DEPARTMENT OF EDUCATION AND CHILDREN'S SERVICES

Human Resources

WorkCover Building Level 4 - 100 Waymouth Street Adelaide SA 5000 Courier R11/7 GPO Box 1152 Adelaide 5001 Fax: (08) 8226 1177 Phone: (08) 8226 1440

HAZARD ALERT
MACHINE GUARDING AND RELATED COMPLIANCE ISSUES
Attention: Principals of sites and users of Hercus model 'A', 'AR', 'B', and 'C' lathes and other inappropriately guarded machines at High Schools, Area Schools and other sites with a secondary component.
The department has established an executive level OHS&W committee to address issues identified by a consultant engaged by WorkCover to assist the department achieve Level 3 of the 1996 Prevention Performance Standards. As a result of the work of this committee and the observations of the consultant, a number of issues relating to machine safety have been identified as requiring action. This Hazard Alert outlines actions required to address the guarding requirements of Hercus lathes and also broadly discusses the guarding requirements for all machinery. Plant and machine safety in curriculum areas other than Technology Studies will also need to be addressed and the executive committee is working to develop plans to assist sites in addressing this area of concern. Principals are directed to: identify machines that have guards that do not offer appropriate protection due to poor or outdated guard design - access to all nip points must be denied identify machines that are fitted with guards that can be opened, without the use of a tool, during operation Note: Where the use of a tool is seen as an inappropriate action to release a guard then the guard shall be interlocked with the power source so that the machine is stopped if the guard or its parts are moved. These machines must be tagged and locked out immediately until appropriate modifications are made. Principals and site managers must ensure that the principles of safeguarding all items of plant or machinery are followed in order to ensure a safe working environment for staff, students and other people. These general principles for guarding machines and plant are provided in detail in Australian Standard "AS4024.1 Safeguarding of Machinery - General Principles". A summary of the principles relating to the guarding of transmission components is clearly outlined in "AS1485 Safety and Health in Workrooms of Educational Establishments". The relevant section is quoted below.
5.4.2 Transmission Guarding Access to gears, belts, pulleys, shafts, flywheels and other dangerous moving parts shall be prevented by enclosure within the machine or by substantial guards. Guards or parts of them may be moveable to provide access for maintenance or other reasons, but the use of a tool shall be required before such movement is possible. Where tools are not required, the moveable guards or parts of them shall be interlocked with the source of power to the guarded machinery so that the machinery will become inoperative when the guard or part is opened.

The Machine Guarding Audit Principals are referred to the workshop audit reports that were prepared and forwarded to worksites between 1997 and 2001. Details of the required guarding and the proposed solutions are outlined in each audit. It is acknowledged that all worksites have completed the guarding of machines with a "high classification of risk". The audit identified other machines with hazard classifications "Medium 1", "Medium 2" and "Low". It is expected that all machines that have an "identified hazard" will be guarded according to the principles of 5.4.2 in AS1485, or be removed from service. Guarding details for the most commonly used machines in technology workshops, including lathes, are available on the machine guarding CD which was provided to all worksites

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SPECIFIC ISSUES WITH MODEL AR AND EARLIER HERCUS LATHES The WorkCover consultant recently noted that the Hercus AR lathes, at sites that he visited, were not appropriately guarded. Each had belt drive and gear train guards that could be opened while the machine is in operation providing uncontrolled access to the moving belts, pulleys and gears. It was also noted that the belt guarding did not provide adequate protection from access to the belts and pulleys from the back and side of each machine. There may be machines other than metal lathes in school workshops with similar hazards and the action outlined in this alert must apply to all such machines. Hercus metal turning lathes, models 'A', 'AR', 'B', 'C' have guards that allow uncontrolled access to moving parts, in particular belt drives and gear trains. This is contrary to machine guarding standards. Other brands of Metal Lathes may have similar problems and should be considered when dealing with this notice. Because of the age of these machines, the guards fitted at the time of manufacture, no longer conform to current standards and need modification before the lathes can be returned to service. The OHS Unit is working to find long term solutions to the issues related to guarding of these machines. Schools are asked to consider the curriculum at all year levels and make modifications to courses so that the machines concerned can be tagged and locked out until appropriate long-term solutions can be developed. If the curriculum demands the continued use of these lathes a number of immediate and minimum modifications must be made to each machine before students and teachers can use them. These modifications are outlined in the issues listed below. ISSUE 1 Guard covering Motor to Counter Shaft Belt Drive (Figure 1) The large guard covering the belt and pulleys providing transmission from the motor to the top idler shaft is held in place with knurled nuts. Because these nuts do not require a tool for the removal of the guard, the guard does not comply with current Australian Standards. The remedy is to replace these nuts with hexagonal nuts that require a spanner to loosen. Some care is required to ensure that any protruding thread does not cause a hazard to people walking past the end of the lathe.
Figure 1

ISSUE 2 Gear Train Guard (Figure 2 and 3) The guard covering the gear train at the end of the lathe is hinged for easy access but cannot be latched or fixed shut. Since access to these gears is only needed on an irregular basis it is recommended to bolt the guard shut. In order to meet the Australian Standards and provide a safer environment for operators, it is required that this guard is fixed shut. This can be done using an appropriate nut and bolt. A 50mm long spacer between the guard and the back plate is needed to ensure that this guard does not rub on any part of the gear train. A 75mm long bolt and an appropriate tubular spacer can be a quick and effective method to lock this guard shut. A more permanent option is shown over the page.

Figure 2

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ISSUE 2 cont. Method for locking gear train guard The photograph, figure 3, shows a fixed 50mm long spacer that is drilled and tapped at each end with a 5mm metric thread. The hinged guard and back-plate have holes of 6mm drilled in line with each other in a position that will not interfere with the gear train. The spacer is fixed to the back-plate with a 5mm Hexagon head screw. A spring washer is used between the plate and spacer so that the spacer cannot turn when in use. The door is held shut with another 5mm screw. A 5mm-hexagon head screw is recommended as the Hercus lathe spanner will fit the screw head when adjustments are needed. ISSUE 3 Uncontrolled Access to the Belt Drive from the top, rear or side The belt guard that is currently fitted does not prevent access to the pulleys and belts from the rear or the top or side during operation. Significant modification to the top back and side of this area will be required before the lathe can be returned to service. Modification to the top of the lift-up guard and the holes at the back of the casting are relatively easy but preventing access from the side is a far more taxing problem.
Access from the side to Belt Drive

Figure 3

Access through Top of guard

Access through back of casting

Figure 4

ISSUE 3 cont. Covering the hole in the top of the guard A guard can be fabricated from 1.2mm thickness sheet metal (Aluminium is a good choice but not essential) The blank size for this guard is 120 x 100mm.
Fold 1 12mm from the end, up 50

Fold 3 15mm from fold 2, down 900

It is folded as shown in figure 5 The corners of the small R.H. 12mm fold will need to be trimmed to suit the inside shape of the lift-up guard. Holes are drilled in each corner so that it can be riveted inside the lift up guard. ISSUE 3 cont. Covering the holes in the back of casting A sheet metal cover plate can be fabricated from 1.2mm thickness material. (Aluminium is a good choice but not essential) The blank size is 110x235mm
Plate riveted onto back of casting
00 Fold 2 12mm 12mmfrom fromend end, up up 85 85

Figure 5

Fabricated guard is riveted inside lift-up guard

Holes are drilled at strategic positions so that it can be riveted to the casting. Gaining access past the motor and other protrusions will influence the position of the rivet holes.

Figure 6

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ISSUE 3 cont. Preventing access to pulleys and belt drive from the side Figure 7 Covering the opening at the side of the belt drive is a more complex issue and cannot be covered in detail in this Hazard Alert. It requires the fabrication of a new guard that is attached to the rear vertical casting. This guard must cover the exposed area, be rigid so that it will not deflect into the belt system and not create a new hazard. If the guard is to be fabricated at the school site it must be of a material that can easily be worked using school facilities. It has been designed using 9mm MDF board. This material has: significant strength can be easily shaped using school facilities has the ability to be rounded over at the edges so that the effect of shearing between it and the lift-up guard are minimised Detailed plans for this guard will follow this Hazard Alert by direct distrubition to schools.
Figure 7

ISSUE 4 Guard can be opened when the lathe is in operation The existing belt guard is a lift-up cover over the belt drive to the headstock spindle. This cover can be easily opened when the machine is operating and does not prevent access to the moving parts. Adjustments to the speed of the lathe are a regular and routine part of turning operations and access to this belt drive is required. The guard does not meet current standards in that it is neither interlocked to the motor supply nor able to be fixed shut with a bolt, screw or similar. Micro-switched interlocking guards This is seen as the best possible solution. This guard includes a micro-switch or other interlocking device, which ensures that the machine is disabled when the guard is lifted. Arrangements must be made to fit interlocking micro-switches to all machines that are currently fitted with the style of guard as seen in figure 4. Each worksite must ensure that the belt drive for the headstock spindle is adequately guarded to eliminate uncontrolled access. Worksites are advised to develop a program to guard all lathes with micro-switched interlocking guards. This may be done over time in order to manage the associated costs. A Short Term solution The department has consulted with Workplace Services Inspectorate to identify an immediate solution. It is recognised that frequent adjustments must be made to this belt drive system. However this belt guard can easily be raised while the lathe is in operation exposing the operator to a risk of injury. If interlocking micro switched guards cannot be immediately fitted, schools must devise a method to fix this guard in the closed position with a device that requires the use of a tool to open the guard or 'Tag and Lock Out" the non-compliant machines. An interim solution The knob that is fitted to the guard can be replaced with a 5mm-hexagon head screw and appropriate washer. A nyloc nut and flat washer can be fitted behind the guard to make the screw captive. A matching thread needs to be drilled and tapped into the headstock casting in line with the screw position. Be careful that any holes that are drilled into this casting do not interfere with any bearings or shafts that are within the headstock. A 5mm-hexagon head screw is recommended as the Hercus lathe spanner will fit the screw head when adjustments are needed.

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Principals Must Ensure that close supervision occurs WHEN all machines are used Prevent or limit access to persons who have not had adequate training Revise the safe working practices to take into account the modifications that have been made Restrict some operations Principals must ensure that the site health and safety representative receives a copy of this alert and is engaged in the process of actioning it. Need to allow Time to complete this work It must be recognised that significant time will be needed where schools choose to undertake this work so that the curriculum can continue without adjustment. It is anticipated that between 3 hours to 5 hours will be needed on each machine to complete the modifications as outlined above. Where a school has many machines of the same type and model then the time needed per machine may be less. Principals must ensure that time is made available to any teacher who is asked to complete this work beyond their normal duties. Principals and supervisors must ensure that users of the machine have adequate information, instruction, training and supervision. Safe Operating Procedures, which include clear directions on the safe use of the machine and the use of any modified guards, must be readily available at each lathe.

OTHER MACHINES WITH SIMILAR PROBLEMS Machines such as drill presses, wood lathes, sanding discs and some milling machines have similar guarding issues. Non-compliant machines must be guarded appropriately or immediately Tagged and Locked Out. Managers are referred to the machine guarding CD for further information or are advised to contact their OHS adviser. Additional advice will be provided as soon as alternative solutions are available. A copy of this HAZARD ALERT is posted on the Occupational Health Services Unit web site http://www.dete.sa.gov.au/ohsw then click Bulletin Board then click Hazard Alert Please contact Graeme Cutting 8226 1310 for further information.

Steve Kelton EXECUTIVE DIRECTOR, HUMAN RESOURCES RESPONSIBLE OFFICER, OHS&W Date: