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Operating Manual

Sample

Machine Number: 2016-01

Translation of the Original Instruction

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Preface

This operating manual contains all the information specified by § 3 of the German Equipment Safety Act (Gerätesicherheitsgesetz), “Requirements for Granting Marketing Authorisation" (in conjunction with 2006/42/EC Machinery Directive in its currently valid version). The operating manual is intended for persons who will be/are working on/with the unit described in the following. Malfunction of the unit can only be avoided and error-free operation guaranteed, if the operating manual is read and understood. It is important that relevant personnel are conversant with the operating manual.

The operating manual is an essential part of the user information required for the unit to be marketed and thus must be stored in a place where it is accessible by the plant operator and users. If the unit is moved from location to location, the operating and/or user manual (including the supplier’s instructions) must accompany the unit. The instructions in the operating and/or user manual (including the supplier’s instructions) must be followed at all times, during all life phases of unit. Before you begin your work, read carefully the relevant section. We do not accept liability for damage or malfunction resulting from non-observance of the operating manual. Who has responsibility for the machine (plant operator) and who may work on the machine (user) must be clearly and unmistakably defined within the company. Relevant responsibility must also be properly defined for personnel who are instructed to transport, install, fit, adjust, attend, maintain, service or repair the machine.

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Contents

1 DECLARATION OF CONFORMITY ................................ 5

2 SAFETY ADVICE ............................................................. 6

3 MACHINE INFORMATION .............................................. 7

4 BASIC SAFETY INSTRUCTIONS ................................... 8

4.1 Explanation of symbols and directions ............................ 8 4.1.1 Basic symbols .................................................................. 8

4.2 Risks when in contact with the machine .......................... 9 4.3 Intended use ........................................................................ 9 4.4 Unauthorised operation ..................................................... 9 4.5 Obligation to instruct ....................................................... 10 4.6 Safety devices ................................................................... 10 4.7 Installations with servo and frequency converter ......... 10 4.8 Safety-related guidelines ................................................. 11 4.9 Supervision obligation ..................................................... 11

5 PERSONNEL TRAINING ................................................12

5.1 Specific plant operator obligations ................................ 13 5.2 What to do in the event of a malfunction ....................... 13 5.3 What to do in the event of danger ................................... 13 5.4 Rescue of personnel, first aid ......................................... 13 5.5 Residual risk ..................................................................... 14 5.6 Information about residual risk ....................................... 14 5.7 Particular hazard areas .................................................... 15 5.8 Safety and protection devices ......................................... 15 5.9 Structural changes to the machine ................................. 15 5.10 Servicing, repair and similar work risk ........................... 15 5.11 Unit monitoring ................................................................. 16 5.12 Special safety information ............................................... 16 5.13 Fire fighting ....................................................................... 16 5.14 Accident report ................................................................. 16

6 STORAGE AND TRANSPORT .......................................17

6.1 Safety regulations ............................................................. 17 6.2 Personnel requirements ................................................... 18 6.3 Pictorial symbols used on transit objects ..................... 18 6.4 Transport mode ................................................................ 18 6.5 Receipt and checking ....................................................... 18 6.6 Unpacking.......................................................................... 19 6.7 Storage environment ........................................................ 19

7 POSITIONING AND SET-UP ..........................................20

7.1 Unit location, operation location ..................................... 20 7.2 Setting-up and securing ................................................... 20 7.3 Supply connections .......................................................... 20 7.4 Interface ............................................................................. 20

8 START-UP / SET-UP ......................................................21

8.1 Operation preparation ...................................................... 21 8.2 Safety instructions ........................................................... 21 8.3 Personnel requirements ................................................... 21 8.4 First start-up ...................................................................... 21

9 SERVICING AND CLEANING ........................................22

9.1 Maintenance table ............................................................. 22

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9.2 Cleaning ............................................................................. 22

10 REPAIRS ........................................................................23

10.1 Safety instructions ........................................................... 23 10.2 Personnel requirements ................................................... 23

11 REPLACEMENT PARTS ................................................24

12 ERROR CORRECTION ..................................................24

13 SHUT-DOWN, TAKING-OUT-OF-SERVICE ...................24

13.1 Safety instructions ........................................................... 24 13.2 Personnel requirements ................................................... 25 13.3 Taking-out-of-service ....................................................... 25

14 SERVICING .....................................................................26

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1 Declaration of conformity

Declaration of conformity In the sense of EC Directive 2006/42/EG

The manufacturer,

Schuster Sondermaschinenbau GmbH

Moosweg 1

D-82389 Böbing, Germany

hereby declares that the machine described in the following

Construction: Sample Station Year of

construction: 2016

Proper use: testing from Assemblies

Machine no.

2016-01

complies with the provisions of the above mentioned directive.

� The objectives of the Low Voltage Directive 2006/95/EC were observed in line with

Annex I, No. 1.5.1. of the Machinery Directive

� The following harmonised standards were applied:

• DIN EN ISO 12100, 2010

• DIN EN ISO 13857, 2008

• DIN EN 349, 2008

• DIN EN ISO 13850, 2008

• DIN EN 953, 2009

• DIN EN ISO 13849, 2008

• DIN EN ISO 13849, 2008

• DIN EN ISO 14119, 2013

• DIN EN 60204-1, 2006

• DIN EN 60825-1, 2007

This EU Declaration of Conformity loses its validity if

� the machine is reengineered, modified or used for an unintended purpose;

� the user fails to observe the operating instructions.

Name of authorised representative of the technical documentation: Dirk Schmidt, address see manufacturer

(Tel. +49(0)8867/9102-26)

Böbing, 13.06.2016 _____________________________ Place Date Signature Management

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2 Safety advice

on machine no.

from as manufacturer

for as customer.

On signing, the customer confirms that he has,

1. duly received two complete copies of the operation instructions for machine no. 2016-

01

2. the acknowledgement that the operation instructions contain extremely important

information (in particular safety instructions) and advice on residual dangers.

3. the acknowledgement that the commissioning of the machine may only take place

after the operation instructions have been thoroughly studied.

4. the acknowledgement that the machine may only be operated by trained, instructed

and qualified personnel.

5. the acknowledgement that observance of the operation instructions does not absolve

the user from upholding existing laws and regulations, in particular when the machine

is used outside the EU. This also applies when amendments to laws and regulations

due to legal decisions mean additional requirements have to be implemented.

2016-01


Moosweg 1

D-82389 Böbing

Fa.

Mustermann GmbH

Mustermannstrasse 1

12345 Musterstadt

__________________

Place

__________________

Date

____________________

Name in block letters

____________________

Signature

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3 Machine information

Supplying Value

Air pressure maximum: 8 bar

Air pressure minimum: 6 bar

Tension: 3AC / 200V / 50 Hz

Back-up fuse: C32 A

Dimensions L x B x H 3560mm x 1250mm x 2130mm

Total weight approx. 550 kg

Noise level under 75 dB(A)

Environmental conditions dry,

+10°C to +50°C,

frost-free,

corrosion protected (e.g. salt water)

Manufacturer’s address Schuster

Sondermaschinenbau GmbH

Moosweg 1

D-82389 Böbing

Germany

Tel.: +49(0)8867 / 9102-0

Fax: +49(0)8867 / 9102-20

Machine Number: 2016-01

Please quote in all enquiries.

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4 Basic safety instructions

The safety and health of employees can only be guaranteed if the following safety precautions are followed at all stages of use (construction, transport, installation, etc.).

4.1 Explanation of symbols and directions

4.1.1 Basic symbols

General danger! This symbol means there is a threat or immediate threat of danger to the life or health of persons. Ignoring this danger warning can result in damage to property or minor injury, but also severe health-damaging effects or life-threatening injury.

Danger electricity! Failure to observe this warning may result in serious injury or death!

Danger of laser Failure to observe this warning may result in injury!

Wear eye protection It must be taken appropriate safety equipment. Failure to observe this warning may result in injury!

Use gloves It must be taken appropriate safety equipment. Failure to observe this warning may result in injury!

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4.2 Risks when in contact with the machine

In general, the standard accident prevention regulations apply, in particular the accident prevention regulations for machinery. The plant operator is required to observe the laws and regulations currently in force, especially if the unit is to be operated outside the EU. This is particularly important when amendments to laws and regulations result in additional requirements to be implemented.

4.3 Intended use

Operation safety for the supplied unit is only guaranteed if it is used for the purpose intended. Intended use includes observation of the operating and/or user manual (including the supplier’s instructions) and performance of all maintenance and service work. This machine may be used solely for

testing for Assemblies

by the company Mustermann GmbH.

No objects (e.g. screw drivers, etc.), other than those explicitly intended for the machine and included in the delivery, may be introduced into the machine, (e.g. mixed in the above parts, etc.). Equally, there must be no small parts unrelated to the production in the vicinity of the machine. Such objects can present a risk of damage to the machine or personnel. Schuster Sondermaschinenbau GmbH is not liable for any such damage. In the event of an accident, responsibility remains with the operator and can not be transferred to Schuster-Sondermaschinenbau GmbH.

4.4 Unauthorised operation

Guarantee claims and liability claims for person damage or property damage are excluded when they originate from one or more of the following causes:

• Incorrect installation, start-up, operation or maintenance of the machine,

• Operation of the unit

- in a faulty condition,

- without protective clothing

• positioning in a hazardous location

• inappropriate use of

- equipment,

- auxiliary equipment,

- peripheral equipment, etc.

• Operation without safety devices

• Operation with safety devices which are

- not in good working order

- not short circuited or

- obsolete

• Use of operating supplies not approved by the manufacturer

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• Inadequate monitoring of machine parts, which are subject to wear and tear

• Faulty repairs

• Emergencies due to the effect of foreign bodies or acts of God

• Unauthorised changes to the structure of the machine

• Unauthorised changes to the performance characteristics (e.g. drive ratios, cylinder velocity, air pressure, motor revs >)

4.5 Obligation to instruct

Before the machine is put into operation, the plant operator must inform his employees about the potential dangers, residual risk and arrangements to prevent the like. The information must be given to each employee who operates the unit or enters the vicinity of danger.

Correct use of the machine presupposes knowledge about how to use and maintain the machine in accordance with the following service, maintenance and cleaning regulations for the machine. The machine operator must possess suitable qualifications (to ensure work is carried out to a standard in keeping with technical state of the art specifications). This includes the ability to assess residual risk. The operator/owner of the machine is responsible for keeping the operating manual updated and that it is observed regarding company internal instructions on operating procedures, supervision duties, reporting requirement, organisation of work, personnel qualifications, etc. Individual competencies required for the different tasks working on and with the machine or in the vicinity of the machine must be clearly defined by the plant operator, identified by task code and adhered to. Potential danger and risks must be considered.

4.6 Safety devices

The machine may only be operated if all safety devices are in good working order. The safety devices must not be removed, circumvented and/or disabled. The software safety programme is also a safety device. Changes to the safety programme are not permitted (see also section 5.9 “Structural changes to the machine”). In general, structural changes to the machine or its accessory parts require the written permission of the company Schuster. Contravention of this requirement voids all liability and warranty! All components of the machine, in particular safety components may be exchanged against other Schuster components only with original parts or with the written consent of the company. If a malfunction or error in the safety system is discovered, the machine must be shut down immediately. In such a situation the following action must be taken:

• plant stop

• switch off main switch

• secure main switch with a padlock

• label the machine as “out of order”

• notify the staff member responsible for the machine immediately

Before restarting the machine, the cause of the malfunction must be determined, documented and eliminated by appropriate technicians in accordance with technical regulations.

4.7 Installations with servo and frequency converter

We would like explicitly to point out here that the integrated “safe restart lock” does not

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interrupt the voltage supply to the motor. It merely prevents the buildup of a rotating field and thereby safely prevents the motor from starting. If electrical work is to be carried out on the motor, the power supply must be interrupted by the mains breaker or the master switch. Please also observe that the intermediate circuit requires a discharge time of at least 5 minutes,before any electrical work can be carried out. The fact that the LEDs on the amplifier are switched off does not mean that the voltages are switched off and the intermediate circuit has discharged below 42V!

4.8 Safety-related guidelines

The safety devices must be checked every time the machine is switched on, i.e. daily or following correction of malfunction as follows:

• Visual inspection of the safety devices to verify the general intended condition and functional safety (e.g. potential bridging must be removed immediately, etc.)

• Check all locking systems, if present Every time the safety devices are checked, verify that no person body parts or objects reach into the exposed danger zones through the opened cover, or that machine parts can escape.

4.9 Supervision obligation

When the machine is committed into the hands of the machine operator by the plant operator, responsibility for the maintenance, supervision and safety devices is transferred from the plant operator to the machine operator!

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5 Personnel training

• Only trained and instructed personnel may work on the unit. In general, the machine may only be operated by employees who have been instructed by the plant operator to operate the machine, who are suitably qualified and only when they have studied in detail all sections of this operating manual and the accompanying operating instructions for all components.

• Personnel responsibility for the operation, re-fitting and maintenance must be clearly defined.

• Trainees may only work on the unit in the presence of an experienced staff member.

• Maintenance and repair work may only be carried out by specially trained and qualified technicians. The technicians must observe the information on maintenance, all relevant safety rules and local regulations.

• Work on electrical systems may only be carried out by electricians, technicians for specialist electrical work (TSEW) or personnel instructed in electro technical matters.

Persons

Activity

Instructed

persons

Persons with

suitable

technical

qualifications

Persons with

electro

technical

qualifications

Line manager

with

appropriate

competence

servicing

personnel from

Mustermann

GmbH

Transport X X X X X

Start-up X X X X

Automatic

operation

X X X X X

Installation,

fitting

X X X X

Malfunction

examination

X X X

Mechanical

malfunction

repair

X X

Electrical

malfunction

repair

X X

Maintenance X X X X X

Remedial repair X X X X

Disposal X X X X X

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5.1 Specific plant operator obligations

All plant operators must write an operating manual which defines the:

- Organisational provisions for working with the machine.

- Operational safety.

The plant operator and user are both responsible for ensuring that the operating manual and/or user manual (also that from the supplier) are to hand near the unit. The plant operator is required to maintain the unit in good-working order at all times. The plant operator must check that malfunctions are corrected before the unit is started-up. The plant operator is required to maintain order and cleanliness in the workplace, at the unit and the vicinity of the unit by issuing instructions and checks. The plant operator is required to permit only persons to work on the machine who

• are acquainted with the basic regulations about work safety and accident prevention and who have been instructed in handling the machine,

• have confirmed with their signature that they have read and understood the operating manual section on safety and the warnings.

The plant operator is responsible for ensuring that the user personnel wear the prescribed person protection equipment, e.g. work clothes, safety shoes, protective gloves, protective glasses, ear protectors, > Regular checks on safety-conscious performance of work by the personnel must be made.

5.2 What to do in the event of a malfunction

Stop work in the event of malfunction or irregularities. Switch off the unit. Wait for the machine to shut down. If the main switch cannot be seen, ensure re-start-up is not possible by padlocking the main switch. In addition, attach signs to the unit indicating work on the unit. Correct the malfunction; if necessary inform the line manager, customer service / service.

5.3 What to do in the event of danger

Shut down the unit by activating the emergency off-switch. Further action is determined by the plant operator.

5.4 Rescue of personnel, first aid

Provisions must be defined by the operating company.

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5.5 Residual risk

• The lead from the switch cabinet to the main switch is always live.

• Even when the main switch has been switch off, some components in the switch cabinet may be live.

• Live parts in the switch cabinet and distribution box are touch-proof, but due to the contact with tools there is nonetheless a danger of contact with live parts. If investigation of the error requires work on live parts, a second person with electrical training is required to be present as an observer, who if necessary can switch off the main switch and fetch help in compliance with the German Accident Prevention & Insurance Association regulation A2.

• Pneumatic components can return to the home position once the pneumatic pressure has been switched off.

• Danger of injury from sharp tools.

5.6 Information about residual risk

Following risks may be incurred:

hazard result or safety

objective comment

phases of life hazard causes

1. transport, assembly, installation 1.1 Loading/unloading

with conveyance

Crushing /

Collision

Gravity In leg lifting/moving, the

machine’s centre of gravity can

be lost sight of, so that the machine crashes around/falls

down. In moving it there is

danger of crushing body parts

Specify weight; the motive force of the

industrial conveyance must correspond to the

weight of the machine; secure the machine on the conveyance to prevent slipping

1.2 Drop off at the installation site

and orientate

Crushing / Collision

Gravity Make sure that the surface is viable, otherwise, tipping is

possible

Specify the weight and measurements; requirements on the ground capacity at a min. of

1000 kg/m²

1.3 Loading/unloading with conveyance


Gravity Prevent work item carrying elements on the machine from

harming people via falling

In transporting remove the work item carrier and separately transport, or suitably secure

1.4 Loading/unloading with conveyance


Movable elements

Prevent items on the machine and movable items (e.g. control

panel, doors, screen) from

harming people

Secure movable elements against accidental tilting or slipping

2. bringing into service 2.1 Connecting

electrics

Electrical shock Contact with

energised parts

Wrong connection or lack of

grounding could cause machine

parts to have voltage

Only qualified personnel (electricians) may

connect machines

3. setup, Teachen, programming, rebuilding 3.1 Set-up/servicing General

malfunction

Incorrect

installation

Protection of personnel during

the test run

Only qualified personnel may place the machine

into operation; if necessary appropriate personal will wear protective gear

4. working

5.cleaning 5.1 All cleaning work Crushing Movable objects Prevent uncontrolled

movements

Before any work on the machine, switch off the

machine at the main switch

6. malfunction, troubleshooting, debugging

7. maintenance 7.1 All maintenance

work

Crushing Moving objects Prevent uncontrolled

movement

Before any work on the machine, switch off the

machine at the main switch, lock the main switch and put up a caution sign

8. decommissioning, disassembling, disposal 8.1 Disassembly See point 1

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5.7 Particular hazard areas

• Entire electrical area

• Entire pneumatic area

• Entire hydraulic area (not applicable)

(see section 6.6 “Information about residual risk”)

5.8 Safety and protection devices

• Guard doors with safety switch

• Emergency-off switch

• main control switch

5.9 Structural changes to the machine

Structural changes to the machine or its accessory parts generally require the written agreement of Schuster. Non-compliance with this requirement voids all liability and manufacturer guaranty! Structural changes undertaken by the plant operator or a third party, misalignment of the regulators and restrictors, changes to the electrical system, changes to the SPS hardware and software, the use of non-Schuster Sondermachinenbau GmbH replacement parts or worn parts and similar are the responsibility of the plant operator (particularly in consideration of machine safety and overall function). If damage results, the manufacturer is not liable for the damage, equally the manufacturer is not liable for consequential damage (also to third parties). All components of the machine, in particular safety components may be exchanged against other Schuster components only with original parts or with the written consent of the company.

5.10 Servicing, repair and similar work risk

Repairs and servicing work may only be carried out when the main switch is switched to position “0, OFF” and has been padlocked. The plant operator is required to instruct the operator about the construction, effect and function of the safety devices, hazard areas and correct safety behaviour. Modes of working that interfere with safety at the machine must be refrained from. The plant operator must ensure that unauthorised persons or untrained persons who are not instructed in the requirements of the operating manual do not work on the machine or linger in the vicinity of the machine. No safety device may be dismounted or put out of action. During work, which is not normal operation work (e.g. repairs, re-fitting, etc.) the plant operator must be certain that no parts can escape from the machine. If the repair work requires the dismantling of the safety devices, special care must be taken (see section 5.6 “Information about rest risk”).

Safety devices must be remounted immediately upon completion of the repair work and checked for correct function. Ensure that any seals damaged or removed from the valves or safety devices are renewed.

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Safety elements, splint pins, etc. positive safety elements from safety devices must be replaced. Fixing screws with thread adhesive should be re-glued if re-fixed (see section 5.6 “Information about rest risk”)

5.11 Unit monitoring

• The plant operator must inspect the machine regularly to check for error and must also keep a log of errors. The plant operator must inform the manufacturer immediately of any error identified to allow the manufacturer to correct the error as quickly as possible.

• In the time between error recognition and completion of correction, it is the responsibility of the plant operator to decide whether the machine

• is operated as normal;

• is operated with certain limitations (the difficulty of warning sign requirement and plant operator instruction [compared to Work Equipment Ordinance]);

• is shut down.

If in doubt, always:

Shut down the machine!

5.12 Special safety information

Without fail adhere to the component operating instructions contained in the appendix. These special instructions are a key part of the operating manual and must be observed and complied with. The special instructions may include safety information to protect you from fatal hazards.

5.13 Fire fighting

WARNING! The use of unsuitable fire extinguishing agents

• may result in the production of poisonous gases (vapours),

• cause danger from the electrical system.

Electric shock danger to life! Do not use water! Only use ABC class fire extinguishers. Only use CO2 extinguishers for fires in electrical systems. Inform yourself about

• the location and use of the fire extinguishers,

• the correct method to fight fire.

5.14 Accident report

Inform your line manager and Schuster-Sondermaschinenbau GmbH immediately of accidents, potential hazard sources and any “near-misses”!

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6 Storage and transport

The machine may only be lifted max. 2 cm from the floor when unsecured, because

Suitable elevating equipment may be used to lift the machine. The lifting equipment can be applied to the frame cross-brace between the machine levelling mounts. If the ground is uneven, be careful that the machine is correctly secured against sideways slipping/rolling! During transport, lifting or moving work, the relevant safety regulations must be complied with. Use only certified and suitable lifting equipment! In general, be careful that you never reach under a lifted load. The machine can now be moved slowly, with appropriate safeguards and using a self-propelled vehicle, as long as the anticipated transport route has been suitably secured. If the machine is to be transported to another workshop, the machine must be kept vertical when moved onto the truck. The use of an appropriate loading ramp (for example) is an appropriate method. The machine may not be lifted with a crane! If in doubt, always contact the manufacturer and we will organize a solution.

Never attempt to lift the machine using a method which could pose a risk to persons or equipment! The following environment conditions apply for transport or storage:

• dry

• frost-free

• dust protected

• corrosion protected (e.g. salt water)

6.1 Safety regulations

Use only suitable, undamaged and fully functioning transport means, with sufficient load-bearing capacity. See 3. for transport size and transport weight (max. installed weight) Attach the required transit safety devices and transport appliances. Transport devices / lifting gear should only be attached at the designate points. Secure against slipping. Be aware of the centre of gravity! Avoid setting down backwards. Adhere to accident prevention regulations and local provisions. Transport the unit carefully, do not bring it into contact, rest or prop against fragile objects such as the control console, hand gear, encasement, etc!

!! Beware !!

high tipping hazard during transport,

provide stabilisation,

notify personnel of danger

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Preparation for transport:

- remove tools from fixtures or spindle or magazine

- secure moving parts

- clean machine

- close open cable ends

Energy, supply and waste disposal connections must be disconnected by technicians.

6.2 Personnel requirements

(see section 5 Personnel training)

6.3 Pictorial symbols used on transit objects

Top Fragile Keep dry Keep away from

heat

Use no hooks Sling here

6.4 Transport mode

The unit is not suitable for transport by crane. After delivery, the unit can be moved with elevating equipment, a forklift truck or transport rollers. Transport by truck, train or ship:

- Bolt the machine levelling mounts to the transport floor or crate floor

- Secure the switching cabinet

- Protect from damp and corrosion

- Secure accessory parts against slippage

6.5 Receipt and checking

On delivery of the machine, suitable transport means must be available for use (e.g. forklift truck, elevating equipment).

Check the packing on receipt:

- for transit damage

- other irregularities

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• Document any damage immediately (sketches, digital camera / instant picture camera, description of damage).

• Have the transport company confirm damage in writing on-site!

• Send the documentation to Schuster-Sondermaschinenbau GmbH promptly!

6.6 Unpacking

Transport safety devices, transport support and packing should be removed after the unit has been set in place. Dispose of the packing material in an environmentally compatible manner or re-use it! Customised transport aids and safety devices should remain with the customer. Store them in case you need to move the unit. Inspect the unit after unpacking:

- for transport damage

- for completeness (see delivery document)

- for irregularities

• Document any damage immediately (sketches, digital camera / instant picture camera, description of damage).

• Send the documentation to Schuster-Sondermaschinenbau GmbH promptly!

6.7 Storage environment

For intermediate storage ensure there is

- a suitable storage room e.g. that it is dry, clean, heated to avoid corrosion

- level, horizontal storage (distortion)

Check pneumatic hoses and leads for worn patches and tightness.

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7 Positioning and set-up

The unit must be installed in accordance with the installation plan.

7.1 Unit location, operation location

Hazardous locations are not permitted for this unit. Comply with the maximum load-bearing capacity of the installation floor (structural calculation). A special foundation is not necessary. Ensure there is sufficient area to work and space to manoeuvre! A minimum of 1m around the machine is required. Position the connections (cable, pipes) between units ensuring there is no danger of tripping.

7.2 Setting-up and securing

The unit is a free-standing installation. Secure bolting of the unit is not necessary. Ensure the unit is positioned on an even, horizontal floor (distortion). A precise spirit level should be used at the intended location or on the base plate. Adjust the feet until the machine stands horizontally and all adjustable feet are equally loaded!

7.3 Supply connections

The supply connections must be connected by a technician (see section 5 “Personnel training”) Technical information see section 3

7.4 Interface

- control panel - electric supply - compressed air supply

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8 Start-up / set-up

8.1 Operation preparation

The machine may only be operated by authorised operators who fulfil the requirements regarding training, instruction and qualifications. Authorisation is the sole responsibility of company Mustermann GmbH.

8.2 Safety instructions

Only operate the machine if the following pre-conditions are met:

• The machine is in good technical working order.

• The machine is going to be used for its intended purpose.

• The operating manual is complied with.

• All safety devices are present and functioning.

WARNING! Correct any malfunction immediately. If there is a malfunction, shut down the machine and ensure accidental or unauthorized operation is not possible.

Report any changes immediately to the office or line manager. Make a written report of all malfunctions and changes.


(see section 5 “Personnel training”)

8.4 First start-up

Ensure the handling and functioning mode of the switching and operation elements have been understood. Follow the following instructions to start-up the machine the first time:

• Compare the information on electrical power supply in the switch cabinet with the available mains voltage

If data conforms then:

• Switch the electric main switch to “0, OFF”

• Plug the mains plug into the mains socket

• Plug the pneumatic plug into the connector socket

• Set the pressure regulator of the service unit to 7 bar

This procedure must be repeated every time the machine is re-located. The procedure must be repeated when the machine has been temporarily detached then reconnected to the supply units.

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9 Servicing and cleaning

Servicing, maintenance and cleaning must be carried out by suitably qualified personnel (suitable according to task). The following tasks should be carried out by the plant operator:

9.1 Maintenance table

Interval Place Job Daily Whole machine Visual check for loose objects andv

visible damage

Monthly EMERGENCY-STOP button Check functionality

Monthly Protective housing e.g. automatic operations must not be

possible when open

Monthly Tooling sets Check for functionality and damage

Monthly Stops, initiators Check for tight seating, readjust and

tighten as needed.

Monthly Fastening screws on cyinders,

coupling elements

Check for secure seating and tighten

if necessary

Monthly Electrical lines, connectors and

energy chains

Check, replace if necessary.

Monthly Fans and air conditioning devices Check for function

Every 6 months Filter pads in fans and air

conditioning devices

Replace. Do this at shorter intervals

in case of severe air pollution

annual Pneumatic hoses Check, replace if necessary.

Other maintenance intervals of purchased parts, see the maintenance plans purchased part documentation.

Recommended lubricating grease:

generaly: DIN-label: DIN-number: content KP 2 - K 51502/51825 Lithium soap grease ball bearing guide: KP2K-30 51825 Lithium soap grease roller bearing guide: KP2N-20 51825 Lithium complex

9.2 Cleaning

It is self-evident that the unit must be cleaned and maintained regularly. How often you clean the unit depends on your work and environment. Clean the unit with suitable agents only. Before cleaning is begun, switch the unit off and secure against unauthorised restart. If the main switch is not visible during cleaning, the switch must be secured with a padlock to prevent unintentional re-start. In addition a sign indicating work in progress must be attached to the unit.

Never clean the unit with compressed air.

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10 Repairs


Comply with the accident prevention regulations! Repairs may only be carried out by qualified and authorised personnel. Before service work is begun, switch the unit off and secure against unauthorised restart. If the main switch is not visible during service work and cleaning, the switch must be secured with a padlock to prevent unintentional re-start. In addition a sign indicating work in progress must be attached to the unit. Work on electrical installations may only be carried out by electricians, technicians for specialist electrical work (TSEW). Live parts in the switch cabinet and distribution box are touch-proof, but due to contact with tools there is nonetheless a danger of contact with live parts.

Maintenance work, cleaning, oiling, etc. may only be carried out when the unit is switched off and shut down. During maintenance work or servicing:

- Switch off energy supply

- Wait until the unit has shut down

- Ensure remaining energy has dissipated (e.g. pressure reservoir, electrics, pneumatics)

Do not clean clothes or unit with compressed air. Do not overestimate your own strength. If necessary fetch help or an elevation device, e.g. forklift truck. Do not clean the unit with high-pressure cleaning equipment. Supplied parts must be serviced in accordance with manufacturer’s instructions. Keep proper order and cleanliness during maintenance work. Keep transport routes free. On completion of maintenance work, check the unit is in the correct operational state, for instance, ensure

- loosened screw connections have been reinstated

- safety devices have been properly replaced and function correctly

- correct tightness of connections / cables

All repairs must be carried out in the correct order. Only use approved auxiliary materials and supplies. Only use original replacement parts.



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11 Replacement parts

We recommend that you keep a store of spare parts to avoid wasting valuable production time and to minimise shut-down time when a wear-susceptible part needs replacing. The replacement part store should include all purchasable parts such as proximity switches, leads and cylinders in a reduced form. The purchasable parts can be seen in the accompanying set of drawings. All components of the machine, in particular safety components may be exchanged against other Schuster components only with original parts or with the written consent of the company.

12 Error correction

Never subject yourself or anyone else to risk when correcting a malfunction. All sections of the operating manual must be adhered to, in particular the “Safety instructions” (section 4), “Information about residual risk” (section 5.6) and the current version of the accident prevention regulations, general laws and regulations and plant operator internal regulations. Error correction may only be carried out by trained, instructed and qualified personnel who have been informed that error correction is associated with increased risk, if the aspects illuminated above are not taken into consideration. The following list of errors is based on current knowledge. The list should be continually amended and in line with current knowledge and experience.

The following always applies:

Repairs and servicing may only be carried out when the machine main switch is

switched to “0, OFF” and secured with a padlock (see 5.10 Maintenance, repair and similar work risks):

13 Shut-down, taking-out-of-service


Observe the accident prevention regulations! Taking-out-of-service may only be performed by authorised and qualified personnel. Switch the unit off before shutting it down; secure the unit against unintentional start-up. If the main switch is not visible during service work and cleaning, the switch must be secured with a padlock to prevent unintentional re-start. In addition a sign indicating the work in progress must be attached to the unit. Work on electrical installations may only be carried out by electricians, technicians for specialist electrical work (TSEW). Live parts in the switch cabinet and distribution box are touch-proof, but due to the contact with tools there is nonetheless a danger of contact with live parts. Only take the unit out of service when shut-down and switched off. To take out of service:

- Switch off energy supply

- Wait until the unit has shut down

- Ensure remaining energy has dissipated (e.g. pressure reservoir, electrics, pneumatics)

Do not clean clothes or unit with compressed air.

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Do not overestimate your own strength. If necessary fetch help or an elevation device, e.g. forklift truck.



13.3 Taking-out-of-service

Shut-down

- Switch off, disconnect energy and operational supplies

- Empty fluid and pressure containers

Cleaning

- Clean before storing

Preservation

- Apply corrosion protection agents

- Fill tanks and containers with corrosion protection and/or anti-freeze agents

- Change lubricants

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14 Servicing

On occurrence of malfunction, please use the following contact address:


Moosweg 1

82389 Böbing

Main office: ++49 (0)8867/9102-0

Fax: ++49 (0)8867/9102-20

Service phone electrical: ++49 (0)8867/9102-21

Service phone mechanical: ++49 (0)8867/9102-17

Replacement part service: ++49 (0)8867/9102-0

Service fax: ++49 (0)8867/9102-245

We offer the option of a service contract organised by our customer service department to provide for high operational safety, a long life span for your unit and to avoid the cost of big repairs.

The individual services offered by our servicing service can be arranged to suit individual requirements. We would be delighted to provide you with a quote on request.

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