Table of Contents for the Extrusion Press Maintenance Manual:

Introduction

• Acknowledgments
• References
• Useful Tables:
• Conversion of Units
• Temperature Conversion
• Calculating Stretcher Capacity - English Units
• Calculating Stretcher Capacity - Metric Units
• Weight of Extrusion Billets
• Press Specific Pressure - English Units
• Press Specific Pressure - Metric Units
• Millimeter Conversion
• Time Limits for Tooling in Oven at Temperature
• Thermocouple Types
• Glossary of Terms for Press Components
• Diagrams of Press Components

Routine Inspection and Maintenance

• Scheduled Maintenance
• Mechanical Maintenance
• Lubrication
• "Preventive Maintenance Program Recommendations" (The Voice of Experience), by David Turnipseed
• Daily Check Sheet Procedure
• Daily Check Sheet (Sample)
• Press Troubleshooting Chart
• "Extrusion Press Maintenance - A Predictive Approach" (The Voice of Experience) by P. Gopalan Kutty, Gulf trusions, Dubai
• Farrel Maintenance Training Course information:
• Press Installation
• Mechanical Functions of an Extrusion Press
• Mechanical Maintenance

Press Alignment

• Alignment Procedures
• Recommended Tools
• Alignment and Leveling of the Fixed Press Components
• Alignment of the Moving Press Components
• Use of the Alignment Tool Stack
• Quick Checks of Press Alignment
• Modifying the Press for Easier Adjustment of Alignment
• "Extrusion Press Alignment with Modern Technology," by J.E.V. Mulder and G.J. Smith, University of Otago, New Zealand

Tooling

• Fixed Dummy Blocks
• Loose Dummy Blocks
• Clean-out Blocks
• Stem
• Container
• Container Liner
• "Extrusion Container Care and Maintenance," by James M. Pope, Special Projects Consultant to Lake Park Tool
• Improvements to Container Design
• "Preventive Maintenance of Extrusion Tooling," by Gary Dion, Extrusion Consultant Minimizing the Occurrence of Flared Billets
• "Lubrication of Extrusion Press Tooling" by James Dyla, Amcol Corp.

Inspecting and Repairing Major Components

• Procedure for Repairing Cracked Main Cylinder
• How Major Components are Designed and Tested
• "Adapting Extrusion Presses for a High Cycle Fatigue Load Environment," by J.O. Nøkleby, Det Norske Veritas
• In-Service Inspection, Repair, and Trouble-Shooting
• Failed Components - Repair or Replace?
• Requirements for Replacement Components
• "Catastrophic Failure: A 48 Hour Remedy," by Rick Colden and Adam Cramlet, Alexandria Extrusion

Hydraulic Equipment

• Hydraulic Oil
• Filtration
• Temperature
• Sampling & Analysis
• Air Breather
• Pumps
• Valves
• Piping
• Pressure Gauges
• System Documentation
• Troubleshooting
• "Proper System Maintenance to Avoid Contamination and Cavitation," by Jack Hayes, Oilgear
• Farrel Maintenance Training Course information:
• Hydraulic Maintenance
• Right and Wrong Ways to Install Hydraulic Tubing and Fittings
• Troubleshooting Hydraulic Problems
• Glossary of Hydraulic Terms
• ISO/CETOP Hydraulic Symbols
• Oilgear Training Bulletins:
• Hydraulic System Survival Techniques #90012
• Filtration Recommendations #90007-D
• Piping Information #90011-F
• Resistance of Valves and Fittings to Flow of Fluids
• Storage Recommendations #90006B

Electrical & Controls

• Maintenance of Control Equipment
• Container Heating
• Electric Motors
• "Extrusion Press Electrical Systems,"  by David Turnipseed
• "Tips for Successful Electrical Trouble Shooting of Extrusion Equipment,"  by David Turnipseed

Billet & Log Infeed Systems

• Billet/Log Infeed Conveyors
• Billet/Log Heaters - Gas Fired
• Refractory and Insulation
• Thermocouple Probes
• Combustion Systems
• Billet Heaters - Induction
• Log Shear
• Log Saw
• Billet Transfer Conveyor
• Billet Lubrication

Profile Handling Systems

• High Temperature Textile Materials
• Lead-out Tables
• Run-Out Conveyors
• Water Quench Systems
• Air Quench Systems
• Saws and Shears for Hot Profile Cut-Off
• Pullers
• Profile Transfer Systems and Lift-Overs
• Cooling Tables:
• Walking Beams
• Belt Conveyors
• Stretchers
• Saw Feed Conveyors
• Finish or Cold Saws
• Saw Blade Lubrication
• Saw Length Gauges
• Off-Load Conveyors
• Profile Stackers

Age Ovens

• Temperature Surveys
• Basic Age Oven Configurations
• Combustion Systems
• Routine Combustion System Maintenance
• Improving Age Oven Energy Efficiency

Die Ovens

Maintenance Schedules

• When to Perform Extrusion Plant Maintenance
• Master Maintenance Schedule
• Daily Maintenance
• Weekly Maintenance
• Monthly Maintenance
• Quarterly Maintenance
• Six Months Maintenance
• Annual Maintenance

Spare Parts

• Recommended Spare Parts
• Storage of Spare Parts

Modernizing Older Presses

• Specifying a New Press
• Modernizing the Press Feed Line
• Modernizing the Handling System
• Downstream Material Handling
• Auxiliary Equipment
• Vendor Request form for Press Upgrades
• "The Extrusion Press Line for 2024: A Forecast," by Al Kennedy
• Double-Length Run-out Systems

Safety & Environment

• Extrusion Tooling Safety
• Safe Lifting Techniques
• Mechanical Press Equipment
• Keeping Overhead Cranes Safe
• Check List of Safety Hazards
• Personal Protective Equipment
• Lock-Out Tag-out Procedures
• Environment

Managing Extrusion Plant Maintenance

• The Maintenance Level Audit
• Staffing and Required Skills
• Maintenance Engineering
• Equipment Information Files and History
• Spare Parts Inventory
• "Ten High-Tech Tools for Extrusion Plant Maintenance," by Al Kennedy

Manual Sponsors

• Albarrie
• Amcol
• Belco
• Butech
• BWF Tech
• COMPES
• Castool
• Dunaway, Inc.
• Granco Clark
• Kennedy Eurotech, Inc.
• Lake Park Tool
• Marathon Belting
• Oilgear
• OMAV
• R.L. Best

Prices: Book version:  $275 Now US$ 250, CD and surface shipping included (add $40 for air mail, recommended for orders outside the US)

CD-ROM version only: $145 Now US$ 125, air mail shipping included

To order the manual online, click on the Home page above !! 

The manual may also be ordered from:
Aluminum Extruders Council  - 1000 N. Rand Road, Suite 214 - Wauconda IL 60084 USA

Tel: 847-526-2010  -  Fax: 847-526-3993   mail@AEC.org  http://www.aec.org/
Send your mailing address and full payment to above address.  Checks must be in US funds, drawn on a US bank, net of any collection fees.  International Money Orders accepted.  VISA and MasterCard Accepted - call or fax for information.