Technician Safety Information
INJURY DURING HYDRAULIC SYSTEM REPAIRSPotential Danger
Risk of injury Serious injuries can be caused to the skin or eyes when loosening hydraulic lines without depressurizing the system beforehand, due to the very high pressures (above 200 bar)
Damage to the skin may be caused if unprotected skin comes into contact with hydraulic fluid, particularly central hydraulic fluid (this is especially harmful to health)
Risk Of Poisoning
Anyone who swallows hydraulic fluid can expect to suffer symptoms of poisoning including headaches, dizziness, stomach ache, vomiting, diarrhea, cramps and unconsciousness
Safety Measures/Operating Instructions
Before starting work on hydraulic systems they should be depressurized and the system must be emptied if necessary
Do not pour hydraulic fluid into drinking containers
Ensure adequate ventilation, particularly in the case of central hydraulic fluid
Ensure only authorized persons have access to hydraulic fluid
Seal disconnected lines and hoses and connections on the subassemblies immediately with blind plugs
Wear safety gloves, protective clothing and safety glasses
If it is not possible to wear safety gloves, the following points are to be observed:
Only allow hydraulic fluid to come into contact with the skin for as short a time as possible, wash fluid off skin with soap and water
Change wet clothing as quickly as possible
First Aid
Have the casualty drink plenty of water with activated charcoal additive
After swallowing larger quantities consult a doctor
If hydraulic fluid gets into the eyes, rinse out the eyes immediately with plenty of clean water/using a eye rinsing glass
In the event of injuries to skin or eyes from a jet of hydraulic fluid, consult a doctor immediately
Disconnecting And Connecting Pressure Lines
Clean contaminated line connections before disconnecting them
Seal disconnected lines and hoses and connections to components immediately with blind plugs
Only use open box wrench and special tool when loosening and tightening pressure lines to avoid damage to the line connections
Check the component concerned and line connections for leaks after assembly work on the suspension system
INJURY WHILE ENGINE IS RUNNING
Possible Dangers
Risk of accident from vehicle starting off during starting operation (e.g. when testing compression pressure) as a result of gear engaged or when engine running and vehicles with automatic transmission as a result of selector lever position "P" or "N" not engaged (with the exception of vehicles which do not have any selector lever position " P ")
Risk Of Injury
Severe injuries may be caused by freely rotating parts in the area of the running engine
The heat produced by the engine when it is operating can result in severe burns if contact is made with individual, unshielded parts
Rules Of Conduct/Protective Measures
As a general rule, carry out work on the running engine only if this is absolutely essential
Before starting the engine, apply parking brake
On models with manual transmission, move gearshift lever into Neutral position
On models with automatic transmission, move selector lever into position "P" or "N" (with the exception of vehicles which do not have any selector lever position "P")
On models which do not have selector lever position "P" secure selector lever to prevent it being operated unintentionally
Wear closed and close-fitting work clothes
Take off any jewelry, such as chains, rings etc.
If you have long hair, wear a suitable head cover
Before commencing work on the running engine, check to obtain a general picture of the positioning of parts which may be hot
When carrying out work when starting the engine or when engine is running, do not touch any hot and rotating parts
INJURY WHILE DISPOSING OF GAS FILLED COMPONENTS
Drilling Gas-Filled Subassemblies Or Components (Gas Filling Cannot Ignite)
Wear safety glasses and face mask
There is an increased risk of injury to the skin and eyes due to drilling chips blown up when drilling gas-filled subassemblies
The drilling chips are carried along due to the pressure of the gases escaping and accelerated to a greater or lesser extent depending on the pressure
The extent of injury increases as the pressure
The pressures involved may be 75 bar and above
Operating Instructions/Safety Measures
Wear safety glasses and face mask
First Aid
Do not rub part of skin affected as there is the risk that the drilling chip will break off and part of it remains
If necessary, consult a doctor
INJURY FROM COMPONENTS UNDER TENSION
Risk Of Fingers Etc. Being Jammed Or Crushed When Working On Parts Which Are Under Tension
When releasing or removing parts which are under great tension, the use of non-approved clamping devices may result in severe injury
Instructions/Precautions
Only use approved clamping devices for repair work on springs, sprung bodies, spring actuators and other parts under tension
Spring Clamps
On no account use an impact wrench for tensioning and releasing operations
Checking Clamping Devices
The pressing screw must move easily and be undamaged
Clamping plates must not be warped
Ensure that the right clamping plates are used with the right springs
The coil diameter of the springs must correspond to the groove in the clamping plate
Wear protective gloves for all work operations
LETHAL INJURIES ARE POSSIBLE IF VEHICLE SLIPS OFF OF LIFTING PLATFORM
Align vehicle between lifting platform columns and position the four hoisting plates beneath the lifting platform mounting points specified by the vehicle manufacturer
Lethal Hazard
Lethal injuries are possible when the following accident hazard precautions are not observed
Accident Hazard
Vehicle can slip off if not aligned equally or precisely on lifting platform arms and/or hoisting plates as well as by supporting or lifting components in vehicle
Vehicle can tilt as a result of unequal weight distribution after removing major components and axles
Protective Measures/Rules Of Behavior
^ Center vehicle between lifting platform columns in longitudinal and lateral direction
^ When supporting components ensure that the vehicle is not lifted off of the hoisting plates on the lifting platform, if necessary secure vehicle on lifting platform supporting arms
^ Position hoisting plates on lifting platform mounting points at same height
^ Lift vehicle slightly (wheels still on floor), ensure that hoisting plates are properly positioned on vehicle mounting points, then lift all the way
^ Before removing axles and major components secure vehicle on lifting platform and/or use bags of sand to compensate weight
^ Always observe "Accident prevention regulations point 18.3 Lifting platforms" and "Guidelines from lifting platform manufacturer"