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Brobo Group

brobo.com.au

CHAPTER 2 - Safety & Accident Prevention

The

Brobo Group

BENCH/BUFF GRINDERS 200HD & 250HD

has been designed & manufactured in accordance

with

Australian Standards

. It is

HIGHLY RECOMMENDED

that the instructions & warnings contained in this

chapter be carefully followed for correct usage of the machine.

2.1. Operation of the Machine

This machine is specifically designed for grinding of various ferrous metal sections. Our company has no
responsibility for any damages & risks caused as the result of changing & addition on the machine or removing any
part of the machine.

This machine involves a high-speed revolution; therefore extreme caution is required when operating the
device.

The  employer  is  responsible  for  instructing  the personnel  who, in turn, are  obliged  to inform the operator of any
accident  risks,  safety  devices,  noise  emission  &  accident  prevention  regulations  provided  for  by  national  &
international  laws  governing  the  use  of  the  machine.

The operator must be fully aware of the position &

functions of all the machine’s controls.

All those concerned must strictly adhere to ALL instructions, warnings, & accident prevention standards in
this manual.

The following definitions are those provided for by the

EEC DIRECTIVE ON MACHINERY No. 98/37/CE

:



Danger Zone -

any zone in and/or around a machine in which the presence of a person constitutes a

risk to the safety & health of that person.



Person Exposed

- any person finding him or herself, either completely or partly in a danger zone.



Operator

- the person or persons are given the responsibility of installing, operating, adjusting,

maintaining, cleaning, repairing, & transporting the machine.

2.1.1. Noise Level

The noise level of an idling grinder has been measured to be

below 85 dBA

.

This complies with the

Australian

Occupational Health & Safety (Noise) Regulations 1992

.

Please note that peak impulse noise levels will be experienced due to variables including blade characteristics, type,
& condition. This will also vary accordingly depending on the size & type of sample being ground. Under these
circumstances, management should make available to the operator(s) the appropriate hearing protection equipment
as prescribed under the above-stated act.

WARNING – UNAUTHORISED MODIFICATIONS/REPLACEMENTS/USE

The manufacturer declines any responsibility whatsoever, either civil of criminal, in the case of
unauthorised interference or replacement of one or more parts or assemblies on the machine,
or if accessories, tools & consumable materials used are different from those recommended by
the manufacturer, or if the machine is inserted in a plant system & its proper function is altered.

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Содержание 200HD

Страница 1: ... brobo com au PRODUCT AND MAINTENANCE MANUAL BENCH BUFF GRINDERS 200HD 250HD Precision Drilling Machines Tapping Machines Multi Head Drills Tool Grinders Tool Post Grinders Machine Vices Special Production Equipment Accessories Riveting Machines Pedestal Grinders Metal Cutting Saws Linishers A C N 098 264 316 A B N 42 098 264 316 ...

Страница 2: ...quirements 2 3 Advice for the Operator 2 4 Machine Safety Devices 2 4 1 Reference Standards CHAPTER 3 Main Functions Operation of the Machine 3 1 Main Features 3 2 Preparation for Operation 3 3 Operation Recommendations CHAPTER 4 Drawings Layouts Assembly Spare Parts 4 1 Spare Parts 4 2 200 HD Grinder Assembly Stand Optional 4 3 250 HD Grinder Assembly CHAPTER 5 Maintenance Selection of Consumable...

Страница 3: ... 1 4 240 1 Buff Grinder 3 4 x 20 TPI 200HD 3 PH 3850230 1 1 1 4 415 3 Buff Grinder 3 4 x 20 TPI 200HD 1PH 3850270 1 1 1 4 240 1 Bench Buff Grinder 200mm x 25mm wide x 19 05mm bore 3 4 x 20 TPI 200HD 3 PH 3850220 1 1 1 4 415 3 Bench Buff Grinder 200mm x 25mm wide x 19 05mm bore 3 4 x 20 TPI 250HD 1 PH 3500060 1 1 1 4 240 1 Bench Grinder 250mm x 25mm wide x 19 05mm bore 250HD 3 PH 3500010 1 1 1 4 41...

Страница 4: ...ually supported Position the grinder to the desired location ensuring that a power outlet is available within reach of the grinder power cord Prior to powering up the grinder place the desired wheel buff mop onto the machine spindles Note that if the bore sizes on the grinding wheels or buffering mops do not fit the spindle taper adapters buff adapters are readily available for purchase from most ...

Страница 5: ...Bar no greater than 900kPa 9 Bar Ambient Temperature From 10 C to 50 C Relative Humidity Not more than 90 Lighting More than 500 LUX 1 3 Anchoring the grinder unit Figure 2 Anchoring the grinder unit WARNING OPERATING VOLTAGE VARIATION Each grinder model has an inbuilt safety system to protect it against voltage variations However for the machine to perform efficiently ensure that the grinder unit...

Страница 6: ...itted with a suitable approved four pin plugs i e three phase earthing not provided Figure 3 2 Connection for 4 CORE Wire System with Neutral 3 Phase c Check the power supplied motor specifications before plugging in the machine Check the terminal connection on dual voltage motor terminal box connect it accordingly to the corresponding voltage supply d If the dual motor is requested the motor is a...

Страница 7: ...d for by the EEC DIRECTIVE ON MACHINERY No 98 37 CE Danger Zone any zone in and or around a machine in which the presence of a person constitutes a risk to the safety health of that person Person Exposed any person finding him or herself either completely or partly in a danger zone Operator the person or persons are given the responsibility of installing operating adjusting maintaining cleaning re...

Страница 8: ...cerned For this reason the user of the machine must provide adequate lighting in the working area to eliminate areas of shadow whilst also prevent dazzling illumination sources Reference standard ISO 8995 2002 Lighting of Indoor Workplaces 2 2 2 Connection Check that the power supply cables compressed air supply if applicable coolant system complies with are operating within the acceptable range o...

Страница 9: ...nstructions must be observed during all procedures PRECAUTIONS AGAINST ACCIDENTS Comply with all instructions on the manuals for preventing accidents The machines comply with international standards ISO 9001 MAINTENANCE CLEANING The maintenance cleaning should be done by the qualified person COPYRIGHT The copy or simulation of our machines or some parts is not allowed without written permission fr...

Страница 10: ...upply to the machine before carrying out any maintenance work or adjustments This includes cases of abnormal operations of the machine The operator MUST NOT conduct any risky operations or those not required for the grinding in course Never move the grinder while the machine is operating Always keep the workplace are as clean as possible Remove equipment tools or any other objects from the grindin...

Страница 11: ...tion the grinder also complies with the Australian Standards regarding the safeguarding general requirements for electrical equipment 2 4 1 Reference Standards MACHINE SAFETY EEC Directive No 98 37 CE Machines Directive EEC Directive No 91 368 94 68 Amends sections of EEC Directive No 98 37 CE relating to machine safety EEC Directive No 73 23 Low Voltage Directive AS4024 1 1996 Safeguarding of Mac...

Страница 12: ...d at A24 46 Grit the general purpose grinding wheels are provided on all Brobo bench grinding machines It is advisable for all operators that grinding buffing wheels are available for purchase for various applications from reputable hardware stores Also note that tapered buff wire adaptors are available for purchase from Brobo sold separately 3 1 4 Toolrest As implied the Toolrest provides a stabl...

Страница 13: ...g the workpiece into the grinding wheel Apply a steady even pressure feed downward towards the wheel During grinding use a traversing motion across the face of the grinding wheel up to within the edge of the wheel Take care not to round off the grinding wheel edges Do not grind in the one spot on the wheel as this will damage the wheel Good grinding practice preserves the shape of the grinding whe...

Страница 14: ...Adaptor 3 4 x 20 TPI Wire Brush Adaptor 3801230 L H Wire Bush Adaptor Flanges 3 4 x 20 TPI 3801240 R H Wire Bush Adaptor Flanges 3 4 x 20 TPI Buff Mops 3805550 200 mm Calico Mops Wire Wheels 3805630 Carbon Steel 200x20x19 05 mm Stands 3643100 Sheet Metal 3801430 Column Switch Gear Zero Voltage Release Overload Protection Kit 3501110 Single Phase 3501090 Three Phase Zero Voltage Release Overload Pr...

Страница 15: ...S LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 5 SHEET 1 OF 1 A3 WEIGHT BG01 BENCH GRINDER MAIN DIMENSIONS BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo com au 26 06 2020 0 DRAWN DATE ANH ALL RIGHTS RESERVED THIS DRAWING MAY NOT BE REPRODUCED OR TRANSMITTED IN ANY FORM OR BY ANY MEANS IN PART OR IN WHOLE WITHOUT THE WRITTEN PERMISSION OF BROBO GROUP P...

Страница 16: ...1 12 3635160 BG Safety Eye Shield 500x170x6 1 13 3721060 BG Eye Shield Assembly 2 14 3801250 LHS Guard Spark Arrestor Bracket 200HD 1 15 3803140 Guard 200 End Plate 2 16 3833010 BG Toolrest Arm 2 17 3833020 Grinder Tool Rest 2 18 3723010 BG Spark Arrestor 2 19 8705130 Socket Head Cap Screw M8x25 2 20 8705720 Hex Nut M8 2 21 8715200 Hex Head Set Screw 1 4 BSW x 3 4 8 22 3801260 RHS Guard Spark Arre...

Страница 17: ... NO PART NUMBER DESCRIPTION QTY 26 3632020 Mounting Bracket Top Eyeshield 1 27 3734050 BG Ball Spindle 1 28 3633090 BG Ball Flange 1 29 3632030 Mounting Bracket Bottom 1 30 8705800 Flat Washer M10 1 31 FASEM4X16PTBUT Post Torx Button Screw M4x16 5 32 8715220 Hex Locknut M10 1 33 3635150 BG Eyeshield Spring 3 ITEM NO PART NUMBER DESCRIPTION QTY 14 3833010 BG Toolrest Arm 2 15 8705720 Hex Nut M8 2 1...

Страница 18: ...ff LH 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 5 SHEET 1 OF 1 A3 WEIGHT BG04 GRINDER BUFF ASSEMBLY BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo com au 26 06 2020 0 DRAWN DATE ANH ALL RIGHTS RESERVED THIS DRAWING MAY NOT BE REPRODUCED OR TRANSMITTED IN ANY FORM OR...

Страница 19: ...2 m Long 4 Core 1 5mm2 Flex Cable 1 10 9315230 Contactor 415 V 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 3 SHEET 1 OF 2 A3 WEIGHT 3832080 BENCH GRINDER BASE ASSEMBLY 3PH 415V BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo com au 01 05 2020 0 DRAWN DATE ANH ALL RIGHT...

Страница 20: ...ex Cable 1 10 9315210 Contactor 240V 1 11 9505012 Capacitor 25 uF 1 12 3805420 Capacitor Clip 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 3 SHEET 2 OF 2 A3 WEIGHT 3832090 BENCH GRINDER BASE ASSEMBLY 1PH 240V BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo com au 01 05 ...

Страница 21: ...BY DATE ANH ALL RIGHTS RESERVED THIS DRAWING MAY NOT BE REPRODUCED OR TRANSMITTED IN ANY FORM OR BY ANY MEANS IN PART OR IN WHOLE WITHOUT THE WRITTEN PERMISSION OF BROBO GROUP PTY LT SIZE TO MATCH CAST 6 mm 0 1 0 5 30 mm 0 2 0 5 100 mm 0 3 1 5 300 mm 0 5 2 0 1000 mm 0 6 3 0 2000 mm 1 2 5 0 GRADE RA µm N1 0 025 N2 0 05 N3 0 1 N4 0 2 N5 0 4 N6 0 8 GRADE RA µm N7 1 6 N8 3 2 N9 6 3 N10 12 5 N11 25 0 N...

Страница 22: ......

Страница 23: ...ILEM 10 XTMC9A10 240V AC Contactor 1 6 C25 Capacitor 25 uF 1 7 3805420 Capacitor Clip 1 8 1045750 Cable Gland M16 1 9 1035340 240V 10A 3 Pin Plug Lead Assembly 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 5 SHEET 1 OF 1 A3 WEIGHT E1805 HDG C01 1PH HD GRINDER ELEC COMPONENT STANDARD BR...

Страница 24: ......

Страница 25: ... 10 XTMC9A10 240V AC Contactor 1 6 C25 Capacitor 25 uF 1 7 3805420 Capacitor Clip 1 8 1045750 Cable Gland M16 1 9 1035340 240V 10A 3 Pin Plug Lead Assembly 1 10 MISI 20 1 Pole Isolator 20A 500V 50Hz IP66 1 11 XTOM006AC1 Overload 1 6A 2 4A 1 12 1041650 Mushroom Emergency Footswitch 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SC...

Страница 26: ......

Страница 27: ...1BW Stop E Stop Push Button 1 5 DILEM 10 XTMC9A10 415V Contactor 1 6 1045750 Cable Gland M16 1 7 4CC 2 2 m Long 4 Core 1 5mm2 Flex Cable 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 5 SHEET 1 OF 1 A3 WEIGHT E1805 HDG C03 3PH HD GRINDER ELEC COMPONENT STANDARD BROBO GROUP Address 8 Fow...

Страница 28: ......

Страница 29: ...top E Stop Push Button 1 5 DILEM 10 XTMC9A10 415V Contactor 1 6 1045750 Cable Gland M16 1 7 4CC 2 2 m Long 4 Core 1 5mm2 Flex Cable 1 8 MIS3 20 3 Pole Isolator 20A 500V 50Hz IP66 1 9 XTOM006AC1 Overload 1 6A 2 4A 1 10 1041650 Mushroom Emergency Footswitch 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE...

Страница 30: ...il Zinc Plated Rail 55mm 1 8 PSSM5X10 Pan Head Slotted Screw M5x10 1 9 SCEC1 Single Core 1 0 mm2 Earth Cable 250mm 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 1 SHEET 1 OF 1 A3 WEIGHT E1805 HDG EL01 EARTH LEAD ASSEMBLY BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo co...

Страница 31: ...ASE OR 3 PHASE CIRCUIT ISOLATOR OPTIONAL 2 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 2 SHEET 1 OF 1 A3 WEIGHT E2017 0331 ISOLATOR SCHEMATIC BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo com au 08 07 2020 0 DRAWN DATE ANH ALL RIGHTS RESERVED THIS DRAWING MAY NOT BE RE...

Страница 32: ... MOUNTING PLATE 1 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES LINEAR ANGULAR MATERIAL DO NOT SCALE DRAWING REVISION TITLE DWG NO SCALE 1 2 SHEET 1 OF 1 A3 WEIGHT 1041650 FOOTSWITCH KIT ASSEMBLY BROBO GROUP Address 8 Fowler Rd Dandenong VIC 3175 https brobo com au 08 02 2019 0 DRAWN DATE ANH ALL RIGHTS RESERVED THIS DRAWING MAY NOT BE REPRODUCED OR TRANSMITTED...

Страница 33: ...he main components of the machine o Grade of buffing mops or grit on the grinding wheel o Correct working parameters for the type of material being ground Verify that the quality of the ground material meets the requirements that the final product is free from any machining defects 5 2 Maintenance Requirements All maintenance must be carried out with the power switched off the machine in emergency...

Страница 34: ...lacing grinding wheels The following procedure is recommended for the replacement of the grinding wheels 1 Depress the STOP button 2 Switch off the power point or main isolator switch 3 Install a lockout caliper on the plug or isolator switch 4 Remove the fixed guards from the grinder wheel surrounds 5 Fit a soft jaw clamp as a sprag across the narrow side of each grinding wheel on both sides 6 Us...

Страница 35: ...inding wheel Clogged or worn grinding wheel Incorrect grade of grit on grinding wheel for parent material Broken or worn component The electrical component is worn Verify that the correct grade of grinding is suited for the parent material being ground Reduce the feed rate onto the grinder else it might cause the parent material to break cause harm to the operator Do not abruptly force the parent ...

Страница 36: ...aken The power source is to be isolated prior to opening electrical enclosures Noise Low Under no load testing the noise level measured is below 80db A If the noise level becomes too high during a grinding cycle stop the process inspect for the problem if any are present Substance Low Keep the work area clean regularly remove excess coolant oils another aggregate Hazardous Events Unexpected Start ...

Страница 37: ...spect one piece eye shield Replace if damaged Check Check Check Inspect guards Replace if damaged Check Check Check Inspect safety operating instruction signs Replace if damaged Check Check Check Test Tag Licensed electrician Check Inspect fixings and hardware Replace or re torque Check Check Check APPENDIX 2 SERVICE LOG SERVICE TYPE DATE Scheduled Fault DESCRIPTION INITIALS COMPLETED ...

Страница 38: ... N U M B E R G R O U P B 2 9 6 0 0 T O B 9 9 9 9 9 2 3 C O N S U L T A N T T H E O A V G O U L I S A S S O C I A T E S I A B ROBO G ROUP P TY L TD D ANDENONG S OUTH G ENERIC R ISK A SSESSMENT 200 250 MM HD OHS S ERIES B ENCH G RINDER DISCLAIMER AVGO A A B P W HAVE PREPARED THIS REPORT EXCLUSIVELY FOR THE USE OF THE NAMED CLIENT AVGO BELIEVE THAT THE INFORMATION IN THIS REPORT IS CORRECT AND THAT A...

Страница 39: ...by the Code METHOD HAZARD Parts accessories components or other items together with the likely use materials used as part of the process cleaning procedures and maintenance procedures are some of the items given due consideration as to the likelihood of presenting Health and Safety risks to personnel These items identified as hazards are described under the heading of Hazard The Hazard listed in c...

Страница 40: ...possible L L L L L M Exposure Very Serious 4 1 Very Rare 2 Rare 3 Infrequent 4 Occasional 5 Frequent 6 Continuous 6 Almost Certain S H V V V V 5 Quite possible M S H V V V 4 Unusual but possible L M S H V V 3 Remotely Possible L L M M S H 2 Conceivable L L L L M S Probability 1 Practically Impossible L L L L L L Exposure Catastrophic 6 1 Very Rare 2 Rare 3 Infrequent 4 Occasional 5 Frequent 6 Cont...

Страница 41: ...ically Impossible L L L L L L Exposure Substantial 2 1 Very Rare 2 Rare 3 Infrequent 4 Occasional 5 Frequent 6 Continuous 6 Almost Certain L M S H V V 5 Quite possible L L M S H H 4 Unusual but possible L L L M M S 3 Remotely Possible L L L L L M 2 Conceivable L L L L L L Probability 1 Practically Impossible L L L L L L Exposure Minor 1 1 Very Rare 2 Rare 3 Infrequent 4 Occasional 5 Frequent 6 Con...

Страница 42: ...le of the method used to calculate the risk scores with the aid of the Matrices Sample Risk Assessment table excerpt Hazard Risk Score Control Recommendation Action Taken Yes No Re Score Rotating blade in reach of operator at normal work station of shift Severing injury risks RISK SCORE 6 5 4 V Consequence Very Serious 4 Permanent disability loss to 1 000 000 Probability Quite Possible 5 Quite pos...

Страница 43: ...Assessment TERMS OF REFERENCE The Risk Assessment shall be conducted by a competent assessor the assessor shall take into account The actual use of the plant Constructive comments and input from operators Appointed employee OHS representative group State of Knowledge of the type of Plant Applicable Australian Standards FOLLOW UP This report has been prepared in an easy to use format The Action Tak...

Страница 44: ...and attachments Provide or repair earth points as necessary in accordance with AS 3000 AS NZ 3760 Yes See 2 1 5 5 2 3 M 415 240 Volt power supply Electric shocks burns electrocution risks RISK SCORE 6 5 4 V Fit DANGEROUS VOLTAGE and or ISO international symbol signs to all access covers over dangerous voltage areas of unit Adequate warning of dangerous voltages within must be provided at all areas...

Страница 45: ... protection P P E requirements to site induction with appropriate signs at entry points to machine shop Signage must be in accordance with AS 1319 sign No 421 with supplementary text indicating type of eye protection ie Face shield or goggles Yes See parts list 5 1 3 L Operating noise levels Hearing loss due to noise exposure RISK SCORE 4 5 5 V Fit HEARING PROTECTION MUST BE WORN sign in proximity...

Страница 46: ...ps slides during use Operator injuries plant damage RISK SCORE 3 4 4 S Securely fasten base of grinder to the bench top with dyna bolts or similar Yes See 1 4 3 1 1 L Plant maintenance Unauthorized and untrained personnel carrying out plant maintenance personnel injuries RISK SCORE 5 4 4 V Introduce No unauthorized personnel to carry out maintenance to plant policy to site induction training Yes S...

Страница 47: ... to limitations Risk Control recommendations have been implemented accordingly The Plant system satisfies necessary requirements of the Occupational Health and Safety Act 2004 Signed Dated 01 May 2009 Theo Avgoulis Plant Inspector ASIA Certification is applicable only to current product specifications Certificate of AS 4024 AS 3000 compliance ...

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