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Maintenance and repair
Fundamental safety instructions
Special work in conjunction with utilization of the
machine and maintenance and repairs during operation;
disposal of parts and consumables
Observe the adjusting, maintenance and inspection
activities and intervals set out in the operating
instructions, including information on the replacement
of parts and equipment. These activities may be
executed by skilled personnel only.
Brief operating personnel before beginning special
operations and maintenance work, and appoint a person
to supervise the activities.
In 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.
Ensure that the maintenance area is adequately secured.
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
Carry out maintenance and repair work only if the
machine is positioned on stable and level ground and
has been secured against inadvertent movement and
buckling.
To avoid the risk of accidents, individual parts and
large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and
secured. Use only suitable and technically perfect lifting
gear and suspension systems with adequate lifting
capacity. Never work or stand under suspended loads.
The fastening of loads and the instructing of crane
operators should be entrusted to experienced persons
only. The marshaller giving the instructions must be
within sight or sound of the operator.
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, snow and ice.
Clean the machine, especially connections and
threaded unions, of any traces of oil, fuel or
preservatives before carrying out maintenance/repair.
Never use aggressive detergents. Use lint-free cleaning
rags.
Before cleaning the machine with water, steam jet (high-
pressure cleaning) or detergents, cover or tape up all
openings which - for safety and functional reasons -
must be protected against water, steam or detergent
penetration. Special care must be taken with electric
motors and switchgear cabinets.
Ensure during cleaning of the machine that the
temperature sensors of the fire-warning and fire-
fighting systems do not come into contact with hot
cleaning agents as this might activate the fire-fighting
system.
After cleaning, remove all covers and tapes applied for
that purpose.
After cleaning, examine all fuel, lubricant, and hydraulic
fluid lines for leaks, loose connections, chafe marks
and damage. Any defects found must be rectified
without delay.
Always tighten any screwed connections that have
been loosened during maintenance and repair.
Any safety devices removed for set-up, maintenance
or repair purposes must be refitted and checked
immediately upon completion of the maintenance and
repair work.
Ensure that all consumables and replaced parts are
disposed of safely and with minimum environmental
impact.
The electrical equipment of machines is to be inspected
and checked at regular intervals. Defects such as loose
connections or scorched cables must be rectified
immediately.
Before starting work on high-voltage assemblies and
after cutting out the power supply, the feeder cable
must be grounded
Operate internal combustion engines and fueloperated
heating systems only on adequately ventilated
premises. Before starting the machine on enclosed
premises, make sure that there is sufficient ventilation.
Observe the regulations in force at the respective site.
Carry out welding, flame-cutting and grinding work on
the machine only if this has been expressly authorized,
as there may be a risk of explosion and fire.
Before carrying out welding, flame-cutting and grinding
operations, clean the machine/plant and its
surroundings from dust and other inflammable
substances and make sure that the premises are
adequately ventilated (risk of explosion).
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair damage
immediately. Splashed oil may cause injury and fire.
During operation, all sound baffles must be closed.
Be careful when handling hot consumables (risk of
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