Loading (50 kb)...'
(continued)
(c) Crossovers as defined in Section 3207 of these Orders shall be provided where necessary, which will allow employees to pass over or cross a conveyor. Unless a 6-foot 6-inch headroom clearance is provided, employees shall not be permitted to pass under conveyors.
(d) Conveyors passing over areas that are occupied or used by employees shall be so guarded as to prevent the material transported from falling and causing injury to employees.
(e) Where employees pass under the return strands of chain conveyors a shallow trough or other effective means of sufficient strength to carry the weight of the broken chain shall be provided.
(f) Employees shall not be permitted to ride or walk on a moving power driven chain, belt or bucket.
(g) Conveyors using electrically released brakes shall be constructed so that the brakes cannot be released until power is applied and that the brakes are automatically engaged if the power fails or the operating control is returned to the "stop" position.
(h) Powered conveyors shall not be started until all exposed employees are clear of the conveyor or have been warned that the conveyor is about to start.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4000. Process Machine Power Control.
(a) Each process machine driven by an individual prime mover shall be equipped with a prime mover stopping device which can be safely actuated from the operator's working position unless the machine is equipped with a clutch which will stop all machine operations.
(b) Where an operator attends one or more process machines not having individual drive each machine shall be equipped with a stopping device which can be safely actuated from the operator's working position at the machine. Such a stopping device may stop an entire group of machines by stopping the prime mover power transmission or it may be a machine clutch, cut-off coupling, or tight and loose pulley with belt shifter which can stop all the machine operations at any time on any machine. Pole or hand shifting of belts is not considered adequate means for disconnecting the power.
Exception: Where due to the process, machines must be operated in groups, the machine power control may stop the entire group of machines. Such group drives shall be provided with conveniently located, readily accessible, and properly marked or otherwise identified stop stations.
(c) Each process machine simultaneously attended or operated by more than one employee shall be equipped with a machine power control for each employee exposed to point of operation hazards. Said controls shall be interlocked in a manner to prevent operation of machine, unless all controls are operated simultaneously. Controls for more than one operating station shall be designed to be activated and deactivated in complete sets of two operator's hand controls per operating station by means capable of being supervised by the employer.
(d) Machine power controls shall be maintained in safe operating condition and shall be so designed, installed and/or located that they cannot operate from accidental contact with objects or parts of the body.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4001. Machine Power Control.
All machines shall be equipped with adequate means whereby the operator of the machine or other person can disconnect the power promptly in case of emergency.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4002. Moving Parts of Machinery or Equipment.
(a) All machines, parts of machines, or component parts of machines which create hazardous revolving, reciprocating, running, shearing, punching, pressing, squeezing, drawing, cutting, rolling, mixing or similar action, including pinch points and shear points, not guarded by the frame of the machine(s) or by location, shall be guarded.
(b) Keys, set screws, projections or recesses which create a hazard not guarded by the frame of the machine or by location shall be removed, made flush or guarded.
Note: Section 4002 does not apply to points of operation. For point-of-operation requirements, refer to Group 8, commencing with Section 4184.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4003. Pinch Points and Shear Points.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4050. Shafting, Collars, Clutches, and Couplings.
(a) All exposed parts of line or countershafting or collars, clutches, cut-off couplings and clutch pulleys seven feet or less above floor or other working level shall be guarded.
(b) Wherever shafting extends over a driveway it shall be enclosed or guarded with a trough guard unless it is located 15 feet or more above driveway or is a part of an overhead traveling crane and does not otherwise violate provisions in this order. See (d) below.
(c) Transmission shafting under benches shall be guarded in one of the following ways:
(1) Completely enclosed.
(2) Guarded by a trough guard enclosing sides and top or sides and bottom as the exposure requires. The sides of the trough shall come within at least 6 inches of the underside of the table, or if the shafting is located near floor, within 6 inches of the floor. In every case the sides of the trough shall extend at least 2 inches above or below the shafting.
(3) Guarded on exposed sides with a rigid shield guard extending from the underside of bench top to 2 inches below bottom line of shafting.
Exception: Wherever power sewing machines or other similar light machines are operated by shafting under the machine table, such shafting shall be in compliance when the shafting is 20 inches or more horizontally from the vertical plane of the working edge ofthe bench. When such transmission is so located it constitutes a hazard, it shall be guarded.
(d) Shafting which crosses or runs parallel to elevated runways, walkways, catwalks, or platforms and is within the vertical height of seven feet or within 15 inches of either side of such runway, walkway, catwalk or platform shall be guarded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4051. Projecting Shaft Ends.
(a) Projecting shaft ends within 7 feet of floor or working level shall present a smooth rounded edge and smooth end and shall not project a distance greater than one-half the diameter of the shaft beyond the end of the bearing unless guarded by nonrotating casing.
(b) Exposed unused key-ways 7 feet or less above floor or working level shall be filled, covered, or guarded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4052. Collars, Couplings, Clutches, Cut -Off Couplings and Clutch Pulleys.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4060. Location of Pulleys on Line Shaft and Countershaft.
(a) Where the distance to the nearest fixed pulley, clutch or hanger is equal or less than the width of the belt, a guide shall be provided to prevent the belt from leaving the pulley.
(b) Overhanging flat pulleys on line shafts or countershafts shall be provided with a stop to prevent the belt from running off the pulley.
(c) Where loose pulleys or idlers are not practicable, belt perches in form of brackets, rollers, etc., shall be used to keep idle belts away from the shafts.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4061. Composition and Wood Pulleys.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4062. Pulleys Exposed to Corrosion.
Pulleys exposed to active corrosion shall be of corrosion resisting material.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4063. Composition or Wooden Pulleys out of Service.
Composition or wooden pulleys permanently out of service shall not be allowed to remain on shafting which is in use.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4070. Guarding.
(a) All moving parts of belt and pulley drives located 7 feet or less above the floor or working level shall be guarded.
Note: For clearance between guards and belts, see Table G-1 and Figure G-2.
Exceptions:
1. Flat or crowned step-cone pulley drives on lathes may be guarded by a bar or rod located above the contact point of the belt to prevent a worker's hand being drawn into the nip point. Lathe belts, with metallic belt fasteners or lacings, and which are shifted by hand, shall have all fasteners or lacings clinched or maintained so that there are no projections on either the surfaces or edges of the belt.
2. The following belts when operating at 250 feet per minute or less: Flat belts 1-inch or less in width; flat belts 2 inches or less in width which are free from metal lacings or fasteners; round belts 1/2-inch or less in diameter; and single strand V-belts, the width of which is 13/32-inch or less.
This exception does not include spokes, hazardous nip points, or other hazards of pulleys. Such hazards which are 7 feet or less above the floor or working level shall be guarded by nip-point belt and pulley guards.
3. In industries where there is an excessive deposit of lint (which constitutes a serious fire hazard), open bottom nip-point belt and pulley guards may be used, provided that where metallic belt fasteners or lacings are used they shall be clinched and maintained so that there are no projections on the outside face or edges of the belt.
4. Fan belt drives on motor vehicles used primarily for transportation of employees and materials.
5. Internal combustion engine fan belt drives guarded by side screens extending to the shoulder of the engine block.
6. Industrial and commercial sewing machines: See Section 4475.
(b) If the bottom of the guard is within 4 inches of the floor or supporting structures, the bottom of the guard need not be enclosed.
(c) Where a group of flat belt drives is guarded by guardrails, such drives shall be considered guarded where the distance from the vertical plane of the rail to the nearest point of any belt or pulley is not less than 15 inches nor more than 20 inches and where the distance between any two adjacent belts or pulleys does not exceed 36 inches.
(d) Horizontal overhead belts more than 7 feet above a floor, platform or other working level shall be guarded for their entire length if located over passageways or working places.
(e) American or continuous system rope drives so located that the condition of the rope (particularly the splice) cannot be constantly and conveniently observed shall be equipped with a "telltale" device (preferably electric-bell type) that will give warning when rope begins to fray.
(f) All rope drives shall be guarded as required for belt drives.
(g) If dressing is applied while the belt or rope is in motion, it shall be performed at a safe distance from the nip point.
(h) Metallic belt fasteners or lacings shall be clinched and maintained so that there are no projections on the outside face or edges of the belts.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4071. Belt Tighteners.
Counter-balanced belt tighteners shall be of substantial construction. Means shall be provided to prevent tightener from falling in case the belt breaks, or the area directly beneath the tightener shall be guarded by a standard railing guard set not less than 15 inches nor more than 20 inches from the vertical projection of the outermost parts of the tightener.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4072. Variable Speed Drives.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4075. Gears and Sprockets.
(a) All gears, sprockets and sprocket chain drives located 7 feet or less above the floor or working level shall be guarded.
(b) If band guards are used the guard shall extend inward beyond the root of the teeth and the spokes shall be guarded with a disk guard.
(c) Where employees pass under chain drives, the requirements of Section 3943(c) and (f) shall be met.
(d) Guards on overhead silent chain-drives shall not be less than one-quarter inch from the nearest moving chain part, except that on drives of over 20 inch centers the distance shall not be less than one-half inch.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4076. Friction Drives.
Friction drives located 7 feet or less above floor or other working level shall be guarded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4077. Sprocket Chains.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4085. Belt Shifters and Other Disconnecting Devices.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4086. Momentary Contact Devices.
Six months after the effective date of this regulation, all portable pipe threading/cutting machines and portable power drives shall be permanently equipped with a momentary contact device.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4184. Guarding Required.
(a) Machines as specifically covered hereafter in Group 8, having a grinding, shearing, punching, pressing, squeezing, drawing, cutting, rolling, mixing or similar action, in which an employee comes within the danger zone shall be guarded at the point of operation in one or a combination of the ways specified in the following orders, or by other means or methods which will provide equivalent protection for the employee.
(b) All machines or parts of machines, used in any industry or type of work not specifically covered in Group 8, which present similar hazards as the machines covered under these point of operation orders, shall be guarded at their point of operation as required by the regulations contained in Group 8.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4185. Foot-Operated Devices.
All foot-operated devices (i.e., treadles, pedals, levers, bars, valves, and switches) shall be protected from unintended operation, if such operation creates a hazard.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4186. Maintenance and Use of Point of Operation Tools and Guards.
(a) All saws, cutting tools, heads, shears, and knives that are part of any machine shall be kept sharp, properly set up, adjusted and firmly secured.
(b) All point of operation guards shall be properly set up, adjusted and maintained in safe and efficient working condition in conformance with Figure G-8 and Table G-3 or other guard configurations which will prevent the operator's hand from entering the point of operation.
(c) All repair work performed on metal forming and/or cutting machines, such as punch presses, press brakes, forming rolls, shears, power presses, forging presses and hammers, shall be made:
(1) In accordance with the recommendation of the manufacturer(s), or
(2) In accordance with good engineering practice.
Point of Operation Guarding Figure G-8
Explanation of Above Diagram:
This diagram shows the accepted safe openings between the bottom edge of a guard and feed table at various distances from the point of operation.
The minimum guarding line is 1/2-inch from the point of operation. The various openings are such that with average size hands, an operator's fingers will not reach the point of operation.
After installation of point of operation guards and before a job is released for operation, a check should be made to verify that the guard will prevent the operator's hands from reaching the point of operation.
Table G-3
______________________________________
______________________________________
Distance of Opening
from Point ........... Maximum Width
of Operation Hazard .. of Opening
(Inches) ............. (Inches)
______________________________________
______________________________________
1/2 .................. to 1 1/2........ 1/4
1 1/2 ................ to 2 1/2........ 3/ 8
2 1/2 ................ to 3 1/2........ 1/ 2
3 1/2 ................ to 5 1/2........ 5/ 8
5 1/2 ................ to 6 1/2........ 3/ 4
6 1/2 ................ to 7 1/2........ 7/ 8
7 1/2 ................ to 12 1/2....... 1 1/ 4
12 1/2 ............... to 15 1/2....... 1 1/2
15 1/2 ............... to 17 1/2....... 1 7/8
17 1/2 ............... to 31 1/2....... 2 1/8
______________________________________
Refer to Table G-1 in Section 3944 for the maximum width of openings permitted in guards at various distances from the moving parts of power transmission equipment, prime movers, machines and machine parts.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4187. Rolls.
(a) The in-running side of the rolls shall be protected with a fixed or self-adjusting barrier so arranged that the material can be fed to the rolls without permitting the fingers of the operator to be caught between the rolls or between the guard and the rolls, or
(b) The control device for the rolls shall be of the constant contact type and shall be so located as to prevent the employees from contacting the danger zone, or
(c) The prime mover shall be equipped with an effective brake and there shall be installed across the front of the rolls at approximately knee height a control bar, lever or other device which when actuated will stop the motor and apply the brake.
Note: (1) The intent of this section is primarily to achieve point of operation guarding as required by Subsection (a) above. Where, because of work procedures or other valid reasons, the requirements of Subsection (a) cannot be achieved, the requirements of Subsection (b) shall control. Where neither the requirements of (a) or (b) can be achieved, compliance with Subsection (c) shall then be mandatory. (2) In those instances where there are other orders covering specific rolls, those orders shall prevail over those contained in this section.
Exception: Rolls which do not expose any employees to a point of operation hazard.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4188. Definitions.
(a) General Definitions.
Classes. The designation "Class-A" with an order means that the rule applies for all kinds of work. The designation "Class-B" means that the order applies unless the nature of the work, type of machinery, or size and shape of material being worked will not permit.
Danger Zone. Any place in or about a machine or piece of equipment where an employee may be struck by or caught between moving parts, caught between moving and stationary objects or parts of the machine, caught between the material and a moving part of the machine, burned by hot surfaces or exposed to electric shock.
Interlock. A device that operates to prevent the operation of a machine while the cover or door of the machine is open or unlocked, and which will also hold the cover or door closed and locked while the machine is in motion.
Point of Operation. That part of a machine which performs an operation on the stock or material and/or that point or location where stock or material is fed to the machine. A machine may have more than one point of operation.
(b) Specific Definitions for Power Operated Presses. Adjustable Barrier Guard. A barrier requiring adjustment for each job or die setup.
Antirepeat. The part of the clutch/brake control system designed to limit the press to a single stroke if the operating means is held operated. Antirepeat requires release of all tripping mechanisms before another stroke can be initiated. "Antirepeat" is also called single stroke reset or reset circuit.
Brake. The mechanism used on a mechanical power press to stop and/or hold the crankshaft, either directly or through a gear train, when the clutch is disengaged.
Brake Monitor. A sensor designed, constructed, and arranged to monitor the effectiveness of the press braking system.
Bolster Plate. The plate attached to the top of the bed of the press having drilled holes or T-slots for attaching the lower die or die shoe.
Certification or Certify. In the case of design certification/validation that the manufacturer has reviewed and tested the design and manufacture, and in the case of installation certification/validation and annual recertification/revalidation that the employer has reviewed and tested the installation, and concludes in both cases that the requirements of sections 4192 through 4211 and Appendix A have been met. The certifications are made to the validation organization.
Certification/Validation and Certify/Validate. The combined processes of certification and validation.
Clutch. The coupling mechanism used on a mechanical power press to couple the flywheel to the crankshaft, either directly or through a gear train.
(1) Full Revolution Clutch. A type of clutch that, when tripped, cannot be disengaged until the crankshaft has completed a full revolution and the press slide a full stroke.
(2) Part Revolution Clutch. A type of clutch that can be disengaged at any point before the crankshaft has completed a full revolution and the press slide a full stroke.
Concurrent. Acting in conjunction, and is used to describe a situation wherein two or more controls exist in an operated condition at the same time.
Control System. Sensors, manual input and mode selection elements, interlocking and decision-making circuitry, and output elements to the press operating mechanism.
Continuous. Uninterrupted multiple strokes of the slide without intervening stops (or other clutch control action) at the end of individual strokes.
Counter-balance. The mechanism that is used to balance or support the weight of the connecting rods, slide, and slide attachments.
Device. A press control or attachment that:
(A) Restrains the operator from inadvertently reaching into the point of operation, or
(B) Prevents normal press operation if the operator's hands are within the point of operation as the dies close.
(C) Automatically withdraws the operator's hands if the operator's hands are within the point of operation as the dies close, or
(D) Prevents the initiation of a stroke, or stops stroke in progress, when there is an intrusion through the sensing field by any part of the operator's body or by any other object, or
(E) Locating single cycle operating controls so that the slide completes its downward travel or stops the ram motion before the operator's hands can reach into the point of operation.
Combined Stroking-Control Systems. Combined stroking-control systems are two independent control systems on the same machine, only one of which is used at a time.
Die. The tooling used in a press for cutting or forming material. An upper and a lower die make a complete set.
Die Builder. Any person who builds dies for power presses.
Die Set. A tool holder held in alignment by guide posts and bushings and consisting of a lower shoe, an upper shoe or punch holder, and guide posts and bushings.
Die Setter. An individual who places or removes dies in or from mechanical power presses, and who, as a part of his duties, makes the necessary adjustments to cause the tooling to function properly and safely.
Die Setting. The process of placing or removing dies in or from a power press, and the process of adjusting the dies, other tooling and safeguarding means to cause them to function properly and safely.
Die Shoe. A plate or block upon which a die holder is mounted. A die shoe functions primarily as a base for the complete die assembly, and, when used, is bolted or clamped to the bolster plate or the face of slide.
Direct Drive. The type of driving arrangement wherein no clutch is used; coupling and decoupling of the driving torque is accomplished by energization and de-energization of a motor. Even though not employing a clutch, direct drives match the operational characteristics of "part revolution clutches" because the driving power may be disengaged during the stroke of the press.
Division-Recognized Third Party Validation Organization. An independent third-party validation organization which has been recognized by the U.S. Labor Department, Occupational Safety and Health Administration (OSHA) in accordance with the requirements specified in Appendix C of paragraph (h), 29 CFR 1910.217, revised March 14, 1988 which is hereby incorporated by reference.
Ejector. A mechanism for removing work or material from between the dies.
Face of Slide. The bottom surface of the slide to which the punch or upper die is generally attached.
Feeding. The process of placing or removing material within or from the point of operation.
Foot Control. The foot operated control mechanism designed to be used with a clutch or clutch/brake control system.
Foot, Kick, and Hand Presses. Machines actuated by foot or hand power only, and fitted with rams or dies for the purposes of blanking, trimming, drawing, punching or stamping, forming or assembling cold material.
Foot Pedal. The foot operated lever designed to operate the mechanical linkage that engages the clutch and/or disengages the brake.
Gate or Movable Barrier Device. A movable barrier arranged to enclose the point of operation before the press stroke can be started.
Guide Post. The pin attached to the upper or lower die shoe, operating within the bushing on the opposing die shoe, to maintain the alignment of the upper and lower dies.
Hand Feeding Tool. Any hand-held tool designed for placing or removing material or parts to be processed within or from the point of operation.
Holdout or Restraint Device. A mechanism, including attachments for operator's hands, that when anchored and adjusted, prevent the operator's hands from entering the point of operation.
Inch. An intermittent motion imparted to the slide (on machines using part revolution clutches) by momentary operation of the "Inch" operating means. Operation of the "Inch" operating means engages the driving clutch so that a small portion of one stroke or indefinite stroking can occur, depending upon the length of time the "Inch" operating means is held operated. "Inch" is a function used by the die setter for setup of dies and tooling, but is not intended for use during production operations by the operator.
Jog. An intermittent motion imparted to the slide by momentary operation of the drive motor, after the clutch is engaged with the flywheel at rest.
Knockout. A mechanism for releasing material from either die.
Liftout. The mechanism also known as knockout.
Manual Feeding. Feeding wherein the material or part being processed is handled by the operator on each stroke of the press.
Operator's Station. The complete complement of controls used by or available to an operator on a given operation for stroking the press.
Pinch Point. Any point other than the point of operation at which it is possible for a part of the body to be caught between the moving parts of a press or auxiliary equipment, or between moving and stationary parts of a press or auxiliary equipment or between the material and moving part or parts of the press or auxiliary equipment.
Point of Operation. (See section 4188(a).)
Power Operated Presses. For the purposes of Article 55, power operated presses include all mechanically powered machines that shear, punch, form, or assemble metal or other materials by means of tools or dies attached to or actuated by slides, commonly referred to as mechanical power presses (punch presses), press brakes, hydraulic power presses (punch presses), and rivet setting machines.
Power Press, Hydraulic (Punch Press). A machine which is hydraulically powered that shears, punches, forms, draws, or assembles metal or other material by means of tools attached to or actuated by slides.
Power Press, Mechanical (Punch Press). A mechanically powered machine that shears, punches, forms or assembles metal or other material by means of cutting, shaping, or combination dies attached to or actuated by slides. A press consists of a stationary bed or anvil, and a slide (or slides) having a controlled reciprocating motion toward and away from the bed surface, the slide being guided in a definite path by the frame of the press.
Power Press, Pneumatic. A machine which derives its primary mechanical action (i.e. shearing, punching, bending, forming, drawing, extruding, assembly or other action) from a pneumatic energy source (i.e. pneumatically driven ram). A fully pneumatic power press differs from a mechanical or hydraulic press which may utilize pneumatic systems to only activate a brake/clutch, slide counterbalance or other system but which uses mechanical means or hydraulic fluid to power the ram.
Presence Sensing Device. A device designed, constructed and arranged to create a sensing field or area that signals the clutch/brake control to deactivate the clutch and activate the brake of the press when any part of the operator's body or a hand tool is within such field or area.
Presence Sensing Device Initiation. An operating mode of indirect manual initiation of a single stroke by a presence sensing device when it senses that work motions of the operator, related to feeding and/or removing parts, are completed and all parts of the operator's body or hand tools are safely clear of the point of operation.
Press Brake, General-Purpose. A mechanically or hydraulically operated machine having only one operator at the front of the machine and with a single operating foot control device which permits the operator to exercise full and final control over the movement of the ram.
Press Brake, Special-Purpose. A machine that can be mechanically or hydraulically operated by one or more operators from the front of the machine, each provided with an operating control station. Concurrent operation of each station being used is required to place the ram in motion.
Ram. See definition for Slide.
Repeat. An unintended or unexpected successive stroke of the press resulting from a malfunction.
Rivet Setting Equipment. Powered machines designed to insert and clinch fasteners commonly called rivets.
Safety Block. A prop that, when inserted between the upper and lower dies or between the bolster plate and the face of the slide, prevents the slide from falling of its own deadweight.
Safety System. The integrated total system, including the pertinent elements of the press; the controls; the safeguarding, any required supplemental safeguarding, and their interfaces with the operator; and the environment designed, constructed and arranged to operate together as a unit, such that a single failure or single operating error will not cause injury to personnel due to point of operation hazards.
Setting up Operations. Operations in which fixtures or tooling which support, secure, or act upon the workpiece are mounted on the machine surfaces or in machine components designed to accept such tooling.
Single Stroke. One complete stroke of the slide, usually initiated from a full open (or up) position.
Single Stroke Control. An arrangement used to limit the travel of the slide to one complete stroke at each engagement of the clutch.
Slide. A reciprocating part of the machine or press. It is also referred to as a ram, plunger, platen, or mandrel.
Stop Control. An operator control designed to immediately deactivate the clutch control and activate the brake to stop slide motion.
Stripper. A mechanism or die part for removing the parts of material from the punch.
Stroking Selector. The part of the clutch/brake control that determines the type of stroking when the operating means is actuated. The stroking selector generally includes positions for "Off" (Clutch Control), "Inch," "Single Stroke," and "Continuous" (when continuous is furnished).
Trip or (tripping). Activation of the clutch to "run" the press.
Turnover Bar. A bar used in die setting to manually turn the crankshaft of the press.
Unitized Tooling. A type of die in which the upper and lower members are incorporated into a self-contained unit so arranged as to hold the die members in alignment.
Validation or Validate. For PSDI safety systems that a Division-recognized third-party validation organization:
(A) For design certification/validation has reviewed the manufacturer's certification that the PSDI safety system meets the requirements of sections 4192 through 4211 and Appendix A and the underlying tests and analyses performed by the manufacturer, has performed additional tests and analyses which may be required by sections 4192 through 4211 and Appendix A, and concludes that the requirements of sections 4192 through 4211 and Appendix A have been met; and
(B) For installation certification/validation and annual recertification/revalidation has reviewed the employer's certification that the PSDI safety system meets the requirements of sections 4192 through 4211 and Appendix A and the underlying tests performed by the employer, has performed additional tests and analyses which may be required by sections 4192 through 4211 and Appendix A, and concludes that the requirements of sections 4192 through 4211 and Appendix A have been met.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4189. Scope.
The requirements of this article apply only to those mechanically or hydraulically powered machines that shear, punch, form, or assemble metal or other material by means of tools or dies attached to slides, commonly referred to as power operated presses. Pneumatic power presses (as defined in section 4188), hot bending and hot metal presses, forging presses and hammers are excluded from the requirements of this article.
Sections 4192 through 4211 of article 55 apply to all mechanical power presses (punch presses). Sections 4196 through 4202(a) and 4203 through 4205 of article 55 apply to all power operated presses regardless of type (with the exception of those machines excluded above).
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4190. Control Identification.
(a) All control buttons and switches for power operated presses shall be properly identified as to the function and purpose of such control buttons and switches.
(b) All control buttons and switches for power operated presses shall be color coded to conform to the following code:
Start, run, or inch ...... -- .. Black, green, silver or other
similar metallic color
Emergency stop ........... -- .. Red
Cycle Stop or Auto Stop .. -- .. Yellow or red
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4191. Power Presses and Foot and Hand Power Presses (Class A).
s 4192. Machines Using Full Revolution Positive Clutches.
(a) Machines using full revolution clutches shall incorporate a single-stroke control.
Exception: Automatically fed machines with the point of operation completely protected by a fixed barrier guard.
(b) If the single-stroke control is dependent upon spring action, the spring(s) shall be of the compression-type, operating on a rod or guided within a hole or tube, and designed to prevent interleaving of the spring coils in event of breakage.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4193. Machines Using Part Revolution Clutches.
(a) The clutch shall release and the brake shall be applied when the external clutch engaging means is removed, de-activated, or de-energized.
(b) A red color stop control shall be provided with the clutch/brake control system. Momentary operation of the stop control shall immediately de-activate the clutch and apply the brake. The stop control shall override any other control, and re-actuation of the clutch shall require use of the operating (tripping) means which has been selected.
Exception: Mechanical press brakes.
(c) A means of selecting Off, "Inch," Single Stroke, and Continuous (when the continuous function is furnished) shall be supplied with the clutch/brake control to select type of operation of the press. Fixing of selection shall be by means capable of supervision by the employer.
(d) The "Inch" operating means shall be designed to prevent exposure of the worker's hands within the point of operation by:
(1) Requiring the concurrent use of both hands to actuate the clutch, or
(2) Being a single control protected against accidental actuation and so located that the worker cannot reach into the point of operation while operating the single control.
(e) Two-hand controls for single stroke shall conform to the following requirements:
(1) Each hand control shall be protected against unintended operation and arranged by design, construction, and/or separation so that the concurrent use of both hands is required to activate the press.
(2) The control system shall be designed to require concurrent pressure from both hands during the die closing portion of the stroke.
(3) The control system shall incorporate an antirepeat feature.
(4) The control systems shall be designed to require release of all operators' hand controls before an interrupted stroke can be resumed.
(f) Controls for more than one operating station shall be designed to be activated and deactivated in complete sets of two operators' hand controls per operating station by means capable of being supervised by the employer. The clutch/brake control system shall be designed and constructed to prevent actuation of the clutch if all operating stations are bypassed.
(g) Those clutch/brake control systems which contain both single and continuous functions shall be designed so that completion of continuous circuits may be supervised by the employer. The initiation of continuous run shall require a prior action or decision by the operator in addition to the selection of Continuous on the stroking selector, before actuation of the operating means will result in continuous stroking.
(h) If foot and hand controls are provided, the selection method between hand and foot control shall be separate from the stroking selector and shall be designed so that the selection may be supervised by the employer.
(1) For those machines using pull back or restraining devices, the control system shall be such that when the foot control is used the necessary safeguards shall be required before the machine will operate.
(i) The control of air-clutch machines shall be designed to prevent a significant increase in the normal stopping time due to a failure within the operating valve mechanism, and to inhibit further operation if such failure does occur. This requirement shall not apply to machines intended only for continuous, automatic feeding applications.
(j) The clutch/brake control shall automatically de-activate in event of failure of the power or pressure supply for the clutch engaging means. Re-activation of the clutch shall require restoration of normal supply and the use of the activating control(s).
(k) The clutch/brake control shall automatically de-activate in event of failure of the counter-balance(s) air supply. Re-activation of the clutch shall require restoration of normal air supply and use of the activating control(s).
( l) Selection of bar operation shall be by means capable of being supervised by the employer. A separate pushbutton shall be employed to activate the clutch, and the clutch shall be activated only if the driver motor is de-energized.
(m) Where the operator feeds or removes parts by placing one or both hands in the point of operation, and a two-hand control, presence sensing device or Type B gate or movable barrier is used for safeguarding:
(1) The employer shall use a control system and a brake monitor which comply with Sections 4193(o) and 4200(b).
(2) The control of air clutch machines shall be designed to prevent a significant increase in the normal stopping time due to a failure within the operating valve mechanism, and to inhibit further operation if such failure does occur, where a part revolution clutch is employed.
(n) The employer shall provide means for handling scrap from roll feed or random length stock operations. Scrap cutters used in conjunction with scrap handling systems shall be safeguarded in accordance with Section 4236.
(o) When required by Section 4193(m) the control system shall be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent initiation of a successive stroke until the failure is corrected. The failure shall be detectable by a simple test, or indicated by the control system. This requirement does not apply to those elements of the control system which have no effect on the protection against point of operation injuries.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4194. Slide Counter-Balance Systems.
(a) Spring counter-balance systems when used shall incorporate means to retain system parts in event of breakage.
(b) Spring counter-balances when used, shall have the capability to hold the slide and its attachments at midstroke, without brake applied.
(c) Air counter-balance cylinders shall incorporate means to retain the piston and rod in case of breakage or loosening.
(d) Air counter-balance cylinders shall have adequate capability to hold the slide and its attachments at any point in stroke, without brake applied.
(e) Air counter-balance cylinders shall incorporate means to prevent failure of capability (sudden loss of pressure) in event of air supply failure.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4195. Air Controlling Equipment.
Air controlling equipment shall be protected against foreign material and water entering the pneumatic system of the power operated press. A means of air lubrication shall be provided when needed.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4196. Hydraulic Equipment.
The maximum anticipated working pressures in any hydraulic system on a mechanical power operated press shall not exceed the safe working pressure rating of any component used in that system.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4197. Design, Construction, Setting and Feeding of Dies.
(a) General. It shall be the responsibility of the employer to:
(1) Use dies, safety devices and operating methods designed to eliminate hazards to operating personnel, and,
(2) Furnish and enforce the use of hand tools for freeing and removing stuck work or scrap pieces from the dies to avoid requiring the operator or other personnel from reaching into the point of operation.
Note: The employer should consider the design and use of dies and feeding mechanisms to eliminate the need of an operator(s) to place his/her hand(s) in the point of operation.
(b) Provision shall be made in both the upper and lower shoes for securely mounting the die to the bolster and slide. Where clamp caps or set screws are used in conjunction with punch stems, additional means of securing the upper shoe to the slide shall be used.
(c) Handling equipment attach points shall be provided on all dies requiring mechanical handling.
(d) If unitized tooling is used, the opening between the top of the punch holder and the face of the slide, or striking pad, shall be guarded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4198. Tonnage, Stroke, and Weight Designation.
(a) All dies shall be:
(1) Stamped with the tonnage and stroke requirements, or have these characteristics recorded if these records are readily available to the die setter;
(2) Stamped to indicate upper die weight when necessary for air counter-balance pressure adjustment; and,
(3) Stamped to indicate complete die weight when handling equipment may become overloaded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4199. Diesetting.
(a) The employer shall establish a diesetting procedure that will ensure compliance with this section.
(1) The employer shall provide spring loaded turnover bars for power operated presses designed to accept such turnover bars.
(2) The employer shall provide die stops or other means to prevent losing control of the die while setting or removing dies in power operated presses which are inclined.
(3) The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the power operated press.
Exception: Press brakes using general purpose dies.
(4) The employer shall provide brushes, swabs, lubricating rolls, and automatic or manual pressure guns so that operators and diesetters shall not be required to reach into the point of operation or other hazard areas to lubricate material, punches or dies.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4200. Brakes.
(a) Brakes provided for stopping or holding a slide movement shall be inherently self-engaging by requiring power or force from an external source to cause disengagement. Brake capacity shall be sufficient to stop the motion of the slide quickly and capable of holding the slide and its attachments at any point in its travel.
(b) Brake System Monitoring. When required by Section 4193(m) of this section, the brake monitor shall meet the following requirements:
(1) Be so constructed as to automatically prevent the activation of a successive stroke if the stopping time or braking distance deteriorates to a point where the safety distance being utilized does not meet the requirements set forth in Section 4208(c)(4) or (g)(3). The brake monitor used with the Type B gate, movable barrier device, or presence sensing device shall be installed in a manner to detect slide top-stop overrun beyond the normal limit reasonably established by the employer.
(2) Be installed on a press in such a manner that it indicates when the performance of the braking system has deteriorated to the extent described in Subsection (b)(1) of this section; and
(3) Be constructed and installed in a manner to monitor brake system performance on each stroke.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4201. Pressure Vessels.
All pressure vessels used in conjunction with power operated presses shall comply with Unfired Pressure Vessel Safety Orders.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4202. Inspection, Maintenance and Modification of Power Operated Presses.
(a) The employer shall establish and follow a program of periodic and regular inspections of power operated presses to ensure that all parts, auxiliary equipment, and safeguards are in a safe operating condition and adjustment.
(b) A functional performance check shall be conducted at least once a week to determine the safe operating condition of the clutch/brake mechanism, anti-repeat feature and single stroke control. Necessary maintenance or repair or both shall be performed and completed before the press is operated. These requirements do not apply to those presses which comply with Sections 4200(b) and 4193(o).
(c) The employer shall maintain a certification record of inspections, tests, and maintenance work which includes the date of the inspection, test, or maintenance; the signature of the person who performed the inspection, test, or maintenance; and the serial number or other identifier of the press that was inspected, tested, or maintained.
(d) Any person who modifies a power operated press shall furnish instructions with the modifications to establish new or changed guidelines for use and care of the modified power operated press.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4203. Training.
(a) The employer shall ensure the continuing competence of personnel inspecting and maintaining power operated presses. (continued)