Metal Brake Lathe Safe Work Procedure

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Division: RETSD Analysis By: Kildonan- Date: May/21/2013 East Colleg iate

Department: Kildonan-East Collegiate Supervisor: Frequency: Hourly

Job Title: Auto Tech Approved By: JSA Number: AT42

Job Title: Brake Lathe (Hunter BL505) Job Performed By: Teacher and AT42 or stude nts

REQUIRED PERSONAL PROTECTIVE EQUIPMENT: CSA approved safety glasses or goggles, CSA approved steel-toed footwear, 100% cotton coveralls preferred, and hearing protection required in confined space/area and/or per RETSD policy.

GENERAL NOTES: No lighters, matches or cell phones are allowed in the shop area. Long necklaces, bracelets and rings should be removed. Gloves, long necklaces, bracelets and rings should be removed. Long hair should be tied back. Strings and hoods hanging from pullovers/sweaters should be removed or tucked inside of coveralls.

JOB SAFETY ANALYSIS:

Step Description Hazard Controls Pre-Setup Inspection 1 Ensure clean work area, check Fire, Explosion. Good Housekeeping, keep area clean, clear away debris. Ensure that for any flammable or Slip/Trip/Fall Hazard flammable or combustible materials are moved away before starting combustible materials. Keep Unbalanced operator is at a higher risk of work. Make sure surface is clean and dry. floor clear of obstructions and contacting sharp or moving parts. tripping hazards.

Page 1 of 7 Print Date: May/31/2013 2 Check the electrical cord for cuts May cause electric shock. Do not use machine if the electrical cord is damaged. Notify the or frays. If cuts are found notify teacher/instructor before using. instructor before using the machine. 3 Inspect the machine for Risk of Chips/Projectiles. If guards are damaged, notify instructor immediately. Do not use damaged parts including guards, until repaired or replaced. arbor, centering cone and Bent arbor causes improper operation, If arbor is bent it needs replaced. adapters. Check for proper poor cuts and risk of damage to persons alignment of moving parts. Make and equipment. sure they are not binding or broken.

Disc Re-Surfacing 4 Prepare work piece (disc or Poor contact surfaces may cause risk of If contact surfaces are not clean, smooth and flat, sand them with a drum) by cleaning with Brake flying debris and poor cut quality. fine emery cloth or replace as per teacher’s instructions. Cleaner, and removing rust and corrosion from the mounting Excessive dust inhalation. Wear a dust mask if cutting operation is dusty. surfaces with emery cloth. Measure disc thickness to make sure it is thicker than specification. If too thin, disc should be replaced. 5 Secure all work pieces properly. Loose work piece/adaptors could fly off Secure arbor nut to hand tight. Do not over-tighten. Follow teacher instruction for lathe. installation method for discs or Damage to persons or machine. drums. Use the Hunter Pro quick Improper finish on work piece. chuck (2 pieces) and proper adaptors and spacers. Secure arbor nut to hand tight using key Risk of whipping parts and/or projectiles. Secure silencer as per teacher instructions. provided. Make sure silencer band is properly attached. 6 Remove adjusting keys and Projectiles. Remove all unsecured accessories from the machine before starting. wrenches from the machine Make this a habit every time. before starting the lathe. 7 Make sure the drum boring bar Red drum retract light will be on. Automatic feed will not start. is retracted. Metal Brake Lathe Safe Work Procedure

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8 With the rotor mounted on the spindle, position the twin cutter so the cutting inserts are on either side of the rotor, near the center. 9 Place the power switch in the Entanglement Keep hands clear of spinning rotor. “ON” position, and verify that Tie back all loose hair and clothing. Jewelry should be removed. the rotor is rotating smoothly Poor Cut/Measurement Turn Off lathe and make sure disc set up is proper. without a wobble. 10 Turn the knob on the detent assembly until the roll pin is aligned with the slot in the detent locking nut. 11 Rotate the twin cutter up to position until the detent pin pops down, roughly aligning the twin cutter on center. 12 Loosen the lock knobs located over the tool holder bars. 13 Tighten the 1 inch detent locking Over tightening the detent locking nut nut slightly tighter than hand- may cause damage to the detent tight with a 1 inch wrench. assembly or the twin cutter. 14 Slowly turn either disc micrometer control knob clockwise, until the cutting insert scratches a full circle. Listen for continuous contact (smooth cut, not a wobble). Repeat for other side of the disc. 15 Press the “zero” buttons on the Digi-Cal display. The disc display should read “0.000.” 16 Turn the micrometers counter clockwise to pull the cutters away from the disc surface.

Page 3 of 7 Print Date: May/31/2013 17 Move the twin cutter to the inner Flying debris, broken cutting bits. Always wear eye protection. Follow proper cutting depth as per edge of the disc surface. Dial May damage work piece and machine. teacher instructions. When cutting, do not force a tool or blade too back down to “0.000” for both deep into the work piece. sides. This may be loud as the inner edge could be thicker. 18 Dial the micrometers until both read “0.002”. Lock the cutting inserts into position by tightening the locking knobs on the tool holder bars. 19 Set the feed rate according to the desired finish of cut, as noted on the feed control dial (typical feed rates: roughing #10, finishing #2 - #4). 20 Don’t over-reach. Keep proper Operator out of control. Keep guards in place, keep proper balance when near machine. footing and balance at all times. Serious injury from contacting rotating surface or cutting blades. 21 Shift the feed selector handle to the “DISC” position. (If the lathe does not automatically feed, check to see if the Drum Retract light is on. If the light is on, manually retract the drum boring bar until the light goes out and automatic feed is engaged.) 22 During cutting operation, do not leave the lathe unattended. 23 Allow the cutting inserts to travel past the outer edge of the disc. 24 Disengage the feed selector. Move to “OFF” position. 25 Turn the power switch to “OFF.” 26 Check surface of disc for quality of cut. Repeat cutting procedure until surface is usable. 27 Measure disc thickness to make sure it is thicker than specification. If too thin, disc should be replaced. Metal Brake Lathe Safe Work Procedure

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28 Remove the disc from the arbor Falling work piece will crush toes/fingers. Wear CSA approved safety shoes. Do not try to catch a falling object. and clean with brake cleaner or Damage to work piece. Use proper lifting techniques. warm soapy water.

Drum Re-Surfacing 29 Using a brake drum diameter gauge, check the drum diameter from at least three points around the circumference, about 1 inch (25.4 mm) in from the outer diameter. If the drum diameter is greater than the maximum diameter established by the manufacturer, or if it will be greater after surfacing, the drum should be replaced. 30 Loosen the detent locking nut Laceration on cutting inserts. Handle with care. and rotate the twin cutter so the cutting inserts point down. 31 Mount the drum on the arbor Loose work piece/adaptors could fly off Secure arbor nut to hand tight. Do not over-tighten. using the appropriate adaptors lathe. and spacers. Follow teacher Damage to persons or machine. instruction for installation Improper finish on work piece. method for discs/drums. Refer to Section 2.2 of Operator Manual for diagrams. 32 Wrap the drum silencer band Risk of whipping parts and/or projectiles. Secure silencer as per teacher instructions. (175-186-2 for cars and 175- 187-2 for trucks) snugly around the drum and secure it by sliding the buckle finger under the top layer of the band. 33 Remove adjusting keys and Projectiles. Remove all unsecured accessories from the machine before starting. wrenches from the machine Make this a habit every time. before starting the lathe. Turn the power switch “ON”.

Page 5 of 7 Print Date: May/31/2013 34 Check the setup and workpiece accuracy. Refer to “Achieving Setup Accuracy and Determining Workpiece Quality/Condition,” page 16. 35 Extend the drum boring bar by turning the drum crossfeed control on the right side of the feed housing. Position the boring bar cutting insert over the most worn section of the drum face. This may be a deep groove or bell-mouth condition. 36 Perform a scratch test to verify setup accuracy and drum condition. Refer to “Achieving Setup Accuracy and Determining Workpiece Quality/Condition,” page 16. 37 Measure the total indicated runout to determine the deepest cut necessary to resurface the drum. Refer to “Measuring Total Indicated Runout (T.I.R.),” page 17. 38 Turn the drum crossfeed control until the cutting insert just contacts shallowest section of drum surface. This may or may not be in a deep groove. 39 Set the depth-of-cut dial to zero and lock it with the thumbscrew. 40 While observing the feed control dial, turn the hand wheel and set the depth of cut for approximately 0.008 inch (0.203 mm) more than that required to resurface the drum. Metal Brake Lathe Safe Work Procedure

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41 Set the feed rate according to the desired finish of cut, as noted on the feed control dial (typical feed rates: roughing #10, finishing #2 - #4). 42 Don’t over-reach. Keep proper Operator out of control. Keep guards in place, keep proper balance when near machine. footing and balance at all times. Serious injury from contacting rotating surface or cutting blades. 43 Shift the feed selector handle to the “DRUM” position. Let cutting continue until the cutting insert has cleared the edge of the drum. 44 When cutting, do not force a tool Flying debris, broken cutting bits. Always wear eye protection. Follow proper cutting depth as per or blade too deep into the work May damage work piece and machine. teacher instructions. piece. 45 Disengage the feed selector. 46 Turn the power switch to the “OFF” position. 47 Remove the drum from the Falling work piece will crush toes/fingers. Wear CSA approved safety shoes. Do not try to catch a falling object. arbor and clean with brake Damage to work piece. Use proper lifting techniques. cleaner or warm soapy water.

AUTHORIZED EMPLOYEE INFORMATION:

ID NUMBER: LAST NAME: FIRST NAME: REMARKS: JOB HISTORY INFORMATION:

DATE: REMARKS:

Approval Signature: Date:

Page 7 of 7 Print Date: May/31/2013