| Description and Operation General Appropriate repair methods and carrying out repairs correctly are particularly important for the operating safety of vehicles and for the safety of people. WARNING:There is danger of injury through: - High voltage when electrical welding.
- Do not perform welding work in a damp environment or on a wet substrate. Use suitable insulation underneath. - Flammable substances in the welding area.
- Remove flammable substances from the danger area. Remove the fuel tank and components which supply fuel. When welding in the battery area, the battery must be completely removed. - Welding fumes, which are harmful to health.
- Ventilate the workplace well and use the welding fumes extraction system. - Welding spatter and UV radiation.
- Wear protective clothing, gloves and welding mask or welding goggles. - Pyrotechnic components.
- Disconnect the battery negative clamp and cover the battery terminal. Remove any airbag components. All the regulations governing Health and Safety at Work must be complied with during body repairs. Personal protection Welding gases and grinding dusts can be harmful to the health. For this reason, make sure that rooms are well ventilated and work using the welding fumes extraction system. Sealants, underbody protection and paint residues must not be burnt down with an unshielded flame, as this will produce gases which are damaging to health. A dedicated extraction system must always be used when welding or brazing. When working with substances containing solvents, good ventilation must be provided, respiratory protection must be worn and an extraction system must be used. Do not weld in damp areas, if necessary use an insulation mat. Welding and grinding work near the battery presents the danger of explosion. For this reason, it must be removed before the work is started. Cutting, grinding and alignment work on metal panels can cause a noise level of 85 to 90 dB (A) or even more. For this reason, you must always wear ear defenders. The various body areas are subject to very high forces during realignment work. Should any component suddenly become detached during this process, there is a very great danger of injury. For this reason, pulling chains and pulling shackles must be secured with arrester cables. NOTE:Work on airbag systems may only be performed by persons who have a relevant certificate of competence. Some special instructions must be followed when working on airbag systems: - Always stand to the side of it when removing or installing an airbag.
- Always store an airbag or an airbag/steering wheel with the airbag side pointing upwards and in a safe place.
- Only install the airbag again when the vehicle is fully repaired and the complete electrical systems has been tested.
- Take into account the location of air curtains and shoulder airbags.
Protection of the vehicle Protect affected areas from weld spatter and dust during all welding and grinding work on the vehicle. If metallic dust stays on the vehicle for some time, there is the likelihood of film rust formation. Grinding or sanding work produce tiny spots of damage to the paint surface, which may cause corrosion. For this reason, make sure to: - Use carbon fibre blankets to protect the vehicle body.
- Use covering film to protect the vehicle body from sanding dust and metal dust.
Use suitable protective measures to protect the interior when performing repair operations which relate to the inside of the vehicle. Carbon fibre blankets are used directly around the working area. They offer maximum protection to the areas of the vehicle. In addition, take into account: - Remove fuel supply components as necessary.
- Protect working areas which are in danger of catching fire with a fireproof blanket.
- The welding must not cause components of the air conditioning system to become heated.
- Removal of any attached components in the space adjoining the repair area.
- Use covering paper to protect the interior from grinding dust.
- Create a definite barrier between the work area and the interior by using a carbon fibre blanket.
Protective equipment The following protective equipment must always be used: - Protective helmet or welding mask.
- Ear defenders and breathing protection.
- Protective gloves and safety boots.
- Welding fume extraction.
Electronic components Increased use of comfort and safety electronics in modern motor vehicles also requires the greatest attention to be paid during body work. Overvoltages produced during welding and in alignment work during bodyshell rectification may cause electronic systems to be damaged. In particular, the safety instructions for performing welding work on vehicles with airbag systems must be adhered to. NOTE:After disconnecting the power supply and before performing further work, a wait time of up to 15 minutes must be maintained, depending on the vehicle. Work on airbag systems may only be performed by persons who have a relevant certificate of competence. Pay attention to the following points: - Disconnect the battery negative clamp and cover the battery terminal.
- Disconnect the electrical connector at the airbag control module.
- If welding is to be performed directly near a control module, it must be removed beforehand.
- Never connect the negative cable of the welder near an airbag or a control module.
- Connect the negative cable of the welder close to the location of the weld.
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