damaged part due to heat
near or in the opposite side of this part. (such as
pipe hoses and wire harnesses)
Leave overlapping parts of 30~50mm
(1.18~1.97in) at the cutting and connecting
portions and then roughly cut the damaged body
panels.
Overview I-6
Installation Preparations
Use of welding primer
To prevent corrosion, remove the paint, grease
and other substances from new parts and welding
portions and then apply welding primer.
Determination of welding methods
If the overall thickness of weld points is higher
than or equals to 3mm(0.12in), adopt CO2
shielded welding for rivet welding.
Drilling for CO2 shielded welding
For the locations in which the spot welding can’t
be adopted, drill a hole with drilling machine or
hand-held drilling machine for CO2 shielded
welding.
mm {in}
Panel thickness Hole diameter
0.60-0.90{0.02-0.03} 5{0.19}
0.91-1.20{0.04-0.05} 6{0.23}
1.21-1.80{0.051-0.07} 8{0.31}
1.81-4.50{0.071-0.017} 10{0.39}
Grind the hatched portion shown in the figure below,
drill a hole on 3~4 pieces of metal panels stacked
together, and weld tightly together these metal
panels, in order to eliminate the further development
of gap.
Rough Cutting of New Parts
For cutting and splicing portions, leave
overlapping parts of 30~50mm {1.18~1.97in} on
the body side and then roughly cut the new parts.
Overview I-7
Efficient Installation of Body Panels
Observation and checking of pre-welding sizes
Adjust the standard sizes as per the body size
descriptions and install new parts to correct
positions.
Welding precautions
Precautions for spot welding
The shape of welding head of the spot welding
machine shall be fabricated as per D=(2×t)+3. In
even of different thickness between upper steel
plate and lower steel plate, the thinner steel plate
shall prevail.
As the shape of welding head of the spot welding
machine influences the welding strength, always
maintain the welding head under best status.
The spot welding points shall be staggered from
the original welds.
Before the welding, use a material same with that
of the body for a welding test, in order to inspect
the welding strength.
Indice
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