Safety Instructions For Welding
Safety instructions for welding
Dangers of injury when welding
DANGER: Risk of fatal injury from high voltage during electric welding.
Danger of explosion and fire when welding in the area of highly inflammable materials.
Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanized steel.
Danger of injury from weld spatters and UV light when welding.
Danger of injury from false releases of pyrotechnical safety components.
- Do not perform welding work in a humid environment or on a wet background; there is a risk of fatal injury from the voltage being conducted through the human body. Persons with heart pacemakers should not perform welding work. Use insulating underlays.
- Remove highly flammable materials from the work area; if necessary, remove units with fuel-carrying parts and protect work areas in the vehicle that are at risk of catching fire using fire-proof covers.
- Ventilate the work area well.
- Remove smoke gases with a suitable extraction system.
- Wear suitable protective equipment, such as protective clothing, gloves, a welding shield and, if necessary, a protective mask.
- For welding work, always disconnect both terminals on the battery. In the case of welding work in the immediate vicinity of the control modules for pyrotechnical safety systems, remove the control modules before beginning work.
- In addition, the guidelines of the welding equipment manufacturers and the legal accident prevention regulations and those of the mutual indemnity association (BGV D1) must be observed.
Safety instructions for flying sparks during grinding and welding work
CAUTION: Danger of explosion and fire from flying sparks during grinding and welding work. Danger of damage to vehicle parts and other vehicles due to flying sparks.
- Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with fire-proof covers and, if necessary, remove batteries and fuel-carrying components.
- No other vehicles may be left unprotected in areas used for body repair.
Safety instructions for fuel tank
CAUTION: Danger of fire due to fuel tank or fuel-carrying parts heating up during grinding and welding work.
- When carrying out grinding and welding work near the fuel tank or fuel-carrying parts, make sure that these parts do not heat up:
- It is recommended to remove endangered parts.
- Cover the welding area comprehensively with fire-proof covers.
Safety instructions for air conditioning
CAUTION: Danger of injury due to the filled air-conditioning system bursting during welding and soldering work.
- In the case of extreme heating of filled air-conditioning systems, a very strong overpressure may be caused in the system which may lead to an explosion.
- No welding, soldering or hot-air heating may take place on parts of the filled air-conditioning system:
- While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a maximum temperature of 80 degrees C:
- Make sure that parts of the air-conditioning system do not heat up during welding or soldering work on the vehicle.
Safety instructions for sticking
Safety instructions for Teromix-6700 two-component adhesive
CAUTION: Danger of damage to side section if binding time of adhesive is not observed.
- The new part must be welded in within 30 minutes:
Safety instructions for installation work
Safety instructions for sharp-edged body and unit parts
CAUTION: Danger of injury from sharp edges on body and unit parts:
- Wear protective gloves when working in the area of sharp-edged body and unit parts.
Safety instructions for airbag system
CAUTION: Danger of injury if airbag units are triggered while ignition key is not removed.
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed:
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair.
Safety instructions for door
CAUTION: Danger of material damage if the door lock is installed incorrectly: Malfunctions in the alarm system.
- The door lock should be installed only when the actuating lever is in basic position.
CAUTION: Damage to plug connection lugs during door removal.
Damage to lugs when pulling the plug connection out of the A-pillar.
- The locking element at the bottom part of the plug connection must be pulled out before the plug connection is disconnected.
CAUTION: Damage to the bowden cable when removing door trim panel.
Damage by bending the bowden cable at the hook.
- Pull the hook out of the end piece only after installation in the inner door release.
CAUTION: There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is triggered: lower and raise door window.
- When carrying out assembly work in the area of the connection piece, the door handle and the door lock, the fuse No. 1 in row D must be removed.