BA 3576-00-01-05-01-00-en

Safety
Contents:

1.0 Symbols and instructions ........................................................................................ 1

1.1 Warning signs ......................................................................................................... 2
1.2 Mandatory signs...................................................................................................... 2
1.3 Prohibition signs...................................................................................................... 3
2.0 Safety instructions ................................................................................................... 4
2.1 Principle .................................................................................................................. 4
2.2 Organizational measures ........................................................................................ 4
2.3 Personnel ................................................................................................................ 6
2.4 Function and Maintenance ...................................................................................... 6
2.5 Instructions for special dangers .............................................................................. 8
2.5.1 Electric system ................................................................................................. 8
2.5.2 Hydraulic, pneumatic system ............................................................................ 8
2.5.3 Oil, grease and other chemical substances ...................................................... 9
2.5.4 Gas, dust, fumes .............................................................................................. 9

1.0 Symbols and instructions

The following descriptions and signs for dangers are used in the operating
instructions:

Danger!
This symbol can be found at all working safety advices in this
documentation/operating instructions (BA) which imply a risk for limb and life of
persons. Kindly observe these advices and act with special caution in these
cases. Hand over these working safety instructions also to other operators.
Besides the advices given in this documentation/BA the safety and accident
preventing regulations generally valid have to be taken into consideration.
Attention!
This attention! can be found at all places in the documentation/BA which have to
be especially taken into consideration in order to observe guidelines, regulations,
advices and the correct sequence of operations as well as to avoid a damage and
destruction of the machine and/or parts of the plant.

Note!
This refers you to special facts which need to be observed to ensure a proper and
efficient handling of the machine/plant.

All notes have to be fulfilled with regard to a current use of the machine/plant.
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Furthermore, the following symbols refer to particular danger zones:

1.1 Warning signs

Danger!

Attention!

Warning - Hot surface!

Warning - Overhead load!

Warning - Corrosive Materials!

Warning - Explosives!

Warning!

If the machine is completely shut down for maintenance and repair

work, it must be secured against inadvertent starting by:

- locking the principal control elements and removing the ignition key.

and

- attaching a warning sign to the main switch.

1.2 Mandatory signs

Eye protection must be worn!

Use ear protectors!

Protective clothing must be worn!

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Eye and ear protection and safety helmets must be worn!

Hands must be washed!

Gas mask must be worn!

Safety gloves must be worn!

Protective headgear must be worn!

Safety boots must be worn!

Gas cylinders must be secured by a chain!

1.3 Prohibition signs

Do not step here!

No eating or drinking!
When handling this product it is forbidden to take any foods or tobacco
and/or to keep the same within the work and storage room. Clean your
hands carefully after work and before any breaks.
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2.0 Safety instructions

The following safety instructions have to be particularly observed.

2.1 Principle

• The machine/plant has been built in accordance with state-of-the-art standards

and the recognized safety rules. Nevertheless, its use may constitute a risk to
life and limb of the user or of third parties, or cause damage to the
machine/plant.

• The machine/plant must only be used in technically perfect condition in

accordance with its designated use and the instructions set out in the
operating manual, and only by safety-conscious persons who are fully aware
of the risks involved in operating the machine/plant. Any malfunctions,
especially those affecting the safety of the machine/plant, should therefore be
rectified immediately!

2.2 Organizational measures

• The operating instructions must always be at hand at the place of use of the
machine/plant!

• In addition to the operating instructions, the user has to observe and instruct
all other generally applicable legal regulations relevant to accident prevention
and environmental protection!

• Every person in charge with the assembly, the dismantling and re-assembly,
with the commissioning, operation and maintenance (inspection, maintenance,
repair) of the machine/plant in the works of the user has to read and
comprehend the entire operating instructions and especially the chapter
"security". (This applies especially to persons working only occasionally on the
machine.) It is recommended to the user to obtain a written confirmation
hereabout.

• Check - at least from time to time - whether the personnel is carrying out the
work in compliance with the operating instructions and paying attention to risks
and safety factors!

• The machine/plant is only to be operated and maintained by authorized,

trained and instructed personnel. This personnel has to receive a special
instruction of the risks and dangers which may arise.

• Never carry out any modifications, additions or conversions at the

machine/plant which might affect safety without the supplier's approval!

This also applies to the installation and adjustment of safety devices and
valves as well as to welding work on load-bearing elements.
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• Spare parts must comply with the technical requirements specified by the
manufacturer. Spare parts from original equipment manufacturers can be
relied to do so.

• Replace hydraulic hoses within stipulated and appropriate intervals, even if no

safety-relevant defects have been detected!

• Adhere to prescribed intervals or those specified in the operating instructions

for routine checks and inspections!

• Take the necessary precautions to ensure that the machine is used only in a
safe and reliable condition!

Operate the machine only if all protective and safety-oriented devices, such as
removable safety devices, emergency shut-off equipment, sound-proofing
elements and exhausters, are in place and fully functional!

• Observe the adjusting, maintenance and inspection activities and intervals set
out in the operating instructions, including information about the replacement
of parts and equipment. These activities can only be executed by skilled
personnel.

• Inform the operating personnel before beginning special operations and

maintenance works! Appoint a person to supervise the activities!

• If the machine/plant is completely shut down for maintenance and repair work,
it must be secured against advertent starting by:

- locking the principal control elements and removing the ignition key
and

- attaching a warning sign to the main switch.

• For the operation of the machine/plant resp. during maintenance and repair
work the local safety and accident preventing rules are applicable at any rate.

• For the execution of maintenance work, tools and workshop equipment

adapted to the task on hand are absolutely indispensable.

• Observe all fire-warning and fire-fighting procedures!

• See to it that all safety instructions and warnings attached to the machine/plant
are always complete, perfectly legible and observed.

• The responsibilities during assembly, dismantling and re-assembly,

commissioning, operation and maintenance have to be clearly fixed and
observed so that no unclear competence questions regarding the security
aspect may arise.
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2.3 Personnel

• Employ only trained or instructed staff and set out clearly the individual
responsibilities of the personnel for operation, set-up, maintenance and repair!

• Make sure that only authorized personnel works on or with the machine!

• Do not allow persons to be trained or instructed or persons taking part in a

general training course to work on or with the machine/plant without being
permanently supervised by an experienced person!

2.4 Function and Maintenance

• Avoid any operational method that might be prejudicial to safety!

• Use personal protective equipment wherever required by the circumstances or

by law!

• Check before starting operation and after maintenance whether all security
devices have been mounted.

• Check the machine/plant at least once per working shift for obvious damages
and defects! Report any changes (incl. changes in the machine's working
behaviour) to the competent organization/person immediately! If necessary,
stop the machine immediately and lock it!

• In the event of malfunctions, stop the machine/plant immediately and lock it!
Have any defects rectified immediately!

• Before starting up or setting the machine/plant in motion, make sure that

nobody is at risk!

• In case of any work concerning the operation, conversion or adjustment of the

machine and its safety-oriented devices or any work related to maintenance,
inspection and repair, always observe the start-up and shut-down procedures
set out in the operating instructions and the information on maintenance work!

• To avoid the risk of accidents, individual parts and large assemblies should be
carefully attached to lifting tackle and secured for replacement. Use only
suitable and technically perfect lifting gear and suspension systems with
adequate load capacity! Never work or stand under suspended loads!
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• Ensure that the maintenance area is adequately secured!

• If the dismantling of safety devices is required for set-up, maintenance or

repair purposes, these safety devices have to be refitted and checked
immediately upon completion of the maintenance and repair works.

• Always tighten any screwed connections that have been loosened during
maintenance and repair works!

• For carrying out overhead assembly work always use specially designed or
otherwise safety-oriented ladders and working platforms! Never use machine
parts as a climbing aid. Wear a safety harness when carrying out maintenance
work at greater heights!
Keep all handles, steps, handrails, platforms, landings and ladders free from
dirt!

• Never switch off or remove suction and ventilation devices when the
machine/plant is in operation!

• Before carrying out welding, flame-cutting and grinding operations, clean the
machine/plant and its surroundings from dust and inflammable substances
and make sure that the premises are adequately ventilated (risk of explosion)!

• Never modify the programme (software) of programmable control systems!

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2.5 Instructions for special dangers

2.5.1 Electric system

• Work on the electrical system or equipment of the machine/plant may only be

carried out by a skilled electrician himself or by specially instructed personnel
under the control and supervision of such electrician and in accordance with
the applicable electrical engineering rules.

• Use only original fuses with the specified current rating. Switch off the
machine/plant immediately, if trouble occurs in the electrical system!

• The electrical equipment of a machine/plant is to be inspected and checked at

regular intervals. Defects such as loose connections or scorched cables must
be rectified immediately.

• If provided for in the regulations, the power supply to parts of machines and
plants, on which inspection, maintenance and repair works are to be carried
out, must be cut off. Before starting any work, check the de-energized parts for
the presence of power and ground or short-circuit them. Insulate adjacent live
parts and elements!

• Necessary works on live parts and elements must be carried out only in the
presence of a second person, who can cut off the power supply in case of
danger by actuating the emergency shut-off or main power switch. Secure the
working area with a red-and-white safety chain and a warning sign. Use
insulated tools only.

2.5.2 Hydraulic, pneumatic system

• Work on the hydraulic devices must be carried out only by personnel with
special knowledge and experience of hydraulic equipment!

• Check all lines, hoses and screwed connections regularly for leakages and
obvious damages! Repair damages immediately!
Splashed oil may cause injury and fire.

• De-pressurize all system sections and pressure pipes (hydraulic system,

compressed-air system) to be removed in accordance with the specific
instructions for the unit concerned before carrying out any repair work!
Protect against unauthorized re-closing of circuit!

• Hydraulic and compressed air lines must be laid and fitted properly! Ensure
that no connections are interchanged! The fittings, lengths and quality of the
hoses must comply with the technical requirements.
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2.5.3 Oil, grease and other chemical substances

• When handling oil, grease and other chemical substances, observe the
product-related safety regulations!

• Be careful when handling with hot operating and auxiliary materials (risk of
burning and scalding)!

2.5.4 Gas, dust, fumes

• In premises in which an explosive atmosphere may be produced, sparking has

to be avoided (deflagration)!

Gas mask must be worn!

Protective clothing must be worn!

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