5000AW Safety Notes

Safety Notes

Safety instructions for raising vehicles

Danger of injury when raising vehicles

DANGER: Risk of fatal injury due to vehicles slipping or tilting off lifting platforms.
- 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 mounting plates by raising the vehicle slightly and conducting a visual inspection.
- In order to guarantee that the vehicle is not lifted off the mounting plates during assembly work, the vehicle must be secured on the lifting platform when removing or supporting units or the shift in the centre of gravity must be compensated with corresponding loads in the vehicle.
- 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.

- Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper alignment of the lifting platform arms or mounting plates, and by raising, supporting or removing units on raised vehicles.

Damage when raising vehicles

CAUTION: Danger of material damage if the vehicle is raised incorrectly.
- Lift the vehicle only at the approved take-up points.
- Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the underbody area.

- Lifting or supporting the vehicle at unsuitable take-up points can lead to material damage on the vehicle.

Safety instructions for welding

Dangers 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 galvanized steel. Danger of injury from weld spatters and UV light when welding. Danger of injury from false releases of pyrotechnical safety components.
- Do not perform welding work in a humid environment or on a wet background; 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 equipment, 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 modules for pyrotechnical safety systems, remove the control modules before beginning work.
- In addition, the guidelines of the welding equipment manufacturers 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 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 comprehensively with fire-proof covers.

Safety instructions for air conditioning

CAUTION: Danger of injury due to the filled air-conditioning system bursting during welding and soldering work.
- No welding, soldering or hot-air heating may take place 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 soldering 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 sticking

Safety instructions for Teromix-6700 two-component adhesive

CAUTION: Danger of damage to side section if binding 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 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

CAUTION: Danger of injury if airbag units are triggered while ignition key is not removed.
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed.
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair.

Safety instructions for door

CAUTION: Danger of material damage if the door lock is installed incorrectly. Malfunctions in the alarm system.
- The door lock should be installed only when the actuating lever is in basic position.

CAUTION: Damage to plug connection lugs during door removal. Damage to lugs when pulling the plug connection out of the A-pillar.
- The locking element at the bottom part of the plug connection must be pulled out before the plug connection is disconnected.

CAUTION: Damage to the bowden cable when removing door trim panel. Damage by bending the bowden cable at the hook.
- Pull the hook out of the end piece only after installation in the inner door release.

CAUTION: There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is triggered: lower and raise door window.
- When carrying out assembly work in the area of the connection piece, the door handle and the door lock, the fuse No. 1 in row D must be removed.

Safety instructions for corrosion protection

Safety instructions for plug location plan (body)

CAUTION: Danger of corrosion and of uncontrolled water penetration when removing plugs.
- The body apertures are sealed with plugs in the factory, and must be sealed with the plugs provided once more following disassembly or repair work.

Safety instructions for water drains (body)

CAUTION: Water drainage hoses can be pushed out or pressed in by blowing them out of the body during cleaning.
- When cleaning, only blow the water drainage hoses out with light compressed-air pressure.