5000AW Safety Notes
Safety Notes
Safety instructions for raising vehicles
Danger of injury when raising vehicles
DANGER: Risk of fatal injury. Vehicle can slip or topple off the lifting platform.
- Risk of (fatal) injury due to vehicles slipping or tilting off lifting platforms may be caused by improper alignment of the lifting platform arms or support plates, and by raising, supporting or removing units on raised vehicles.
- Align the vehicle evenly between the lifting platform columns.
- Lift the vehicle only at the take-up points provided.
- Check the correct seating of the support plates by raising the vehicle slightly and conducting a visual inspection.
- In order to ensure that the vehicle is not lifted off the support plates during assembly work, the vehicle must be secured on the lifting platform, or the shift in the centre of gravity must be offset by a corresponding load in the vehicle, when units are removed or supported.
- In addition, the guidelines of the lifting platform manufacturers and the legal accident prevention regulations and those of the mutual indemnity association (VGB 14) must be observed.
Damage when raising vehicles
CAUTION: Danger of material damage if the vehicle is raised incorrectly.
- Lifting or supporting the vehicle at unsuitable take-up points can lead to material damage on the vehicle.
- Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the underbody area.
- Lift the vehicle only at the approved take-up points.
General warning notes
Danger 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 galvanised steel.
- Danger of injury from unintentional triggering of pyrotechnical safety components.
- Danger of injury from weld spatters and UV light when welding.
- Do not perform welding work in a damp environment or on wet ground; 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 gear, 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 units for pyrotechnical safety systems, remove the control units before beginning work.
- In addition, the guidelines of the welding equipment manufacturer 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 injury and 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 generously with fire-proof covers.
Safety instructions for air conditioning
CAUTION: Danger of injury. Bursting of the filled air-conditioning system during welding and brazing work.
- Danger of injury due to the filled air-conditioning system bursting during welding and brazing work.
- No welding, brazing or hot-air heating may be performed 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 brazing work on the vehicle.
- 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.
Safety instructions for adhesive bonding
Danger of poisoning and injury when adhesive bonding
CAUTION: Danger of poisoning and injury when handling adhesive.
- Danger of poisoning from breathing in vapours or from swallowing adhesive.
- Risk of injury due to contact with skin or eyes.
- Ventilate the work area well.
- Do not eat, drink, or smoke while carrying out work.
- Avoid direct contact with eyes and skin. Wear suitable protective equipment, such as protective clothing, gloves, and if necessary, a protective mask.
- If clothing is soiled with adhesive, change clothing immediately and only use again after they have been cleaned.
- Also observe the product-specific processing and safety instructions on the packing container and packing container imprints.
- In case of eye contact: Rinse eyes immediately and thoroughly with lukewarm running water and consult an eye doctor.
- In case of skin contact: Rinse contacted skin areas immediately with lukewarm running water and soap.
- If adhesive is swallowed: Rinse mouth and consult a doctor.
Safety instructions for Teromix-6700 two-component adhesive
CAUTION: Material damage. Setting time of adhesive is not observed.
- Danger of damage to side section if setting 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. Sharp-edged burrs on body and unit parts.
- Injuries 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
DANGER: Danger of injury. Unintentional activation of airbag units.
- Serious injury due to unintentional activation of airbag units.
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench jobs when the body is being repaired.
- After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must not be started until after a waiting period of 1 minute.
Safety instructions for corrosion protection
Safety instructions for plug location plan (body)
CAUTION: Material damage when removing plugs.
- Danger of corrosion and of uncontrolled water penetration.
- The body apertures are sealed with plugs at the factory, and must be sealed with the plugs provided once more following disassembly or repair work.
Safety instructions for water drains (body)
CAUTION: Danger of material damage when cleaning the water drainage hoses.
- Water drainage hoses can be pushed out or deformed by blowing them out of the body during cleaning.
- When cleaning, only blow the water drainage hoses out with light compressed-air pressure.