May 2022 Volume 4

MAINTENANCE

• Remove crankshaft from frame. • Remove gibbing and gib plates. • Remove hard plate from bed and wedge assembly. • Remove the upper and lower knockouts.

• Furnish new bronze material, machine to fit connection leaving extra stock on the IDs to allow for finish machining diameter for proper clearance with the mating components. NOTE: The reason for this it that the bushings unless they are split will be frozen to create installation clearance. • Set connection up on mill and finish machine bores with proper clearance to mating components. • Hand fit and assemble with mating components. Wrist Pins: • Set up in lathe and indicate TIR. • If straight and true, polish with emery cloth and oil to clean up round and true. • Prepare for final assembly. Ram andWear Plates/Gib Blocks: • If there is a pocket bushing, remove the bushing from the pocket. • Set ram up on milling machine and machine bottom for minimum clean up flat and true. • Machine pocket and wrist pin bores as needed to ensure that they are round and true in parallel with the bottom of the ram. • Machine all way surfaces flat and true with each other, lower and tail as required. • Furnish new bronze material as needed, machine and install new pocket bushing and wrist pin bushings as required. • Finish machine to fit properly with mating components. • Machine or grind all wear plates, replace worn out plates. • Measure frame pocket for ram, measure ram and wear plates. • Calculate wear plate shim thicknesses, manufacture new shim plates, fit, and install with mating components. Brake Assembly: • Disassemble, clean, and inspect. NOTE: If drum brake, is the OD of the drum worn? Does the brake drum fit properly with the end of the crankshaft? If the OD of the drum is worn, then machine flat and true for minimum clean up. • Provide and install new rod bushings. • Provide and install new brake linings. • Assemble complete and test operate. Bull Gear and Clutch Assembly: • Disassemble complete and thoroughly inspect all components for cracks and excessive wear. • Check all splined surfaces to determine if clearances are within proper operational tolerances. • Remove roller bearings, clean, and thoroughly inspect. Due to the cost of removal and installation we recommend that you consider replacing the bull gear bearings. • Check fit of friction plates with mating hubs. • Provide and install new linings as required if out of tolerance. • Brake cylinder: disassemble, clean, and inspect. • Deburr and polish bore and piston assembly. • Provide and install new seals.

• Load components and transport to rebuilding facility. Receive all components at machine rebuilding company. • Disassemble complete, clean, and inspect all components for cracks and excessive wear. • Make prints of machine components as needed to perform working scope. • Process and engineer required repairs. Forging Press Frame: • Inspect frame for cracks and excessive wear. • Weld and machine wedge surfaces to remove excessive clearances. • Weld and peen any small cracks in the frame. • Grind hard plate for very minimum clean up. • Weld and machine wedge assembly components and fit with frame pockets. • Check the fit of the main bushing barrel carriers. Make sure that they fit to the frame radii properly. Crankshaft andMain Bushings: • Set the crankshaft up in the lathe and inspect for cracks and excessive wear. If the crankshaft is not cracked and is straight, • Inspect bores without bushings for being round and true. • Furnish new bronze bushings with clean up stock on the ID of the bushings. • Freeze and install the new bushings, pin in location as required as per machine design. • Finish machine the bores to fit the crankshaft main journals with the proper operational clearance. NOTE: There will be slight procedural differences depending upon the machine manufacturers design. • Fit and install in frame. NOTE: Frame alignment is critical. If the main bushing bores are not in alignment with each other it will reduce the operational clearance for the crankshaft and may cause premature failure of the main bushings. Upper Connection or Pitman: • Remove the existing bronze bushings from the crankshaft bore. • If there is a wrist pin bushing remove the bushing from the wrist pin bore also. • Thoroughly inspect the connection assembly for cracks and excessive wear. • It is critical that the bores and running surfaces are parallel with each other, round, flat and true. • Verify that the surfaces where the connection cap fits to the connection body fit properly and are true. then polish the entire shaft with emery cloth and oil. • Prepare the crankshaft for final fitting and assembly • Main bushing carriers RH and LH • Remove existing bronze bushings.

FIA MAGAZINE | MAY 2022 21