Mechanical Safety

The following guidelines must be used to promote mechanical safety of the operation and maintenance personnel:

• During maintenance, the main power disconnect must be shut off and locked out. Follow ECPL procedures.
• Mechanical maintenance must only be conducted by authorized, qualified personnel.
• All machinery and work areas must be kept free of dirt, rags, and other refuse.
• A machine must not be restarted until the system has been double-checked, safety guards reinstalled, and all personnel have been informed of impending start-up.
• When available, always use lock-out pins or other suitable devices to prevent machine or component movement. This includes all systems and components adjacent to the machine.
• Extra caution must be exercised while working near an operating tool. Serious injury can result if personnel get in the way of moving parts while the machine is in any of its operating modes.
• Personnel should keep clear of all air discharge vents. The air may be under high pressure, be very hot and also may contain small particles of foreign matter.
• Before closing any movable protective paneling of the machine, ensure that no persons are in the hazard area. Before switching on or starting the machine, ensure that this will not compromise the safety of any persons.
• When the feed drive is shut down, the vertical and oblique slide units are held in place by a brake. Since the drives are not self-locking, the slide unit can, when the brake is released, move downwards under its own weight and cause a collision. When carrying out maintenance work, secure the slide unit before releasing the brake.

Tooling

• Every tool must be used only up to its individual maximum speed. Excessive peripheral speeds can result in tool breakage representing a danger of personal injury to the operator.
• Ensure that tools required for machining are inserted and positioned correctly in the machine.
• If specific tool changing positions have been defined for the machine, tools must only be changed manually if the corresponding operating unit is in the tool change position.
• During a manual tool change, the machine must be secured against accidental start-up and the guard facilities secured against accidental closure.

Fixtures and workpieces

• Ensure that the correct fixture has been selected and correctly fitted.
• The use of an unsuitable fixture or the incorrect installation of a fixture can put the operator at risk and/or cause serious damage to the machine.
• The workpiece must be placed correctly in the attachment or clamped onto the pallet. Where an attachment is clamped manually, all securing elements must be properly tightened. An incorrectly loaded machine presents a risk of injury to the operator and damage to the machine.

First Step

The following safety precautions must be carried out before carrying out any maintenance operations:

• Position the machine in such a way that the part to be serviced is easily accessible.
• Before removing any guard panels, make sure that the machine is in the appropriate operating status and secure it against being switched on.
• Provide support for vertical slides or similar machine parts prior to all work in their area.

If necessary, mark the maintenance area as appropriate and place warning signs.

Special care during maintenance work

In the following cases, no persons must be in the machine's danger area:

• If machine movements can be carried out.
• If any pressure lines or vessels are under pressure.
• If any electrical components are live.

Transport of sub-assemblies

When replacing larger sub-assemblies, these must be carefully attached and secured to lifting gear.

Use of working aids

For assembly work above floor level, use appropriate ladders and working platforms that comply to applicable safety standards. Do not use machine parts as steps or working platforms. For maintenance work at greater heights, safety harnesses must be worn. Keep all handles, treads, railings, platforms, and ladders free from dirt and lubricants.