Precautions For Operations

BODY REPAIR FUNDAMENTALS

PRECAUTIONS FOR OPERATION

In body repair, great importance is attached to quality, efficiency and cost. Consideration for workers' safety and health should, however, be deemed as the most important item. In reality, it is essential that measures be established to prevent accidents and to make the work environment safer and healthier.




1. PROTECTORS
- While working, suitable work clothes, a work cap and safety shoes must be worn. To prevent burns, a long-sleeve shirt and trousers must also be worn and must not be taken off under any circumstances.
- Keep work clothes clean. Do not keep a lighter or other flammable materials in pockets.
- During oxygen and acetylene gas welding, to protect eyes wear goggles according to the quantity of infrared rays.
- During arc welding, to protect eyes wear a safety goggles with a shading plate according to the quantity of ultraviolet rays.
- Gloves, apron, foot covers, earplugs and arm covers should be used to prevent burns.

2. SAFETY STAND
- After jacking up a vehicle body, be sure to support it with the safety stand. For the supporting positions, refer to "Lifting Points" for each model.




3. INFLAMMABLES
- Before starting repair work, be sure to disconnect the negative terminal of the battery.
- When welding parts near the fuel tank fuel filler, be sure to remove the fuel tank. Plug the filler port of the tank.
- Plug the fuel pipe and brake pipes to avoid leakage when removing connectors from the pipes.




4. WORKING ENVIRONMENT
- Pay attention to ventilation and the health of operators.
- Paint and sealant may generate poisonous gases when heated by fire. To prevent this, do not use a gas welder for cutting off damaged portions.
Use an air saw or an air chisel.
- Use a belt sander or rotary wire brush for removing paint from the panel.

5. HANDLING OF WELDING EQUIPMENT




1. STORAGE OF GAS CYLINDERS
- In a well ventilated area, post a "No Fire" sign.
- Avoid the direct rays of the sun. Maintain temperature below 40 degrees C (104 degrees F).
- Inflammable gas cylinders and oxygen cylinders must not be stored in the same place.
- Acetylene cylinders must be stored upright; check that they cannot fall down.




2. MOVEMENT AND TRANSPORTATION OF CYLINDERS
- Be sure to properly close the valve and securely install the cap.
- Do not drag or roll the cylinder.
- Use a cylinder transportation cart.
- When moving, tilt the cylinder slightly and roll it carefully on the bottom edge with one hand while supporting its cap with the other hand.




3. USE OF CYLINDERS
- The cylinder valve must be kept clean and free from oil.
- After opening the cylinder, leave the open-end wrench attached to the valve so it can be turned off quickly in an emergency.
- When the cylinder is replaced, open the valve of the new cylinder slightly and remove dust from around the valve seat.
- To check the cylinder for leakage, apply soapy water.
- The valve should be fully open for oxygen and open 1.5 turns or so for acetylene.
- To prevent the cylinder from falling down, ensure that it is properly secured.
And never give a shock to the cylinder.

4. HANDLING OF THE PRESSURE REGULATOR
- Always handle the pressure regulator with care and avoid impact.
- Inspect the regulator periodically (at least once a year).
- After use, purge the gas, and set the gauge to "0" (except the indoor type pressure regulator).




5. HANDLING OF WATER-SEALED SAFETY DEVICES
- This device must be installed vertically. Check the water level every morning.
- In case of freezing, antifreeze solution can be added.

6. HANDLING OF HOSES
- All hoses must be checked before use for flaws or leaks.
- Never use the pipe coupling made of copper or 70 % copper alloy for the acetylene hose
- Do not use compressed oxygen to clean the gas hose.
- Do not use any hose that has experienced backfire.




7. HANDLING OF THE TORCH
- Keep the torch clean and free from oil.
- To replace the nozzle, use a special tool.
- Do not use the torch as a hammer, etc.
- Do not place it directly on the ground or on the floor.
- Check suction of the torch at the end of the inflammable gas pipe coupling.

8. DANGER OF ARC WELDING ELECTRICAL SHOCK
- keep cables and connections in good shape.
- Do not place machine in a wet place. Do not stand in a wet place when welding.
- Electrical ground welder. The vise clamp is not an electrical ground connection.