Health and Safety Precautions. Description and Operation

General

Proper repair methods and correct execution are very important for both vehicle safety and personal safety.

Exercise caution when performing high-voltage electric welding.

• Do not perform welding in a humid environment or on a wet surface. Use suitable insulation underneath.

• Remove flammable materials from the hazard area. Remove the fuel tank and, if necessary, the components that supply fuel.

• Always ventilate the work area well and use an exhaust system.

• Wear protective clothing, gloves, and a welding mask or welding goggles.

• Disconnect the negative battery cable and insulate the battery terminal. Remove all airbag components.

Personal Protection

Welding fumes and grinding dust can be hazardous to health. For this reason, make sure the work area is well ventilated and use a welding fume extraction system. Sealers, underbody protection and paint residue must not be burned with an open flame, as this releases gases that are harmful to health. A special extraction system must always be used when welding or brazing.

When working with substances containing solvents, there must be good ventilation. If necessary, wear respiratory protection and an extraction system must be used.

Do not weld in damp areas; if necessary, use an insulating mat. Welding and grinding work near the battery presents an explosion hazard. For this reason, it must be removed before starting work.

Wear hearing protection when cutting or grinding, or when the noise level is 85 to 90 decibels (dB) and above.

When repairing supplemental restraint systems (airbags)

Vehicle Protection

Protect affected areas from weld spatter and dust during all welding and grinding work on the vehicle. If metal dust remains on the vehicle for some time, there is a possibility of surface rust forming. Grinding or abrasive work produces tiny scratches in the paint surface, which may cause corrosion.

• Use carbon fiber blankets to protect the vehicle body.

• Use protective film to protect the vehicle body from grinding dust and metal dust.

• Take appropriate measures to protect the vehicle interior during any repair work.

• If necessary, remove the fuel supply components.

• Protect flammable areas with a fire-resistant blanket.

• Welding must not heat air conditioning system components.

• Remove any attached components in the area adjacent to the repair area.

• Protect the interior from grinding dust.

Protective Equipment

The following protective equipment must always be used:

• Protective helmet or welding mask.

• Hearing and respiratory protection.

• Protective gloves and protective boots.

• Welding fume extraction.

Electronic Components

Voltage spikes occur during welding, and body adjustment may damage electronic systems. In particular, the safety instructions for welding on vehicles with supplemental restraint systems (airbags) must be observed.

• Disconnect the negative battery cable and insulate the battery terminal.

• If necessary, disconnect the control modules.

• If welding is to be performed directly near a control module, it must be removed beforehand.

• Never connect the negative welding cable near an airbag or control module.

• Connect the negative welding cable close to the welding area.