Aegis 2000 User manual

Windshield Repair
System
Kit 2000
Instruction
CONTENTS
FOR CUSTOMER ASSISTANCE………………………………………………..……..Inside Front Cover
LIMITED WARRANTY INFORMATION………………………………………….…….Inside Front Cover
INTRODUCTION TO YOUR QUICKSILVER TECHNOLOGY™SYSTEM
Welcome to the System………………………………………………………...1
Learning the to Use AEGIS®Equipment.……………………………………..2
AEGIS®Training Seminar………………………………………………………2
Types of Windshield Breaks……………………………………………………3
General Repair Guidelines……………………………………………………..4
Your AEGIS®QuickSilver Technology™ Equipment………………………..6
How the AEGIS®QuickSilver Technology™ Repair System Works………11
MAKING REPAIRS
Repair Procedure………………………………………………………………..12
Preparing the Windshield………………………………………………………13
Which Resin to Use……………………………………………………………..13
Setting Up Your Repair Fixture………………………………………………...14
Preparing the Injection Chamber………………………………………………16
Primary Dry Vacuum Cycle…………………………………………………….17
Initial Pressure Cycle……………………………………………………………18
Secondary Vacuum Cycle………………………………………………………18
Final Pressure Cycle…………………………………………………………….19
Curing the Resin…………………………………………………………………19
Finishing the Repair Process…………………………………………………..20
SPECIAL TECHNIQUES
Drilling Techniques………………………………………………………………21
Pit Filling………………………………………………………………………….24
Repairing Cracks………………………………………………………………...25
Advanced Techniques for Difficult Breaks…………………………………….26
TROUBLESHOOTING GUIDE
Problems and Solutions………………………………………………………...28
MAINTENANCE
Maintenance Schedule………………………………………………………….34
Replacement Parts……………………………………………………………...36
Save These Instructions

By Phone:
US/Canada: 888.247.6000
International: 608.274.9254
By Internet:
Website: www.aegistools.com
e-mail: [email protected]m
By Fax: [phone]
By Mail:
Letters: PO Box 259688, Madison, WI 53725-9688 USA
Packages: 2810 Syene Road, Madison, WI 53713 USA
Please provide the following information when you contact us: model number, serial number
(if applicable), date of purchase, your complete mailing address including zip code, your day-
time telephone number including area code and a description of the problem.
FOR CUSTOMER ASSISTANCE
LIMITED WARRANTY
What Does This Warranty Cover? Products manufactured by Aegis Tools International®are expressly warranted
to be free from defects in material and workmanship.
How Long Does The Coverage Last? Items covered by this expressed warranty are covered for one year from
the date of delivery. Parts and products not manufactured by Aegis®are covered by the warranty of the original
manufacturer. For additional information concerning parts or products not manufactured by Aegis®, you may con-
tact Customer Service. Service work and repairs performed at Aegis®are warranted for six months from the date of
repair.
What Will Aegis Tools International®Do? Seller’s exclusive obligation under this warranty is to repair the defec-
tive item or replace it, at Aegis’®option, without charge, provided the defective item is returned no later than 30
days after the end of the applicable warranty period. Aegis®reserves the right to use new, reconditioned or used
parts in performing warranty work.
What Does This Warranty Not Cover? This warranty is non-transferable. This warranty is void if the item has
been repaired, damaged, or modified by anyone other than Aegis®or has been damaged as a result of vandalism,
acts of God, misuse or abuse. This warranty does not cover normal wear and tear or damage caused by shipment.
How Do You Get Service? In order to be eligible for service under this warranty you must call Aegis®Customer
Service at 888.247.6000 or 608.274.9254 to get a return authorization number. Return the complete product with a
copy of the original purchase receipt and return authorization number, freight pre-paid and insured to Aegis®. Ae-
gis®will pre-pay return freight on warranty service. Return authorization numbers expire 30 calendar days after
issue.
Your Rights Under State Law: This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING IMPLIED
WARRANTIES OF MERCHANTIBILITY OF FITNESS FOR PARTICULAR PURPOSE ARE DISCLAIMED. IN NO
EVENT SHALL AEGIS TOOLS INTERNATIONAL®BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSE-
QUENTIAL DAMAGES, INCLUDING LOSS OF PROFITS.
This statement supersedes all previously published expressed warranties.
LIMITED WARRANTY
What Does This Warranty Cover? Products manufactured by Aegis Tools International®are expressly warranted
to be free from defects in material and workmanship.
How Long Does The Coverage Last? Items covered by this expressed warranty are covered for one year from
the date of delivery. Parts and products not manufactured by Aegis®are covered by the warranty of the original
manufacturer. For additional information concerning parts or products not manufactured by Aegis®, you may con-
tact Customer Service. Service work and repairs performed at Aegis®are warranted for six months from the date of
repair.
What Will Aegis Tools International®Do? Seller’s exclusive obligation under this warranty is to repair the defec-
tive item or replace it, at Aegis’®option, without charge, provided the defective item is returned no later than 30
days after the end of the applicable warranty period. Aegis®reserves the right to use new, reconditioned or used
parts in performing warranty work.
What Does This Warranty Not Cover? This warranty is non-transferable. This warranty is void if the item has
been repaired, damaged, or modified by anyone other than Aegis®or has been damaged as a result of vandalism,
acts of God, misuse or abuse. This warranty does not cover normal wear and tear or damage caused by shipment.
How Do You Get Service? In order to be eligible for service under this warranty you must call Aegis®Customer
Service at 888.247.6000 or 608.274.9254 to get a return authorization number. Return the complete product with a
copy of the original purchase receipt and return authorization number, freight pre-paid and insured to Aegis®. Ae-
gis®will pre-pay return freight on warranty service. Return authorization numbers expire 30 calendar days after
issue.
Your Rights Under State Law: This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING IMPLIED
WARRANTIES OF MERCHANTIBILITY OF FITNESS FOR PARTICULAR PURPOSE ARE DISCLAIMED. IN NO
EVENT SHALL AEGIS TOOLS INTERNATIONAL®BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSE-
QUENTIAL DAMAGES, INCLUDING LOSS OF PROFITS.
This statement supersedes all previously published expressed warranties.
FOR CUSTOMER ASSISTANCE
QuickSilver Technology™ is a trademark of AEGIS Tools International®, Inc. The device is patented under
United States Patent 6,485,281 and United States Patent 6,663,371.

Welcome to AEGIS®
Congratulations on your purchase of AEGIS®windshield repair equip-
ment! Your AEGIS®windshield repair equipment was designed and
manufactured by auto glass professionals for use by professionals.
Please read these instructions thoroughly before attempting to repair a
customer’s windshield.
PLEASE REVIEW AND FOLLOW THESE INSTRUCTIONS BE-
FORE ATTEMPTING A REPAIR ON A CUSTOMER’S VEHICLE.
Before doing any actual customer repairs please: READ ALL
INSTRUCTIONS and practice. We recommend repairing at least 6 breaks before
working on a customer’s windshield. Remember to wear eye protection, gloves
and protective clothing to prevent exposure to adhesives.
Disclaimer: AEGIS Tools International®, Inc., its principals and suppliers are
not responsible for damages resulting from misuse of this equipment.
THE WINDSHIELD REPAIR PROFESSION
To be successful at windshield repair, you need professional equipment, experience using your equip-
ment and a good understanding of the best practices in the industry. In the United States, windshield
repair professionals have the benefit of a voluntary standard that outlines proper procedures and prac-
tices. The standard, known as the Repair of Laminated Automotive Glass Standard (ROLAGS), was
approved in 2007 by the American National Standard Institute (ANSI).
The ROLAGS standard was developed by the National Glass Association (NGA) and the National
Windshield Repair Association (NWRA), two trade organizations in the automotive glass and windshield
repair industries. You can review and download the standard at www.rolags.com.
The guidelines and instructions for AEGIS®Windshield Repair equipment are intended to be compliant
and consistent with the ROLAGS standard. Our manual is updated and printed as needed to ensure
that it reflects the ROLAGS standard at the time of purchase. Since revisions to ROLAGS may have
occurred since purchasing your kit, it is best to check the ROLAGS website or www.aegistools.com for
the most up-to-date information.
The NWRA also administers a program to certify repair technicians who demonstrate proficiency and
compliance with ROLAGS. Information on NWRA certification is contained in your kit.
Introduction to the QuickSilver Technology™ System
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5/19/2011
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LEARNING TO USE AEGIS®EQUIPMENT
While operating AEGIS® Windshield Repair equipment is not difficult, practice is required to become proficient.
The more you practice, you will learn each break is unique, and certain techniques yield better results on some
breaks than others.
For best results, follow these steps:
Get a scrap windshield and make several breaks with an AEGIS®Hook Tool (TLS2526).
Let the breaks stabilize 24 hours.
Review this manual.
 Repair the breaks according to the “Making Repairs” instructions in this manual before working on a cus-
tomer’s windshield.
If problems or questions arise, see the “Troubleshooting Guide” in this manual. If you do not find the solution,
contact AEGIS®. Our technical support staff is available 8 am to 4 pm CST, Monday through Friday.
AEGIS®TRAINING SEMINAR
Most AEGIS®users are self-trained, but training is available for those who want it. AEGIS®offers a compli-
mentary, hands-on windshield repair training at our Madison, Wisconsin headquarters. In a one-day, compre-
hensive session, you will learn from our experts how to perform repairs and care for your equipment. You only
pay for your travel and related expenses. However, for a fee, an AEGIS®trainer can conduct a seminar at your
location. Please contact us directly for more information about AEGIS®training seminars.
WINDSHIELD REPAIR SCIENCE
The windshield repair process involves evacuating trapped air, moisture and debris from a break using a vac-
uum, then using pressure to fill the damaged area with adhesive. The process permanently prevents the dam-
age from spreading and greatly improves the appearance of the break.
About Laminated Glass
Laminated glass is used in windshields and some side windows (sidelites) because it holds together when
shattered. Laminated glass consists of a polyvinyl butyral (PVB) interlayer bonding two layers of glass (lites).
The PVB layer is also called the laminate.
To view a 5-minute video of how windshields are made, go to the following web address:
http://www.youtube.com/watch?v=fg3moEI9V5g&feature=channel_page
Only laminated glass can be repaired. Back windows (backlites) and most sidelites are made of tempered
glass. Tempered glass shatters into small pieces when broken and cannot be repaired.
You will be able to repair a break in the outer layer of glass as long as it does not penetrate the PVB. When a
break damages the PVB (causing a foggy or
cloudy appearance) or affects the inside layer of glass,
the windshield should be re- placed.
Introduction to the QuickSilver Technology™ System
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5/19/2011
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Any type of break in a windshield is called damage. Damage
can occur from the impact of an object or from stress on a
windshield caused by twisting or improper installation. The lo-
cation where a windshield is struck by an object is called the
impact point. Stress damage typically does not have an iden-
tifiable impact point.
There are four common categories of breaks. Although no
two breaks are ever exactly the same, most breaks will fit into
one of these four categories.
BULL’S EYE BREAK
A bull’s eye break will have a small impact point and a circu-
lar air-gap surrounding it.
This type of break is generally quick and easy to repair. A
properly repaired bull’s eye break will leave only a slightly visi-
ble pit at the impact point where the surface of the glass was
damaged or missing.
STAR BREAK
A star break has cracks of varying lengths and widths radiat-
ing from a center impact point.
This type of break will spread very easily from temperature
changes or stress placed on the glass. The star break is a more
difficult break to repair. A properly repaired star break will leave
a skeleton outline of the cracks and a slightly visible pit at the
impact point where the surface of the glass was damaged or
missing.
CRACK
A crack is a single line of separation in the outer layer of
glass with a microscopic gap. A crack may extend from an im-
pact point and sometimes will not penetrate the outer surface of
the glass. A crack is a more difficult break to repair. Even a
properly repaired crack will remain visible from the head-on
view. Instructions for crack repair will be covered in the
“Special Techniques” section of this manual.
COMBINATION BREAK
A combination break includes two or more of the break types
described above. The most common type of break is a combi-
nation of a bull’s eye break and star break. Combination
breaks can be filled very effectively, although the repaired
break will remain more visible than a bull’s eye.
TYPES OF WINDSHIELD BREAKS
TYPES OF WINDSHIELD BREAKS
Star Break
Crack
Combination
Bull’s Eye
Introduction to the QuickSilver Technology™ System
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GENERAL REPAIR GUIDELINES
With your AEGIS®windshield repair equipment, you will be able to repair most, but not all, windshield breaks.
It is important that you analyze each break before beginning the repair process. Although there are no laws
regulating windshield repair in most countries, some states and countries require vehicle inspections. In these
locations, inspectors may have the authority to reject a windshield if they consider it unsafe.
The break size, condition and location should all be considered when evaluating the repairability of a break.
LOCATION
The Driver’s Primary Viewing Area (DVPA) is an area on the windshield approximately 12 inches wide (or
30.5 cm), from the top to the bottom of the wiper sweep centered directly in front of the driver.
ROLAGS allows repairs to be done in the DPVA depending on the size of the break. Refer to the table below
for size limitations. More than one repair is allowed in the DPVA as long as they are not closer than 4 inches to
each other.
However, AEGIS®does not recommend repairing damage in the DPVA; AEGIS®has always recom-
mended replacement as the best option in these instances due to customer acceptance and to prevent any pos-
sible effects on vision, especially at night.
SIZE
There are recommended limits on the size and type of damage that should be repaired. While it is possible to
repair larger damage, the structural integrity of the repaired glass may suffer. In addition, larger repairs will show
more evidence of the original damage and may not meet your customer’s expectations. The time it will take to
complete the larger repair may also be a deciding factor. ROLAGS size limits are:
*AEGIS® recommends 1.5 inches/ 3.8 cm diameter, including all legs.
*AEGIS® does not recommend repairs in the DPVA.
***AEGIS® recommends 6 inches/ 15.2 cm.
NOTE: It is to your advantage to know the regulations pertaining to vehicle inspection and wind-
shield damage in your area.
Type of Break Size Limit
Bull’s eye/Half Moon 1”/ 2.5 cm in diameter
Star Break/Combination Break
Outside DPVA 2”/ 5 cm in diameter, including all legs*
Inside DPVA 1”/ 2.5 cm in diameter**
Cracks
Outside DPVA 14”/ 35.6 cm long***
Inside DPVA 1”/ 2.5 cm long**
Surface Pit
Outside DPVA 1/8”/ 3 mm diameter, 3/8”/ 1 cm depth
Inside DPVA 3/16”/ 5 mm diameter**
Introduction to the QuickSilver Technology™ System
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CONDITION OF THE BREAK
Repairs should NOT be made in the following situations:
 The damage penetrates both the inner and outer lites;
 There are 3 or more long cracks extending from the impact point;
 The damage is on the laminate or has discolored the laminate;
 The damage is on the inner lite;
 The damage has contamination that cannot be removed;
 The damage is in an area where value-added features, such as rain sensors, may be affected;
 The pit depth is greater than 3/8 inch (1 cm);
 Edge crack touches more than one edge of the windshield, and
 Any stress crack
CUSTOMER EXPECTATIONS
Properly setting the customer’s expectations prior to a repair can be the most important step to insuring customer
satisfaction. Visual aids are helpful in showing the customer what the finished product will look like.
Review of Repairable Breaks
 Break is in the outside lite
 Laminate/PVB layer is intact
 Break is outside the Driver’s Primary Vision Area
 Break is less than 1.5 inches (4 cm) or less than 6 inch (15 cm) crack
 No local or state restrictions
 Customer understands repair results
Introduction to the QuickSilver Technology™ System
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PARTS OF YOUR AEGIS®
QUICKSILVER TECHNOLOGY™ WINDSHIELD REPAIR SYSTEM
FIX4500 Repair Fixture
FIX4000 QuickSilver Technology™ Chamber
PMP4015 Gauged Vacuum Pump
HOS2000 Hose Assembly
MIR2000 Mirror
LMP3000 12-volt UV lamp w/ suction cups
LIQ2060 Single Shots, Extreme II - 25 PK
LIQ2070 Single Shots, Crack Fill - 25 PK
LIQ2080 Single Shots, Polymer II - 25 PK
LIQ3000 Alcohol, 125 mL (4.2 oz)
LIQ2000 Glycerin, 30 mL (1.0 oz)
LIQ2030 Pit Polish, 60 mL (2.0 oz)
FRM9412 Instructions
CAS2019 Carrying Case
Supply Box (SBX5001) contents:
HDW5412 Razor blades – 6 PK
HDW3000 Mylar squares – 100 PK
SBX2017 Insert Seals, 10 PK
SBX2019 O-Rings, Small, 12 PK
SBX2021 O-Rings, Large, 12 PK
SBX2018 Single Shot Filling Adaptor (4)
KIT 2000 Contents
Your AEGIS® QuickSilver Technology™ Equipment
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YOUR AEGIS® QUICKSILVER
Your AEGIS®QUICKSILVER TECHNOL-
OGY™ Windshield Repair System (KIT2000) in-
cludes everything you need to make top-quality
repairs. In order to follow along with this manual,
it is important that you are familiar with the names
and uses of each component included in your kit.
REPAIR FIXTURE (FIX4500)
The repair fixture is the heart of your AEGIS®sys-
tem. It is designed to attach securely and easily to
any windshield. By pumping the plunger, the suction
cup holds the repair fixture tightly against the wind-
shield. The fixture holds the chamber assembly. The
adjustment lever allows you to center the chamber
over the break. The adjustment screw changes the
angle of the chamber so that you can work on curved
areas of the windshield.
QUICKSILVER TECHNOLOGY™ CHAMBER (FIX4000)
The QUICKSILVER Technology™ Chamber is made
up of the outer chamber, injection chamber and piston.
On the side of the outer chamber is the quick connect
plug where the hose attaches. At the base of the outer
chamber is the reusable insert seal which creates the air-
tight seal around the break.
The injection chamber, which screws into the outer
chamber becomes a reservoir for the resin. The piston
and injection chamber are rotated throughout the repair
process to draw dry suction, force hydraulic pressure and
inject resin into the break.
HOSE ASSEMBLY (HOS2000)
Quick-connect sockets at each end link the hose to
the chamber and the gauged vacuum pump.
GAUGED VACUUM PUMP
Pull the handle in a pumping motion to draw the vac-
uum. Pump attaches to the hose assembly. Readings
will vary slightly due to altitude and barometric pressure.
YOUR AEGIS® QUICKSILVER
TECHNOLOGY™ EQUIPMENT
Your AEGIS®QUICKSILVER TECHNOL-
OGY™ Windshield Repair System (KIT2000) in-
cludes everything you need to make top-quality
repairs. In order to follow along with this manual,
it is important that you are familiar with the names
and uses of each component included in your kit.
REPAIR FIXTURE (FIX4500)
The repair fixture is the heart of your AEGIS®sys-
tem. It is designed to attach securely and easily to
any windshield. By pumping the plunger, the suction
cup holds the repair fixture tightly against the wind-
shield. The fixture holds the chamber assembly. The
adjustment lever allows you to center the chamber
over the break. The adjustment screw changes the
angle of the chamber so that you can work on curved
areas of the windshield.
QUICKSILVER TECHNOLOGY™ CHAMBER (FIX4000)
The QUICKSILVER Technology™ Chamber is made
up of the outer chamber, injection chamber and piston.
On the side of the outer chamber is the quick connect
plug where the hose attaches. At the base of the outer
chamber is the reusable insert seal which creates the air-
tight seal around the break.
The injection chamber, which screws into the outer
chamber becomes a reservoir for the resin. The piston
and injection chamber are rotated throughout the repair
process to draw dry suction, force hydraulic pressure and
inject resin into the break.
HOSE ASSEMBLY (HOS2000)
Quick-connect sockets at each end link the hose to
the chamber and the gauged vacuum pump.
GAUGED VACUUM PUMP
Pull the handle in a pumping motion to draw the vac-
uum. Pump attaches to the hose assembly. Readings
will vary slightly due to altitude and barometric pressure.
Repair Fixture and Chamber Assembly
Suction Cup
Piston knob
Suction Cup
Adjustment lever
Injection Chamber
Plunger
Outer Chamber
Hose Plug
Adjustment Screw
Insert Seal
Insert Seal
Hose Assembly
Gauged Pump
Your AEGIS® QuickSilver Technology™ Equipment
AEGIS® CUSTOMER SERVICE 1-888-247-6000 8am-4pm CST OR [e-mail]
Blue Knurled Nut
QuickSilver Technology ™
Injection Chamber and Piston
Piston
Cap
O-Rings
Injection Chamber
Piston Knob
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Inspection Mirror
INSPECTION MIRROR (MIR2000)
The inspection mirror helps you to monitor the repair proc-
ess without getting in and out of the car. You will be able to
look directly into the rear of the break from your work area at
the front of the windshield.
12-VOLT UV LAMP WITH SUCTION CUPS (LMP3000)
All AEGIS®resins cure with ultraviolet rays. The UV lamp
easily mounts to the windshield with 4 suction cups for hands-
free curing. The 10 ft. power cord plugs into the cigarette
lighter inside the vehicle for complete mobile operation. Cur-
ing time with the LMP3000 is usually 60-90 seconds. If you
are using a different UV lamp, curing times may vary. Uses
AEGIS®UV bulbs (LMP5000 or LMP5002).
SUPPLY BOX (SBX5001)
Your AEGIS®QuickSilver Technology™ Windshield Repair
System includes a supply box filled with razor blades, Mylar
squares, insert seals, large and small o-rings, and single shot
filling adaptors. All supplies can be replenished individually
by ordering directly from AEGIS®. Part numbers can be found
in the Parts List on page 36.
Supply Box with Contents
12-Volt UV Lamp with
Suction Cups
Wear Eye Protection when using UV
lamps, excessive exposure can cause
permanent eye damage.
Your AEGIS® QuickSilver Technology™ Equipment
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5/19/2011
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