Health and Safety Precautions

General

Appropriate repair methods and their correct correct implementation are very important for both vehicle operating safety and personal safety.

Observe caution during high voltage electrical welding.

• Do not perform welding work in a damp environment or on a wet substrate. Use suitable insulation underneath.

• Remove flammable substances from the danger area. Remove the fuel tank and, where required, those components which supply fuel.

• Always ventilate the workplace well and use an extraction system.

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

• Disconnect the battery negative clamp and cover the battery terminal. Remove any airbag components.

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.

Wear hearing protection when cutting, grinding or when noise levels reach of 85 to 90 decibals (dB) and above.

When performing repairs involving air bag systems

Vehicle Protection

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.

• Use carbon fibre blankets to protect the vehicle body

• Use covering film to protect the vehicle body from sanding dust and metal dust.

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

• 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.

• Protect the interior from grinding dust.

Protective Equipment

The following protective equipment must always be used:

• Protective helmet or welding mask.

• Hearing and breathing protection.

• Protective gloves and safety boots.

• Welding fume extraction.

Electronic Components

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.

• Disconnect the battery negative clamp and cover the battery terminal.

• Disconnect control modules as required.

• 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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