Metal Brake Lathe Safe Work Procedure
Page 1 of 8 / WSHMS-02C-SWP-085
Division: /

RETSD

/

Analysis By:

/

Kildonan-East Collegiate

/

Date:

/ May/21/2013
Department: / Kildonan-East Collegiate /

Supervisor:

/

Frequency:

/ Hourly

Job Title:

/

Auto Tech

/ Approved By: /

JSA Number:

/ AT42

Job Title:

/ Brake Lathe (Hunter BL505) AT42 / Job Performed By: /

Teacher and or students

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 for any flammable or combustible materials. Keep floor clear of obstructions and tripping hazards. / Fire, Explosion.
Slip/Trip/Fall Hazard
Unbalanced operator is at a higher risk of contacting sharp or moving parts. / Good Housekeeping, keep area clean, clear away debris. Ensure that flammable or combustible materials are moved away before starting work. Make sure surface is clean and dry.
2 / Check the electrical cord for cuts or frays. If cuts are found notify instructor before using the machine. / May cause electric shock. / Do not use machine if the electrical cord is damaged. Notify the teacher/instructor before using.
3 / Inspect the machine for damaged parts including guards, arbor, centering cone and adapters. Check for proper alignment of moving parts. Make sure they are not binding or broken. / Risk of Chips/Projectiles.
Bent arbor causes improper operation, poor cuts and risk of damage to persons and equipment. / If guards are damaged, notify instructor immediately. Do not use until repaired or replaced.
If arbor is bent it needs replaced.

Disc Re-Surfacing

4 / Prepare work piece (disc or drum) by cleaning with Brake Cleaner, and removing rust and corrosion from the mounting surfaces with emery cloth.Measure disc thickness to make sure it is thicker than specification. If too thin, disc should be replaced. / Poor contact surfaces may cause risk of flying debris and poor cut quality.
Excessive dust inhalation. / If contact surfaces are not clean, smooth and flat, sand them with a fine emery cloth or replace as per teacher’s instructions.
Wear a dust mask if cutting operation is dusty.
5 / Secure all work pieces properly. Follow teacher instruction for installation method for discs or drums. Use the Hunter Pro quick chuck (2 pieces) and proper adaptors and spacers. Secure arbor nut to hand tight using key provided. Make sure silencer band is properly attached. / Loose work piece/adaptors could fly off lathe.
Damage to persons or machine.
Improper finish on work piece.
Risk of whipping parts and/or projectiles. / Secure arbor nut to hand tight. Do not over-tighten.
Secure silencer as per teacher instructions.
6 / Remove adjusting keys and wrenches from the machine before starting the lathe. / Projectiles. / Remove all unsecured accessories from the machine before starting. Make this a habit every time.
7 / Make sure the drum boring bar is retracted. / Red drum retract light will be on. Automatic feed will not start.
8 / With the rotor mounted on the spindle, position the twin cutter so the cuttinginserts are on either side of the rotor, near the center.
9 / Place the power switch in the “ON” position, and verify that the rotor is rotating smoothly without a wobble. / Entanglement
Poor Cut/Measurement / Keep hands clear of spinning rotor.
Tie back all loose hair and clothing. Jewelry should be removed.
Turn Off lathe and make sure disc set up is proper.
10 / Turn the knob on the detent assembly until the roll pin is aligned with the slot inthe detent locking nut.
11 / Rotate the twin cutter up to position until the detent pin pops down, roughlyaligning the twin cutter on center.
12 / Loosen the lock knobs located over the tool holder bars.
13 / Tighten the 1 inch detent locking nut slightly tighter than hand-tight with a 1 inchwrench. / Over tightening the detent locking nut may cause damage tothe detent 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.
17 / Move the twin cutter to the inner edge of the disc surface. Dial back down to “0.000” for both sides. This may be loud as the inner edge could be thicker. / Flying debris, broken cutting bits.
May damage work piece and machine. / Always wear eye protection. Follow proper cutting depth as per teacher instructions. When cutting, do not force a tool or blade too deep into the work piece.
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 notedon the feed control dial (typical feed rates: roughing #10, finishing #2 - #4).
20 / Don’t over-reach. Keep proper footing and balance at all times. / Operator out of control.
Serious injury from contacting rotating surface or cutting blades. / Keep guards in place, keep proper balance when near machine.
21 / Shift the feed selector handle to the “DISC” position. (If the lathe does notautomatically 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 isengaged.)
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.
28 / Remove the disc from the arbor and clean with brake cleaner or warm soapy water. / Falling work piece will crush toes/fingers.
Damage to work piece. / Wear CSA approved safety shoes. Do not try to catch a falling object. Use proper lifting techniques.

Drum Re-Surfacing

29 / Using a brake drum diameter gauge, check the drum diameter from at least threepoints around the circumference, about 1 inch (25.4 mm) in from the outerdiameter. 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 bereplaced.
30 / Loosen the detent locking nut and rotate the twin cutter so the cutting insertspoint down. / Laceration on cutting inserts. / Handle with care.
31 / Mount the drum on the arbor using the appropriate adaptors and spacers. Follow teacher instruction for installation method for discs/drums. Refer to Section 2.2 of Operator Manual for diagrams. / Loose work piece/adaptors could fly off lathe.
Damage to persons or machine.
Improper finish on work piece. / Secure arbor nut to hand tight. Do not over-tighten.
32 / Wrap the drum silencer band (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 toplayer of the band. / Risk of whipping parts and/or projectiles. / Secure silencer as per teacher instructions.
33 / Remove adjusting keys and wrenches from the machine before starting the lathe.
Turn the power switch “ON”. / Projectiles. / Remove all unsecured accessories from the machine before starting. Make this a habit every time.
34 / Check the setup and workpiece accuracy. Refer to “Achieving Setup Accuracyand Determining Workpiece Quality/Condition,” page 16.
35 / Extend the drum boring bar by turning the drum crossfeed control on the rightside of the feed housing. Position the boring bar cutting insert over the most wornsection 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 toresurface 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 handwheel and set the depth of cut for approximately 0.008 inch (0.203 mm) more than that required to resurface thedrum.
41 / Set the feed rate according to the desired finish of cut, as noted on the feedcontrol dial (typical feed rates: roughing #10, finishing #2 - #4).
42 / Don’t over-reach. Keep proper footing and balance at all times. / Operator out of control.
Serious injury from contacting rotating surface or cutting blades. / Keep guards in place, keep proper balance when near machine.
43 / Shift the feed selector handle to the “DRUM” position. Let cutting continue untilthe cutting insert has cleared the edge of the drum.
44 / When cutting, do not force a tool or blade too deep into the work piece. / Flying debris, broken cutting bits.
May damage work piece and machine. / Always wear eye protection. Follow proper cutting depth as per teacher instructions.
45 / Disengage the feed selector.
46 / Turn the power switch to the “OFF” position.
47 / Remove the drum from the arbor and clean with brake cleaner or warm soapywater. / Falling work piece will crush toes/fingers.
Damage to work piece. / Wear CSA approved safety shoes. Do not try to catch a falling object. Use proper lifting techniques.

AUTHORIZED EMPLOYEE INFORMATION:

ID NUMBER: / LAST NAME: / FIRST NAME: / REMARKS:

JOB HISTORY INFORMATION:

DATE: / REMARKS:

Approval Signature:Date:

Page 1 of 8 Print Date: May/31/2013