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TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Blanking
and Cupping Press
r.__.
R R. KEESU
Krk's Ranch, Route One
Qaose, Michigan
BY
Training Department

Western Cartridge Company
2//.
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material ‘holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model,. note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, '7 6th Congress. 3rd Session).
II
/I?) r9 Z9 / I25 *w>Z/<D
./A 1:
1" V _-1' e ‘A’? Q‘ .-I
- ".2: » é'?>4-..a-~c=i<-€-~é
_ v’ 10‘ _V
-2' A
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Process Sequence . . . . . . . . . . . . ._ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . .' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .‘ . . . . . . 19
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._ . . . . . . 20
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._ . . . . . . . . . . . . . . . . . . . . . . . . . 46
III

OVER-ALL VIEW OF BLANKING AND CUPPING PRESS
IV
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Catalogue Data

Manufacturer
Machine
Description
Type of Feed
Machine
Motor
Production
Crankshaft Speed
Cooling Solution
Pump
Lubrication
Tools
Height
Weight
Floor Space
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, N. Y.
Vertical, single, straight side, double action
Crank press, E. W. Bliss #6, 3 V-belt
drive motor to ﬂywheel
Roller Feed
1 15 h.p.; 3 phase; 60 cycle; 220/440
volts; 38/19 amps.; 1750 R.P.M.
564 per minute
94 R.P.M.
Centrifugal (Gusher) 1/10 h.p. Motor;
1 phase; 60 cycle; 110 volts
Force Feed System
Piece No.:
Cupping Punch B-1
Blanking Punch A-1
Blanking and Cupping Die A-1
Sizing Die W-15
Stripper .766
Stripper Spring 2% X .10 x .016
12 ft., 3 in.
22,750 lbs.
5 ft. X 6 ft.
CALIBER .30 CASE BLANKING AND CUPPING PRESS Machine Description
MACHINE DESCRIPTION
Strip metal automatically fed to the Caliber .30 Case Blanking and
Cupping Press is blanked out and formed into the shape of a cup.
_--I— Motor
V-Belts
Flywheel —_-____ . )/ Brake Assembly
Slotted Bur
Guard Covering
Bull Gear
Connecting Rod
Clutch Lever
Outer Rom


,_-_.__ Feed Roller
Assembly
FRONT AND END VIEW OF PRESS
Power and The E. W. Bliss Double Action Draw Press, illustrated above, is powered
Transmission by one 15 h.p. motor, through 3 V-belts to the ﬂywheel pulley and crank-
shaft.
The power is transmitted from the ﬂywheel to the jackshaft. At the right
end of the jackshaft is located a small pinion gear which drives the large
bull gear.
A rolling key clutch incorporated in the hub of the bull gear controls power
to the crankshaft through linkage to the clutch lever.
[21
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description

Power and
Transmission
(Cont)
Feed Rollers
Rom
Shearing
Mechanism
Cooling Solution
A conventional brake drum is located on the outer end of the crankshaft,
next to the ﬂywheel. A lined brake shoe, located and secured by a bracket
attached to the machine frame, provides the friction necessary to hold the
crankshaft in position when the clutch is disengaged. The clutch and brake
action are synchronized through the clutch lever. When the clutch is
engaged, the brake is released;'and when the clutch is disengaged, the
brake is applied. In normal operation, if the clutch is disengaged for any
reason, the crankshaft will always stop at its maximum upward position.
For inspection or adjustment purposes, the ﬂywheel may be rotated by
hand, and the crankshaft stopped and held in any desired position.
There are two sets of feed rollers on the machine, one on the right side and
one on the left side. The feed rollers are rotated and timed for the progres-
sion of the strip metal by gears, located on the inside of a housing which is
attached to the rear of each set of the feed rollers. There is a slotted bar
bolted to the left end of the crankshaft, which through a series of con-
necting rods and a rocker arm controls the action of the rocker arm shaft.
The rocker arm shaft is connected to and controls both the ﬁrst and second
set of feed rollers. The rocker arm moves forward and backward; on its
forward stroke the trip lever-inside the ratchet engages the gear and rotates
the feed rollers. ‘
The ram is in two sections, “outer and inner.” The outer ram is made of
cast iron and is held.in a vertical position by a V-shaped gib arrangement.
The inner ram is made of steel and is recessed on four sides. It has two ma-
chined bearing surfaces which ride on the inner surface of the outer ram. The
mass of the rams assists the power stroke of the punch and absorbs the shock
of impact and subsequent vibration. ' The lower surfaces of both rams are
machined for attachment of the punch holder blocks. The outer ram
is actuated by and connected to the crankshaft eccentric cams by two
connecting rods. The inner ram is connected to and actuated by a sin-
gle adjustable connecting rod attached to the crankshaft throw. The
outer ram is powered by the two eccentric cams and controls the blank-
ing press. The inner ram connected to the crankshaft throw controls the
cupping press.
The shearing mechanism is powered from the crankshaft through an ec-
centric cam, and a connecting rod to the ram. Near the bottom of the
ram is attached a plunger arm. In the center of the plunger arm is the
shearing mechanism. The plunger arm and shearing mechanism are timed
by an automatic cycle repeater. The automatic cycle repeater is chain
driven from a geared sprocket mounted on the crankshaft at the left side of
the press. At each twelve revolutions of the crankshaft, the automatic cycle
repeater causes the cycle breaker to make contact with the solenoid. The
solenoid plunger arm moves in to engage the cutting block sleeve and pis-
ton. The cutting block unit descends to shear off the scrap web. As the
unit rises, it breaks contact with the solenoid and the solenoid plunger rod
goes back to its original position, releasing the cutting block sleeve from
the piston.
To prolong die and punch life, the strip brass and the blanking punch are
bathed by a solution which acts both as a cooling and a lubricating agent.
'[3l
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description

Cooling Solution
(Cont.)
Controls
Lubrication
Chute
Roto ry Wosher
Elevator
The base of the machine forms a reservoir for this solution, which is
pumped through a pipe system to the dies. The pump is located at the
rear of the machine and is driven by a 1/10 h.p. vertical direct drive mo-
tor.
One push button “Start and Stop” switch provides control of the main
drive motor and is attached to the right front of the machine.
One overload switch for the main driving motor is attached to the lower
part of the machine on the right side.
One toggle type switch, for the pump motor, is mounted in front of the
machine directly under the “Start and Stop” switch.
All of the main parts of the machine are lubricated by a force feed lubri-
cating system.
A curved metal chute extends from the screen under the die block to the
rotary washer. The cups ﬂow down this chute from the screen to the rotary
washer.
The rotary washer is located at the left rear side of the press, between the
end of the cup feed chute and the elevator. The cup container, known as a
washer, is a cylindrical shell of perforated brass, equipped with metal pins
attached to the inner surface of the washer. The brass cylinder or washer is
suspended above a metal pan, which rests on the ﬂoor; this arrangement
allows the lower surface to be immersed in the water contained in the pan.
Hot water is piped to a position directly above the washer, allowing the
water to ﬂow over the washer into the pan below. The pan is equipped
with a drain plug which is adjusted to maintain a correct water level at
all times. The washer is rotated by an electric motor. The pins agitate or
tumble the cups through the water in the pan, thus washing them clean.
The washer contains two openings, one at each end. The cups are fed from
the press into the washer by means of a feed chute. They pass from the
washer into the elevator through the opening at the opposite end of the
washer.
The elevator is located directly behind the press and rotary washer. It
extends from the ﬂoor in a vertical position up through the ceiling into
the annealing room.
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description
Rear View Motor,
Jockshoft, Flywheel,
Rocker Arm Shaft
ond Cooling
Solution Pump
Guard Covering
Bull Gear
Feed Roller
Assembly
Feed Roller Rack
This rear view of the Caliber .30 Case Blanking and Cupping Press shows
the motor, belt drives, jackshaft, small pinion drive gear, rocker arm shaft
and cooling pump.
The press is started and stopped by a clutch in the crankshaft bull gear
wheel.
On the lower right hand side of the reservoir is attached the cooling solu-
tion pump. The pump on the motor circulates the cooling solution from
the reservoir in the machine bed, through a pipe system to the punches
and dies. The cooling solution serves both as a cooling and lubricating
agent.
The rocker arm shaft is located at the rear of the press at the base of the
die block and is connected to two housings attached to the two sets of feed
rollers. The function of the rocker arm shaft is to rotate the feed rollers.
'— Mote:
l
1- Flywheel


.
E_ll— U V _;,
Rocker Arm
Shall

REAR VlEW—CAL. .30 CASE BLANKING AND CUPPING PRESS
[5]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description
Guard Covering _


\ Molar
Flywheel
Cross Shaft
“Connecting Rod
Bull Gear
‘ 'iL.
Clutch Lever lit; Clutch Lever Shaft
Ram
Feed Roller U!
Mechanism
Flywheel, Jackshaﬁ,
Bull Gear, and
Clutch


OVER-ALL REAR VIEW OF PRESS
The ﬂywheel is mounted on the left end of the jackshaft. Incorporated in
the hub of the ﬂywheel is a shear pin, necessary as a safety measure for
the protection of the press and its working tools in the event a jam occurs.
The jackshaft is mounted on the upper rear of the press, at a position ap-
proximately level with and running parallel to the crankshaft.
Mounted on the right end of the crankshaft is a spur pinion gear whose
teeth are in constant mesh with the bull gear, and from which the driving
power of the bull gear is received. The jackshaft is supported by and rotates
in two bearings, all of which are enclosed in a cast-iron housing. The ﬂy-
wheel, pinion and bull gears are enclosed in metal guards as a safety meas-
ure for the machine and its operators.
The bull gear is mounted on the right end of the crankshaft, outside the
press frame. Incorporated in the hub of the bull gear is a rolling key
clutch. Located between the bull gear and the press frame is the manually
operated mechanism for engaging or disengaging the clutch. Engaging
the clutch results in a positive action of the crankshaft in relation to the
bull gear.
[6]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description
Spur Gear
Guard Covering ____.-
Bull Gear
Feed Roller /
Mechanism
Crankshaft,
Eccentric Cams
and Crankshaft
Th row


\ Motor
Flywheel
Cross Shaft
“Connecting Rod
OVER-ALL REAR VIEW OF PRESS
The crankshaft consists of one throw, located in the center of the crank-
shaft, and two eccentric cams, one on each side of the throw. Each cam
has a geared section on its outside face. There are two spur gears mounted
on a cross shaft which is held directly in front and parallel to the crank-
shaft. Each spur gear is in constant mesh with its complement gear on
the cams These gears, when rotated, allow a vertical adjustment of the
outer ram stroke.
[7]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description
Sheer Cam and
Slotted Bur
Feed Roller
Control
lnner and Outer
Roms
Slotted
The crankshaft extends through the left side of the machine frame.
Mounted on the crankshaft, on the outside and next to the frame, is an
eccentric cam which operates the shearing mechanism.
Bolted to the left end of the crankshaft is a slotted bar which, through a
series of connecting links, rocker arms and rocker arm shaft, actuates the
feed rollers.

Bur
END VIEW OF PRESS SHOWING FEED ROLLER CONTROLLING MECHANISM
The outer ram is made of cast iron, held in a vertical position by two V-
shaped gibs. The ram is actuated by and connected to the crankshaft
cams by means of two connecting rods. The bottom surface of the ram is
machined to hold the blanking punch holder block assembly.
The inner ram is made of steel, recessed at the four corners. The ram is
provided with two opposed bearing surfaces which ride against the inner
surface of the outer ram. The ram is actuated by and connected to the
crankshaft throw by a Pitman connecting rod which allows a vertical ad-
justment of the ram stroke. The bottom surface of the inner ram is ma-
chined to hold the cupping punch holder assembly. The mass of the rams
assists in the power stroke and absorbs the subsequent shock and vibration
produced by the blanking and cupping operations.
[8]

CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description
Feed Rollers
Motor


V-Belts
Flywheel -__________. Brulce Assembly
Slotted Bur I ‘i ' ~ / Cronlcsholt
F d R ll I ' '
Operzteing Zr: El-Illlirgecﬂiveﬂng
Clutch Lever
. J J 1 I V _. i ‘ I
Fezd Rollller /(C 5 I l_ U \
ssem y ~. ' U ' Feed Roller .
'> ‘ Assembly
OVER-ALL FRONT AND END VIEW
The press is equipped with two sets of feed rollers; each set is held in its
housing. These housings are bolted to the right and left side of the machine
respectively. The feed rollers are connected by a cross shaft and are timed
to operate in unison. Each housing contains two cylindrical feed rollers,
mounted one above the other, between which the strip metal is fed. The
lower roller is driven by a ratchet and pawl arrangement by means of the
cross-shaft at the back of the machine. The upper roller is timed to move
in unison with the lower roller by a set of interlocking spur gears mounted
at the front of the feed roller housing on the ends of the roller shafts. The
spur gears are enclosed by a metal shield for the protection of the working
parts and the machine operator. The upper feed rollers in each housing are
held in contact with the lower roller by two coil compression springs di-
rectly above and bearing against the rollers. A constant pressure brake is
located on the outside and in front of the housing of each lower feed roller
shaft.
The feed rollers are actuated from a slotted bar through a series of con-
necting links and a rocker arm. To regulate the power stroke which op-
erates the feed rollers, an adjustment can be made on the connecting link
attached to the slotted bar on the crankshaft.
[9]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Description
Slotted Bar /
Guard Covering
Flywheel
Feed Roller ..
Controller
Shear Block —"""
Shearing
Mechanism
Solenoid


END VIEW OF PRESS SHOWING FEED ROLLER ASSEMBLY
The shearing mechanism, which is located at the left end of the machine, is
actuated by the eccentric cam through the connecting rod from the ram.
The shear plunger operating bar is connected at one end to the ram and is
held in a horizontal position above the plunger by two strap links connect-
ed to the other end. The strap links are mounted on a stud connected to
the plunger housing, an arrangement which permits a slight rocking mo-
tion of the straps. The plunger and shear operating sleeve are enclosed in
a housing. The piston plunger moves up and down inside the piston sleeve
with every revolution of the machine. Bolted to the left end of the piston
housing is a solenoid switch which actuates a plunger shaft, inserting it
in a hole through the piston into the sleeve, thus forming a single unit of
the piston and sleeve. The solenoid switch actuated by an electrical im-
pulse from an automatic cycle repeater inserts the plunger rod into the
piston and sleeve on every twelfth stroke of the press. The automatic
cycle repeater is chain driven from a geared sprocket mounted on the
crankshaft at the left side of the machine.
[10]
CALIBER .30 CASE BLANKING AND CUPPING PRESS '
Machine Description

Feed Rocks
Clutch Lever
Rollers
Ship Metal Rolls
Ruck
- FEED RACK ASSEMBLY
The feed racks are bolted to the ﬂoor at the right end of the machine di-
rectly in front of the feed roller. The feed racks are built to accommodate
two rolls of strip metal. The strip metal rolls are held upright on a set of
metal rollers which allows the roll to unwind itself, as it is fed into the ma-
chine. The strip metal rollers are mounted in a movable carriage held in
the base of the feed rack. This arrangement permits the second roll to be
moved in front of the feed rollers after the ﬁrst roll of metal is consumed.
The rolls of strip metal are placed in the feed rack by means of an elec-
trically driven chain hoist.
[11]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Tool Holder Description
TOOL HOLDER DESCRIPTION
Punch Holder Fork: Each of the six punch holder
forks is inserted in its proper milled out slot in the cup-
ping punch block from the front side. Its forked end is
placed in the block with the countersunk portion of
the fork up. The fork locks the punch in the punch
holder block.
Cupping Punch: The cupping punch is placed in the
Punch Holder
Assembly


punch is locked in position by the fork which enters its
grooved neck.
Cupping Punch Holder Block: The cupping punch
holder block holds six cupping punches, and is bolted
against the back-up plate on the bottom of the inner
ram by means of four Allen head bolts.
Outer Ram Face Plate: The outer ram face plate has
two dowel pins on its top surface to assist in aligning
it on the under surface of the outer ram. It is attached
to the ram with four Allen head bolts. There are six
holes drilled in the face plate to allow the cupping
punches to travel through it. The blanking punch
holder block is attached to its bottom surface after the
blanking punches have been placed in it, ﬂanged end up,
from the top side. Inserted in each corner is a hollow
guide bushing, into which the guide posts of the die
block holder are inserted. These posts and bushings
keep the die block holder and the punch holder blocks
in alignment.
Blanking Punch: The blanking punch is inserted
ﬂanged end up, into the blanking punch holder block
from the top side. The blanking punches are hollow
to permit the insertion of the cupping punches and to
guide them in their vertical motion.
Blanking Punch Holder Block: The blanking punch
holder block has two dowel pins on its top surface to
assist in aligning it with the under side of the outer ram
face plate. It is attached to the outer ram face plate
by eight screw head bolts. The punch holder block
holds the blanking punches in vertical alignment with
the dies.
cupping punch holder block from the under side. The‘
[12]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Tool Holder Description
Die Block
Assembly
Stripper Plate: The stripper plate rests upon the top
surface of the blanking and cupping die block. It strips
the scrap web from the blanking punch.

Blanking and Cupping Die Block: The blanking and
cupping die block is constructed to accommodate six
blanking and cupping dies which are inserted in it,
flanged end down, from the bottom side. The blanking
and cupping die block rests on the top surface of the
die block holder. The blanking and cupping die block
is fastened by Allen head bolts.
Sizing Die Block: Each of the six sizing die blocks
holds a sizing die and a three segmented stripper which
are inserted from the top side. The sizing die blocks are
inserted in their respective milled out slots in the die
block holder and are held in position by a lock pin.
The stripper plate rests upon the blanking and cupping
die block, which in turn, rests upon the die block holder.
They are attached to the die block holder by means of
eight Allen head bolts, which are inserted through holes
drilled in the stripper plate and the blanking and cup-
ping die block.
Die Block Holder: The die block holder is bolted to
the bed of the machine by four bolts. Located in each
corner is a guide post which is inserted in the hollow
bushings of the outer ram face plate to assist in aligning
the die block and the punch holder block. There are six
slots milled in the top surface of the die block holder
for insertion of the six sizing die blocks.
[13l
CALIBER .30 CASE BLANKING AND CUPPING PRESS Tool Holder Description
Punch Holder Fork
Cupping Punch
Holder Block

l___ Outer Ram Face Plate
\\\/
Cupping Punch
\\
—— Blanking Punch

\
Blanking Punch
Holder Block
Punch
U
CROSS SECTIONAL DRAWING OF DIE BLOCK ASSEMBLY

Stripper Plate
- \ E Blanking and
\\ Cupping Die
Blanking and Cupping
Die Block


\
/ Sizing Die Block
\$izing Die


/ Stripper
\ Sl"pPe' Spring (Coil)
Die Block Holder
CROSS SECTIONAL DRAWING OF DIE HOLDER ASSEMBLY


CALIBER .30 CASE BLANKING AND CUPPING PRESS
Tool Description
STRIPPER
TOOL DESCRIPTION

STPIPPER SPRING
Tool Name: Cupping Punch
Piece No.: B-1
Location: Set vertically in ram
Normal Life: 150,000 pieces
The punch is made of steel, hardened, ground and
polished. Shank is slightly softer than working end.
Tool-Name: Blanking Punch
Piece No.: A-1
Location: Set vertically in ram
Normal Life: 1,000,000 pieces
The punch is made of steel, hardened, ground and pol-
ished. Shank is slightly softer than working end.
Tool Name: Blanking and Cupping Die
Piece No.: A-1
Location: Die block
Normal Life: 1,000,000 pieces
Die is made of steel, hardened and polished. Surfaces
are ground.
Tool Name: Sizing Die
Piece No.: W-15
Location: Die block
Normal Life: 250,000 pieces
Sizing die is made of steel, hardened and polished. Top
and bottom surfaces are only ground.
Tool Name: Stripper
Piece No.: .766"
Location: Die block under die
Normal Life: Indeﬁnite
The stripper consists of three pieces held together by a
coiled spring band. It is made of steel, ground and
polished on the angles.
Tool Name: Stripper Spring
Piece No.: 2% X .10 x .016"
Location: Around stripper
Normal Life: Indeﬁnite
The stripper spring consists of a small coil wire spring.
l 15 l
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Process Sequence

Feed Racks
Feed Rollers
Punch and
Dies Blanking
and Cupping
Stripper
Disposal
Cutoﬁ‘
PROCESS SEQUENCE
Strip brass in the rolls is placed in the double feed racks by the operator.
The operator breaks the band on the roll and removes it; then grasps the
end of the strip, pulling it toward the first set of feed rollers. If the end
of the strip is bent, it should be straightened with a leather hammer be-
fore it is placed between the feed rollers.
Before the end of the strip brass is placed between the feed rollers, the
operator steps on a foot lever which opens a gap between the rollers. This
gap facilitates the feeding of the end of the strip into the dies. The op-
erator places the end of the strip between the feed rollers and sets it be-
tween the stripper plate and blanking dies. The operator then disengages
the foot lever, the gap between the feed rollers is closed, and the press is
ready for operation. As the operator starts the press, the ﬁrst set of feed
rollers starts to rotate, feeding the strip through the die block progressively
with each stroke of the ram.
The outer and inner ram descend simultaneously and the blanking punch
blanks a disc out of the strip brass. The scrap web is stripped from the
blanking punch by the stripper plate. The cupping punch descends through
the center of the blanking punch and forces the disc into and through the
cupping and sizing dies, forming the cup.
As the ram raises, the cup is stripped off the punch by a stripper located
under the dies.
After the cups are forced through the dies, they drop onto a screen under
the press, then fall into a chute which guides them into a rotary screened
washer. As the washer rotates, the cups are bathed with hot water,
which washes off the cooling solution. The cups ﬂow through the washer
and drop into the vertical elevator which conveys them upward to the
annealing room.
On the upward stroke of the ram, the blanked out web moves forward and
enters the second set of feed rollers. At each twelfth stroke of the ram the
cutoff mechanism which is electrically controlled, shears the scrap web
and ejects it into a truck. The scrap web falls from the machine into
a truck.
When the strip reaches its end and leaves the rack, the operator pushes
the full section of the rack in alignment with the ﬁrst set of feed rollers
and repeats the above operation.
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Process Sequence

FLOW CHART

Feed Rack
Strip brass in coils is placed in the double feed racks
by the operator.

I
Feed Rollers
Operator breaks band on coil, grasps end and pulls
it toward ﬁrst set of feed rollers. End of strip, if
bent, is straightened before it is placed between feed
rollers.
The operator places the end of strip brass in the feed
rollers and pulls it between the stripper plate and
blanking dies.
As the operator starts the machine, the two ﬁrst feed
rollers start to rotate feeding the strip through the
die block progressively with each stroke of the ram.


Feed rollers are powered by ratch-
et gear to rocker arm shaft, to con-
necting rod, to slotted bar on
crankshaft.


Blanking and Cupping
The outer and inner rams descend simultaneously,
and the blanking punch forces the strip brass through
the blanking die, forming the blank.
The blank is forced off the blanking punch by the
stripper plate. The inner ram descends and the cup-
ping punches force the blank through the cupping
and sizing die, forming the cup.


Ram is powered by connecting rod
to crankshaft, to clutch, to bull
gear, to pinion gear, to jackshaft,
to ﬂywheel by three V-belts, to 15
h.p. Motor.


Stripper
As the ram raises, the cups are stripped off the punch
by strippers located under the dies.


Disposal
After the cups are forced through the dies, they drop
onto a screen under the press and slide down a chute
into the rotary screened washer. The cups pass
through the washer to the elevator.

l
Cutoff
On the upward stroke of the ram, the blanked out
web moves forward and enters the second set of
rollers. At each twelfth stroke of the ram, the scrap
web is cut off and dropped into a truck.
As the strip reaches its end, the operator pushes the
feed rack into position and places the end of the next
coil between the rollers repeating the above opera-
tion.


The cutoff shear mechanism is
powered by crankshaft to con-
necting rod, to ram, to plunger
arm, to piston, piston to cut off
shear. Cut off shear moves down
with the twelfth stroke of the
ram.


[17]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Product Description

PRODUCT DESCRIPTION
The material when received at the blanking and cupping press is in the
form of ﬂat strip brass (70% copper, 30% zinc), in rolls weighing approx-
imately 250 lbs. After the brass strip has been processed, it is in the form
of a cup. The closed end of the cup is known as the bottom and the open
end as the mouth.
The dimensions of the strip brass The dimensions of the cup after
before the draw are as follows: the blanking and cupping opera-
tion are as follows:
Width of Strip Brass 6%; Outside diameter .'766—.7 60
Thickness Sidewall variation .001—.003
of Strip Brass .135—.139 . Bottom thickness .135—.129
After the blanking and cupping operation, the cups are delivered to the
Annealing Department where they are annealed, pickled and washed
before being delivered to the ﬁrst draw.

FIG. 1 FIG. 2
FLAT STRIP BRASS IN A ROLL CUP AFTER CUPPING AND
BLANKING OPERATION
[18]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Inspection

Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the blanking and cupping operation, a careful
visual inspection of the cups must be made. The cups should be inspected
for scratches on the inside and outside Walls, for crooked heads, and crook-
ed tops. These defects indicate an immediate adjustment of the machine
to correct the fault. Whenever defective cups are found, the lot from which
they come must be removed from the machine and properly identiﬁed to
prevent mixing the bad lot with the good cups.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a cup to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cups are cool since heat causes expansion of the
metal and results in a temporary variation in the cup size.
The outside diameter of the cup
is gaged with a twin ring gage.
Cups must pass through the
larger or “go” ring and must
not pass through the smaller
“no go” ring.


The inside diameter of the cup
is checked with a plug gage.


The bottom thickness of the cup is checked
on a dial indicator. Variation in this dimen-
sion greatly affects succeeding draws.

The above described inspection methods are those most commonly em-
ployed in the manufacture of Caliber .30 Case Blanking and Cupping.
However, other methods may be developed to maintain the manufactur-
ing standards.
[19]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adjustments
ADJUSTMENTS
Objective To maintain satisfactory production a machine must be adjusted to com-
Cautions
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than the starting button to determine
whether the clutch is disengaged.
Make frequent inspection to determine whether proper and sufficient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adjustments

Metal Progression
The metal progresses through the machine between two sets of rollers, one
set at each end of the machine. The action of the rollers determines the
speed at which the metal is fed. The rollers are actuated by a lever con-
nected to the outer end of the crankshaft. ‘The amount that the rollers
turn with each revolution of the crankshaft is determined by the distance
that the controlling lever is set off center. It should be adjusted so that the
holes in the metal do not overlap but are not so far apart that there is a
waste of metal.
Slotted Bar
Guard Covering
Flywheel
Feed Roller
Controller ,’
Solenoid
Shear Block ‘
Tools:
2.
3.


ENLARGED VIEW OF
SLOTTED BAR
; q J I
v\
I .
FEED RLLER ASSEMBLY


11/3" wrench, %" wrench.
Procedure: 1.
Operate the machine and observe the distance between the holes in the
scrap metal. '
Turn off the power and wait until the ﬂywheel stops before proceeding
with the adjustment.
Use a 1%" wrench to loosen the nut on the controlling lever on the
outer end of the crankshaft.
If the holes in the scrap metal are too far apart, decrease the action of
the rollers by using a % ” wrench to adjust the lever connection farther
toward the center of the crankshaft.
If the holes overlap, increase the action of the roller by adjusting the
lever away from the center.
Operate the machine and again observe the distance between the holes
in the scrap metal.
The above procedure must be repeated until the holes in the scrap
metal are evenly spaced.


I21]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adiustmenfs

Feed Roller The metal should be fed smoothly into and through the machine between
Tension the rollers. If there is not sufficient pressure on the rollers, they will slip
on the metal, cause the holes in the metal to overlap and result in de-
fective cups.
A 21/4" wrench is used to turn the two nuts above the feed rollers to in-
crease the tension on the rollers. Each of the nuts should be turned a like
amount so that the pressure is uniform on both sides of the metal strip.


V ENLARGEMENT OF FEED ROLLER
FEED ROLLER ASSEMBLY TENSION ADJUSTMENT
Feed Roller Brake The feed roller brake holds the feed roller to prevent it from turning in the
reverse direction. If the brake fails to perform its function, it can be
tightened by turning the hand knob at the lower part of the brake shoe.


ENLARGEMENT OF BRAKE
HAND KNOB
Brake
Hand Knob

FEED ROLLER BRAKE
I 22 I
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adjustments
Cmnkshoft Broke


The brake connected to the crankshaft keeps the ram from falling when
the clutch is disengaged. It must be adjusted so that the brake drum is
gripped ﬁrmly when the brake is applied, but should not be so tight that it
drags when the drum is in motion. The adjustment is made by turning the
two set screws, one on the lower part of each of the brake shoes.
Brake Adjusting
Screw and Loch
Nu!


CLOSE UP OF TOP
BRAKE ADJUSTING
SCREW AND LOCK NUT
BRAKE ASSEMBLY
Tools:
Procedure:
7/8” wrench, 1/2" wrench.
1. Use a % " wrench to loosen the lock nuts on both of the adjusting screws
on the brake shoes.
2. Use a 1/2" wrench to loosen the adjusting screws a fraction of a turn,
bringing the shoe closer to the brake drum.
3. Tighten the lock nuts on the adjusting screws.
4. Operate the machine and observe the action of the brake.
Caution: The above procedure should be repeated until the brake
drags slightly when the machine is in motion. Then the adjusting
screws should be tightened just enough to free the shoe from the drum.
[23]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adjustments

Broke Release Rod The brake release rod connects the brake lever to the clutch lever. Its
function is to synchronize the action of the brake and the clutch. When the
clutch is disengaged, the brake lever should be released so that the brake
may be applied through the brake spring. When the clutch is engaged, the
rod should act to pull the brake lever sufficiently to release the brake shoe
from the brake drum.


ENLARGEMENT
SHOWING
BRAKE RELEASE ROD


\ Broke Release
Rod Adjustment
BRAKE ASSEMBLY
Tools: Two "/8” wrenches.
Procedure: 1. Loosen the lock nut on the brake release rod with a %;” wrench while
holding the adjusting nut with the other 7 8" wrench.
2. Use a % ” wrench to turn the adjusting nut until the clutch lever is in a
position about 2%” above the clutch lever latch. The brake shoes
should be just free of the drum when the clutch is disengaged.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Check the adjustment by observing whether or not the brake is re
leased when the clutch is engaged.
I24]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adiustments
Sizing Die
and Stripper
Replacement
Procedure:
The sizing die completes the drawing of the cup to its ﬁnished size. The
stripper, located below the die, strips the ﬁnished cup from the punch.
Both the die and stripper are contained in the sizing die block. If either the
die or the stripper is defective, it must be replaced.

1.
Remove the sizing die block lock pin by lifting it out of the hole in the
die block.
Slide the blanking and cupping die block from the die block holder.
Turn the sizing die block over and allow the sizing die and stripper to
fall out into your hand.
Place the stripper and the sizing die back into the sizing die block,
replacing either one with a new part if necessary.
Caution: Observed that the hole in the die and the stripper is tapered.
Make certain that the small part of the taper is on the bottom when the
sizing die block is placed into the die block holder.
. Slide the sizing die block into the die block holder and insert the die
block lock pin into the hole in the die block. If the blanking and cup-
ping die is dropped into the die block holder when the sizing die block
is removed, it must be inserted into the blanking and cupping die block
before the sizing die block can be replaced. '
[25]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adiustments
Blanking and
Cupping Die
Replacement
Tools:
Procedure:
The blanking and cupping die assists in the blanking of the strip and the
drawing of the cup. If the die becomes dull, it must be replaced. It is
removed by removing the stripper plate and the blanking and cupping die
block.

%” Allen wrench, 3/15” Allen wrench.
1. Use a 3/8 ” Allen wrench to remove the Allen screws from the stripper
plate. Lift off the stripper plate.
2. Use a %5” Allen wrench to remove the Allen screws from the blanking
and cupping punch holder.
3. Slide the blanking and cupping die block from the die block holder
allowing the die to fall into your hand.
4. Replace the blanking and cupping die by inserting it up into the die
holder.
5. Slide the blanking and cupping die block back in place on the die block
holder.
6. Place the stripper plate back onto the blanking and cupping holder and
replace the Allen screws.
Caution: Turn the ﬂywheel one complete revolution by hand to check
the adjustment before turning on the power.
l26l
‘ CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adiustments
Cupping Punch
Replacement
TOOlS:
Procedure:
The cupping punch forces the metal slug through the combination die and
then through the bottom draw die. If one of the punches is worn or
broken, it must be replaced. To remove the punch it is necessary to remove
the punch housing; remove the fork that holds the punch in place and
allow the punch to drop down through the dies.

1%" wrench, fork puller, screwdriver.
1. Use a 1% ” wrench to loosen the two outer nuts on the latch that holds
the punch housing in place and release the latch. Remove the punch
housing by grasping the two handles and pulling the housing from the
machine.
2. Use a screwdriver to loosen the screws that hold the strainer in place
beneath the machine. Remove the strainer.
3. Use a fork puller to pull out the fork which holds the punch in place.
The fork slides out of the punch holder block. If there is diﬂiculty in
removing the fork, the Allen screws beneath the punch holder block
can be loosened before removing the fork.
4. Pull the punch from the punch holder block and allow it to drop out
through the dies and into the solution at the base of the machine.
5. Insert a new punch up through the dies with the working end down.
It will be necessary to use a rod or a piece of tubing to push the punch
far enough up into the cupping punch holder.
[27]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adiustments
Procedure (Cont) 6. Hold the punch in place in the punch holder block and replace the fork
to hold it in place.
Caution: Tighten the Allen screw beneath the punch holder block if
it has been loosened.
7. Replace the punch housing; latch, and tighten the nuts to hold the
latch. Replace the strainer.
Caution: Turn the ﬂywheel one complete revolution by hand to check
the replacement before turning on the power.
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Adiustments
Blanking Punch
Replacement
Tools:
Procedure:
If one of the blanking punches is defective and fails to blank out the metal
forming the slug, it must be replaced. To remove and replace the blanking
punch, it is necessary to remove the stripper plate, the blanking and cup-
ping die block and the blanking punch holder block.

%” Allen wrench, %5" Allen wrench, rawhide mallet.
1.
2.
Use a 3/8" Allen wrench to remove the Allen screws from the stripper
plate and remove the stripper plate from the machine.
Use a 3/1’6" Allen wrench to remove the Allen screws that hold the
blanking and cupping die block to the die block holder. Remove the
blanking and cupping die block from the machine.
Use a % " Allen wrench to remove the six Allen screws from the blank-
ing and cupping punch holder block, and remove the punch holder
block from the outer ram face plate.
Use a rawhide mallet to tap on the bottom side of the blanking punch,
forcing the defective punch from the punch holder.
Replace the punch by tapping it into the punch holder gently with a
rawhide mallet.
Caution: If there is a sharp edge on the bottom of the shoulder on the
new blanking punch, it should be removed before inserting the punch
into the punch holder. There is a possibility that the sharp edge may
shear some of the metal from the punch holder, reducing the life of the
holder considerably.
[29]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adiustments

Blanking Punch 6. Place the blanking punch holder block back onto the outer ram face
Replacement plate. Insert and tighten the Allen screws.
(Cont) 7. Replace the blanking die block and the stripper plate back On the
machine.
Caution; Turn the ﬂywheel one complete revolution by hand to check
the replacement before turning on the power.
Shear Knife The shear knife cuts the scrap metal to uniform lengths. If the knife fails
to perform its function, it must be lowered by adjusting the four nuts
above the shear knife.


‘ Shear Knife
: Adjustment
END VIEW OF MACHINE
Tool: 15/8” wrench.
Procedure: 1. Loosen the two lower nuts on the shear knife adjusting screws with a
1%” wrench.
2. Tighten the two upper nuts on the adjusting screw, thus lowering the
shear knife. (Both of the nuts should be tightened a like amount.)
3. Tighten the two lower nuts against the bracket.
Caution: Turn the ﬂywheel one complete revolution by hand to check
the adjustment before turning on the power.
I30]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adjustments
Cupping Punch The cupping punch forces the metal slug through the blanking and cupping
Adjustment die to form the cup. It is actuated by a Pitman connected to the crank-
shaft. The adjustment is made by turning the Pitman screw. If it is not
properly adjusted, the cupping punch may come up out of the blanking
punch, damaging either of the punches on the down stroke of the ram;
or the cupping punch holder block may be lowered too far and hit against
the top of the face plate of the outer ram. For proper adjustment, the Pit-
man should be adjusted so that there is about 14" clearance between the
top of the outer ram face plate and the bottom of the cupping punch
holder block.


Connec§ing ' i I ' ' A ' k_Cam
o — i . -
Pitman
Adjustment

Outer Ram

Tools: 2%" wrench, 1%" wrench, 11/4" wrench.
Procedure: 1. Use a 11/4 " wrench to loosen the two outer nuts on the latch that holds
the punch housing in place and release the latch. Remove the punch
housing by grasping the two handles and pulling the housing from the
machine.
2. Engage the clutch and use a ﬂywheel rod to turn the ﬂywheel until the
Pitman is at the bottom dead center. Disengage the clutch.
3. Use a 1%” wrench to loosen the two nuts in the Pitman that holds the
Pitman screw in place.
4. Use a 2% " wrench to turn the Pitman screw until there is 1/4 " clearance
between the top of the outer ram face plate and the bottom of the
cupping punch holder block.
[31]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adjustments

Cupping Punch 5. Engage the clutch and use a ﬂywheel rod to turn the ﬂywheel until
Adjustment (Cont) the Pitman is at the top dead center.
Caution: Turn the ﬂywheel one complete revolution by hand to check
the adjustment before turning on the power.
Broke Spring The brake spring acts to close the brake shoe against the brake drum.
The spring must have sufficient tension to press the brake shoe firmly
against the brake drum when the brake rod is released.


Brake Release Rod‘
Adjustment


4"’. S 5
- ‘I
ENLARGEMENT OF
BRAKE SPRING


_ Brake Release Rod
BRAKE ASSEMBLY
Tools: Two 1%” wrenches.
Procedure: 1. Use a 1 %" wrench to loosen the lock nut on the brake spring rod while
holding the adjusting nut with another 1%" wrench.
2. Use a 1%" wrench to turn the adjusting nut on the spring rod until
there is a ﬁrm pressure against the brake shoes.
3. Hold the adjusting nut in place and tighten the lock nut against the
adjusting nut.
4. Check the adjustment by operating the clutch lever and observe
whether or not the brake shoe presses ﬁrmly against the drum when
the clutch is disengaged.
l32l
CALIBER .30 CASE BLANKING AND CUPPING PRESS Adjustments
Blanking Punch The blanking punch is forced into the upper portion of the blanking and
Adjustment cupping die, cutting the metal into circular slugs. The punch is actuated
by a connecting rod connected to the crankshaft. Adjustment of the punch
is made by changing the position of the cam on the crankshaft. This is
done by turning a hexagon cross shaft between the two connecting rods
that operate the outer ram. The punch should be adjusted so that it
enters the die a distance a little more than the thickness of the metal.


Cam
Adiustm
Shaft
ConnecltziggI _ Cam
Pitman
Adjustment
Tool: 1% " wrench.
Procedure: 1. Engage the clutch and use a ﬂywheel rod to turn the ﬂywheel until the
ram is at the bottom dead center. Disengage the clutch.
2. Use a 1%" wrench to loosen the nuts on the outer ram connecting rod
bearings.
3. Use a 15/8" wrench to turn the hexagon cross shaft located between the
connecting rods until the blanking punch enters the die a distance a
little greater than the thickness of the metal. (The hexagon rod is
turned down to raise the punch and is turned up to lower the punch.)
4. Tighten the nuts on the connecting rod bearings.
5. Engage the clutch and turn the ﬂywheel to the top dead center.
Caution: Turn the ﬂywheel one complete revolution by hand to check
the adjustment before turning on the power.
[33]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Troubles and Corrections

Objective
Scored or
Scratched Walls
Punch Outs
TROLIBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following operating diﬁiculties can be recognized by visual and gage
inspection of the cups, together with constant observation of the machine
as it operates.
Visual inspection will reveal scratches on the inside or outside walls of the
case. Scratches on the outside walls can be detected by ﬁnger nail in-
spection.
The causes are:
1.
Foreign matter (dirt, grit, shav-
ings, etc.) in the cooling solu-
tion.
Foreign matter (dirt, dried
soap, etc.) on the strip brass.
. Cracked die——a fracture in the
cross section of the die.
. Scratched die-—a scratch on the
inside surface of the die.
.Chipped punch——a piece is
broken off the end of the punch.
. Skinned punch—the punch sur-
face marred.
The corrections are:
1.
Remove the cooling solution,
clean the reservoir, put in clean
cooling solution.
Check the source of supply; call
the inspector.
Replace with a new die.
Polish the die if the scratch is
not too deep, or replace with a
new die if necessary.
Replace with a new punch.
Polish the punch if it is not too
badly skinned. If it is beyond
repair, replace with a new
punch.
Visual inspection discloses that the bottom of the cup is punched out or
the side of the cup is deformed by the punch.
Caution:
Check tool identiﬁcation and dimensions.
If the tools are
within speciﬁcations, shut the machine down until metal hardness has
been checked by the Metallurgy Department.
(Tools must never be
altered by the adjuster.)
The causes are:
1. Brass strip—-—the metal is too
hard.
The corrections are:
1. Check the source of supply;
call the inspector.
I 34 I
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Troubles and Corrections

Punch Outs
(Cont.)
Burred Top
Crooked Tops
Crooked Bottoms
Sidewoll Thickness
Too Large
The causes are: The corrections are:
2. Brass strip—the metal is too 2. Check source of supply; call the
soft. inspector.
3. There is no radius on the 3. Replace with a new punch.
punch. The punch is too large
on the drawing end.
Polish the die to remove excess
brass.
4. Brassed up die—there is an ex- 4.
cessive coating of brass on the
drawing surface of the die.
5. The die is upside down—the 5.
die is not placed in the die block
properly.
Remove the die and replace it
in the proper position.
Visual inspection discloses that the mouth of the cup is burred.
The corrections are:
1. Align the punch with dies
properly.
2. Replace with a new punch.
The causes are:
1. The blanking punch is not in
proper alignment with the die.
2. Chipped punch——a piece is
broken off the end of the punch.
3. Chipped die—a piece broken 3. Replace with a new die.
off the cutting edge of the
blanking die.
Visual inspection discloses that the mouth of the cup is irregular.
The causes are: The corrections are:
1. The brass strip metal is too 1.
hard.
2. Brassed up die——there is an ex- 2.
cessive coating of brass on the
drawing surface of the die.
Check the source of supply;
call the inspector.
Polish the die to remove excess
brass.
3. Worn die—the drawing surface 3. Replace with a new die.
is too large or irregular.
Visual inspection discloses that the bottoms are irregular.
The causes are: The corrections are:
1. Worn die——the drawing surface
is too large or irregular.
1. Replace with a new die.
2. Uneven radius on bottom of
punch.
2. Replace with a new punch.
Gaging discloses that the sidewalls of the cup are too thick.
Caution: Check tool identiﬁcation and dimensions. If the tools are
within speciﬁcations, shut the machine down until metal hardness has
[35]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Troubles and Corrections

Sidewall Thickness
Too Large
(Cont)
Sidewall Thickness
Too Thin
Uneven Feed of
Strip Brass to
Feed Rollers
Smashup
been checked by the Metallurgy Department. (Tools must never be
altered by the adjuster.)
The causes are: The corrections are:
1. Too much taper on the punch. 1. Replace with a new punch.
2. Radius at the end of the punch 2. Replace with a new punch.
is too great.
3. The punch is too small. 3. Replace with a new punch.
4. The die is too large in the draw- 4. Replace with a new die.
ing surface.
Gaging discloses that the sidewalls of the cup are too thin.
The causes are: The corrections are:
1. Not enough taper on the punch. 1. Replace with a new punch.
2. Radius at the end of the punch
insufficient.
2. Replace with a new punch.
3. The punch is too large. 3. Replace with a new punch.
Visual inspection discloses that the feed rollers are not operating properly.
The causes are: The corrections are:
1. Broken spring in the feed roller 1. Replace with a new spring.
ratchet.
2. Worn dog in the feed roll
ratchet.
2. Replace with a new dog.
One or more tools are broken and have to be replaced.
The cause is: The correction is:
1. Broken parts—punches, dies, 1. Replace the broken parts.
etc.
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Tool Servicing
TOOL SERVICING
Obiective Proper tool servicing is essential to maintain standard quality in the
drawing of the bullet jackets and cartridge cases. Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters will be concerned primarily with the removal of brass and small
scratches that appear on working surfaces of dies and punches; and they
must be careful, when using an abrasive on any tool, not to alter materially
its dimensions.
Servicing New
Dies
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1.
Dies as received from the tool room are normally undersize to allow
for expansion pressure, and for lapping to a desired size when necessary.
. The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
. As a precaution, before a test run is made, the die bore should be in-
spected for roughness and polished if necessary. If the bore is rough,
causing undue friction, more metal may be pulled from the bottom of
the jacket or case at the start of the draw than is necessary.
. The product from the test run should be carefully gaged and inspected.
Then, and then only, if an undersize or out of true die is indicated,
should the die be lapped.
If trial in the machine shows that the die is undersize, place it in a
three-jaw chuck on a speed lathe to lap it.
Check the die to see that it is in the chuck straight and secure.

FIG. 1
OVER-ALL VIEW OF SPEED LATHE
[37]
CALIBER .30 CASE BLANKING AND CUPPING PRESS Tool Servicing


FIG. 2 FIG. 3
CORRECT METHOD OF PLACING INCORRECT METHOD OF PLACING
DIE IN CHUCK DIE IN CHUCK
Lapping Procedure 1. When lapping is necessary, proceed as follows: Use a lap stick made
of brass, lead, ﬁber or wood about the same diameter as the die hole.
2. Dip the lap stick in a solution of #120 emery dust and olive oil or
coal oil.
3. Hold the lap stick as nearly as possible in line with the angle of the
taper. When lapping the land, hold the stick at a right angle to the
mouth of the die to keep the land true. A land which is not true causes
irregular wall thickness and crooked tops on jackets and cases.
4. While holding the lap stick against the die, give the stick a rapid in
and out movement. This cuts down the ridges left by the grinder
wheel in the metal surface and makes it smoother. Repeat this op-
eration according to the amount of metal that must be taken out of
the die.
5. Wipe the die clean with a cloth.
6. Next, polish the die with the ﬁnest grade of emery cloth available,
not coarser than #220.
7. Finish the polishing operation with crocus cloth.
8. Wipe out the inside of the die again with a cloth.
9. Remove the die fiom the chuck and check the size of the die with a
plug gage.
10. Be sure the die is free of all emery dust before replacing it in the ma-
chine for production.
Carboloy Dies To lap a Carboloy die, follow the same procedure, using diamond dust
and olive oil instead of emery dust.
[38]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Tool Servicing

Servicing
Scratched Dies
Servicing a
New Punch
-La piping
Polishing
1. Before removing a die from a machine to look for scratches, remove the
stripper to determine whether the stripper, rather than the die, is
scratched. '
2. Check the die or stripper visually to determine how badly it is
scratched. If the die or stripper has a very deep scratch, it should be
sent to the Tool Service Department.
3. If it is found that the scratch is in the die, check the die with a die
“wear limit” plug gage to determine how much metal can be worked
out of it without making the die too large. '
4. To polish the die, place it in a three-jaw chuck on a speed lathe.
5. Polish it with ﬁne emery cloth, then with crocus cloth.
6. If the scratch can't be removed by polishing, the die will have to be
lapped. See lapping procedure, or send to the Tool Service Depart-
ment if necessary.
7. Check the die size with the “wear limit” plug gage before putting it
into production.
Before an abrasive of any kind is applied to a new punch its dimensions
should be carefully checked with a micrometer or proﬁle gage; and its
working surface should be examined for ﬁnishing or handling marks and
lack of polish. A highly polished punch aids in stripping and allows the
metal to flow freely, thereby reducing the tendency of brass to pile up on
the working surface.
An adjuster will not be required to lap more than .0005” from a new punch.
If more than this must be removed to bring the punch to size, it should be
returned to the Tool Service Department for correction.
Lapping is done with a piece of abrasive cloth wrapped around and moved
back and forth along the axis of the punch as it revolves in a speed chuck.
If the abrasive were held stationary, deep rings would be cut into the
surface, thereby ruining the ﬁnish.
The punch is shown in Fig. 4 correctly chucked and in Fig. 5 incorrectly
held. Avoid excessive overhang of the punch as this is a safety hazard, and
make sure that the jaws are correctly set, and tightened securely. Do not
allow the jaws to grasp the working surface of the punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with a cross-hatched effect.
The lapping operation must be followed by polishing. Polishing is done
in the same manner as lapping except that a ﬁner abrasive is used, as for
example crocus cloth, and a ﬁnal operation called draw polishing. This
ﬁnal operation is done after the chuck is stopped. To draw polish a punch
move the abrasive cloth lengthwise over the entire working surface, avoid-
ing rotary motion of thepunch or the abrasive. Continue this ﬁnal opera-
tion until all lapping marks are removed and the desired high polish or
mirror like ﬁnish is obtained.
[39]
CALIBER .30 CASE BLANIGNG AND CUPPING mass Tool Servicing


FIG. 4 FIG. 5
CORRECT METHOD OF PLACING INCORRECT METHOD OF PLACING
PUNCH IN CHUCK PUNCH IN CHUCK
Servicing As a punch is used, its working surface wears, accumulating scratches and
a coating of brass. Excessive wear is determined by measuring with a
micrometer or checking with a proﬁle gage. Obviously, an undersize punch
must be replaced with one of approved dimensions. Scratches, if not too
severe, may be removed by the lapping and polishing operations described
above. A light coating of brass may be removed by the polishing operation
alone. The question of how soon a new punch will need lapping or polishing
can be answered only from experience since many variable factors enter
into the problem.
[40]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Lubrication

MACHINE LLIBRICATION
Centralized Force The blanking and cupping press is equipped with a centralized force feed
Feed Lubricating
System
Friction
lubricating system. This system is a positive, mechanical method of
delivering lubricant, under high pressure, to a group of bearings from one
central station in exact measured quantities, and as frequently as desired.
It consists of a central pumping unit, two main supply lines, and an
automatic measuring valve at each bearing.
The force feed system is operated by opening a valve under the reservoir
and pumping the hand lever until a pressure sufficient to lubricate the
machine is obtained. This operation develops pressure of one of the main
lines throughout the entire system. A hand operated rotary valve in the
pump base directs the flow of lubricant into either main supply line, thus
providing the automatic operation of all valves.
Complete and positive lubrication of a large number of bearings is obtained
in less than one minute from a central point. Every bearing receives the
amount of lubricant required, entirely independent of the judgment of
the oiler or his ability to reach all bearings regularly.
Lubricant is delivered from the central pumping unit through the two
main supply lines to all measuring valves in the system. This pressure is
ﬁrst applied to one supply line and then to the other to provide the
complete operation of all measuring valves. No mechanical connections
are required. Each individual valve is fully adjustable as to quantity and
equipped with a positive sight indicator. The full line pressure is avail-
able to operate all valves because there are no restricted passages.
The efficiency of all machines depends, to a great extent, upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction as far as we are concerned
here, is the force that resists the sliding of one surface over another. It
makes no difference whether these surfaces are flat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all, but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
[41]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Lubrication

Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
Selecting a
Lubricant for
a Given Bearing
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral
oil that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite-tannin is a mixture used with water, oil, or grease for lubri-
cation. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings to
protect the highly polished balls or rollers from rust and corrosion and to
reduce friction between the moving parts.
Some of the factors that govern the selection of a lubricant are:
. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
1
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to have
the adhesiveness that is needed at low speeds. Instead, it must have high
ﬂuidity in order to ﬂow quickly through the small clearances that are
found in high speed bearings and thereby maintain an adequate lubricating
ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
[42]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Lubrication

Grease
' Lubrication
Methods
Methods of
Getting Lubricant
to Bearing
Surface
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen, good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface. The
method used depends to a great extent upon:
Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
.@P‘t'>‘P°.l\"!-‘
Accessibility of bearing.
7. Frequency of lubrication.
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°ﬂ9‘P‘F‘9°!°!-‘
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
Screw down cups. 0
Compression cups.
Pressure guns and patented ﬁttings.
t‘>‘.°°.l\'>£"
Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
[43]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Machine Lubrication

Hints on
Lubrication
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrica-
tion.”
Carry a wiping rag with you when you oil or grease. Wipe the cup or ﬁt-
ting before you open the cup or apply the grease gun. Also wipe the oiler
spout or grease nozzle. Applications of lubricants are necessarily frequent.
If a little dirt is allowed to enter the ﬁtting each time, it can cause a lot
of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor. A
grease gun should be in one of two places, in its rack or in the hands of the
oiler.
The grease barrel should be kept tightly covered at all times—except when
the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way into a
grease barrel can easily be forced into a bearing and cause the machine to
be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think that
it should be changed, take it up with your supervisor.
[44]
CALIBER .30 CASE BLANl(lNG AND CUPPING PRESS
Machine Lubrication
LUBRICATION CHART

Equipment
Part to be
Imbricated
How Applied
Recommendations
E. W. Bliss Blanking
and Cupping Press
Counter
15 h.p. Electric Motor

Plain bearings and
guides
Ball or roller bearings
Gears
Bearings
Bearings
Bearings
Centralized Force
feed System
Packed
Bath
-Oil cups
Pressure gun
Ring Oiler

Semi-Fluid Pressure
Grease
Ball Bearing Cup
Grease
SAE-20
SAE-20
Semi-Fluid
Pressure Grease
SAE-20

I45]
CALIBER .30 CASE BLANKING AND CUPPING PRESS
Index
Adjustment, Blanking Punch, 29
Blanking Punch Replacement, 29
Blanking and Cupping Die Replace-
ment, 26
Brake Release Rod, 24
Brake Spring, 32
Crankshaft Brake, 23
Cupping Punch, 31
Cupping Punch Replacement, 27
Feed Roller Brake, 22
Feed Roller Tension, 22
Metal Progression, 21
Shear Knife, 30
Sizing Die and Stripper Replace-
ment, 25
Anti-friction Bearings, 41
Blanking Punch Adjustment, 33
Punch Holder Block, 12
Punch Replacement Adjustment,
29
Punches, 12, 15
Blanking and Cupping, 17
Blanking and Cupping Die Replace-
ment Adjustment, 26
Bottom Thickness, 18
Brake, 24
Action, 3
Drum, 2, 23, 26
Lever, 24
Release Rod Adjustment, 24
Shoe,2,23,26
Spring Adjustment, 32
Bull Gear, 6
Burred Top, 35
Carboloy Die, 38
Chute, 4
Chftch, 6, 24
Action, 3
Lever, 24
Controls, 4
Cooling Solution, 3, 4
Solution Pump, 1, 5
Crankshaft, 2, 3, 6, 7, 8, 9, 23, 33
Brake Adjustment, 23
Speed, 1
Throw, 7
Crocus Cloth, 38
Crooked Bottoms, 35
INDEX
Crooked Tops, 35
Cupping Punch Adjustment, 31
Punch Holder Block, 12
Punch Replacement Adjustment,
22
Punches, 12, 15
Cutoff, 16, 17
Defects, 19
Dial Indicator, 19
Die, 16, 37
Block, 13, 27
Block Assembly, 13
Block Holder, 14, 25
Disposal, 16, 17
Eccentric Cam, 7
Elevator, 4
Emery Dust, 38
Feed Rack, 17
Racks, 11, 16
Roller Brake Adjustment, 22
Roller Tension Adjustment, 22
Rollers, 3, 8, 9, 16, 17
Floor Space, 1
Flywheel, 2, 5, 6, 21
Friction, 41
Gage Care, 19
Grease, 42
Height, 1
Jackshaft, 2, 5, 6
Lap Stick, 38
Lapping, 37, 39
Procedure, 38
Lubricating Film, 41
Lubrication, 1, 4, 41
Hints on, 43
Methods, 42
Machine Motor, 1
Manufacturer, 1
Metal Progression Adjustment, 21
Methods of Getting Lubricant to
Bearing Surface, 43
Motor, 2, 5
Outer Ram Face Plate, 12
Outside Diameter, 18
Plug Gage, 19
Plunger Arm, 3
Rod, 10
Polishing, 39
Power, 2, 3
Production, 1
Punch, 16
Holder Assembly, 12
Holder Fork, 12
Outs, 34, 35
Ram, 3, 8
Reservoir, 3
Rocker Arm Shaft, 5, 8
Rotary Washer, 4
Scored Walls, 34
Scratched Walls, 34
Scratches, 19, 40
Selecting Lubricant for Given Bear-
ing, 42
Servicing, 40
New Dies, 37
New Punch, 39
Scratched Die, 39
Shear Cam, 8
Knife Adjustment, 23
Shearing Mechanism, 3, 10
Sidewall Thickness Too Large, 35, 36
Thickness Too Thin, 36
Variation, 18
Sizing Die, 15
Die Block, 13
Die and Stripper Replacement Ad-
justment, 25
Slotted Bar, 8
Smashup, 36
Speed Lathe, 37
Stripper, 15, 16, 17
Plate, 13
Spring, 15
Switch, 4
Thickness, 18
Tools, 1
Transmission, 2, 3
Twin Ring Gage, 19
Type of Feed, 1
Uneven Feed of Strip Brass to Feed
Rollers, 36
V-belt, 2
Visual Inspection, 19
Weight, 1
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
First Draw Case
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-4.-81, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was de-
veloped from notes and sketches made by Western Cartridge Company
personnel while in training at Frankford Arsenal early in 1941, and later
completed by them while serving as Chief Instructors in the Training
Department of Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for
the machines and machine parts used in the manufacture of small arms
ammunition. Photographic illustrations have been freely substituted for
drawings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible but they
are as of this date and are subject to changes.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan, -
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more
than $10,000.”
(June 5, 1917, C 30, Title 1, Sec. 1; 40 Stat. 217. Act of March
28, 1940; Public No. 443, 76th Congress, 3rd Session.)
II
MANUAL CORRECTlONS—CALIBER .30 FIRST DRAW CASE
LOCATION ERROR CORRECTION
Page 1l,—Spec Inside diameter after 1st Draw .300-.302 Inside diameter after 1st draw .551—.553
Page 3!,
Loose Ram Omit—-does not apply
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
‘Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._ . . . . . . . . . . . . . . . . . . . 16
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44
III

DRAW PRESS—CALlBER .30 FIRST DRAW CASE
IV
CALIBER .30 FIRST DRAW CASE
Catalogue Data

Manufacturer
Machine
Description
Machine Motors
Type of Feed
Feed Motor
Production
Crankshaft Speed
Stroke
Cooling Solution
Pump
Tools
Floor Space
Over-all Height
Weight
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, New York
Vertical Duplex Straight Side Crank Press; E. W.
Bliss No. 62; 4 V Belt Drive Motor to Fly-
wheel to Crankshaft.
Two 3 h.p. ; 220 / 440 Volts; 3 phase; 60 cycle; 860
R.P.M.
Rotary Hopper (44 R.P.M.)
Gearhead %; h.p.; 115/230 Volts; 1 Phase;
60 cycle; 725 R.P.M.
440 per minute.
110 r.p.m.
5”
Gear Type 1/10 h.p. ; 1 phase; 60 cycle; 110 Volts.
_ Piece No.
Punch D1
Guide Ring .766
Die .655x16°
Stripper .622
Stripper Holder 1.492x60°
51/4 ft. x 7 ft.
7! 9/!
15,000 lbs.
[1]
CALIBER .30 FIRST DRAW CASE Machine Description
MACHINE DESCRIPTION
Hopper Motor
L. H. R. H.
Flywheel Pulley Main Crankshaft Hub
Guard Motor and Clutch


Connecting
Rota / Rod
Hopper
Ram
Clutch Lever
\ Clutch Lever
(huh Trip Cam
Cooling 1" ‘ . I _ - ‘
Solution \ Feed Table
Reservoir
FRONT VIEW
Power and The E. W. Bliss Duplex Draw Press, consisting of two identical presses
Transmission illustrated above, is powered by two 3 h.p. motors, one for each section of
the press, through four V belts, to their respective ﬂywheel pulley and
crankshaft.
Incorporated in each ﬂywheel hub is a rolling key clutch for control of
power to the crankshaft through linkage to an individual clutch lever
which permits individual operation of each press.
[2]
CALIBER .30 FIRST DRAW CASE
Machine Description

Power and
Transmission
(Cont.)
Camshafts
Rotary Hopper
Feed Table
Ram
Cooling Solution
Controls
Safety Guard
Lubrication
A conventional brake drum is located on the inner end of each crankshaft.
A lined brake shoe, secured and located by a bracket attached to the
machine frame, provides the friction necessary to hold the crankshaft in
position when the clutch is disengaged. The clutch and brake action are
synchronized through the clutch lever. When the clutch is engaged, the
brake is released, and when the clutch is disengaged, the brake is applied.
In normal operation, if the clutch is disengaged for any reason, the crank-
shaft will always stop at the maximum upward position of the cranks. For
inspection or adjustment purposes, the machine may be rotated by hand
and the crankshaft stopped and held in any desired position.
Two camshafts for actuation of the fork and ﬁnger mechanisms are located
in the right and left rear of the frame. They are driven by a block chain
and sprocket wheels from the inner end of each crankshaft. A cam on
each camshaft moves the fork and ﬁnger mechanism forward, and a spring
pulls them back. On the outer ends of the camshafts are V pulleys for driv-
ing feed discs and agitators on the feed table. Power is transmitted to
rotary dial shafts by round belts. Rotary dials are driven by bevel pin-
ion and ring gears on their under side.
The rotary hopper -receives the cups from an overhead source and feeds
them, through the medium of the ﬂat feed chute, to the feed table in a
“mouth up” position. The hopper is driven by a % h.p. reduction gear
head motor, through a V belt.
The feed table is for the transference of cups from the feed chute to the
fork and ﬁngers, through the medium of the rotary dials.
The ram is a heavy cast-iron block. Its mass assists the power stroke of
the punch and absorbs the shock of impact and subsequent vibration. The
lower surface is machined for attachment of a punch holder block. Each
ram is driven by and connected to the crankshaft by a connecting rod and
wrist pin. Each ram is held in alignment by a V-shaped gib arrangement.
To prolong die and punch life, each cup is bathed by a cooling solution
which acts as a cooling and lubricating agent. The base of the machine
forms a reservoir for this cooling solution which is pumped through a pipe
system to the die. The pump is located at the rear of the machine and is
driven by a 1% h.p. vertical direct drive motor.
Two push button “Start and Stop” switches provide control of main
drive motors. Two overload switches, one for each main drive motor,
are attached to the right and left rear of the machine. Two toggle switches
are mounted at the rear of the ﬂat feed chute. The left hand switch is for
the pump motor, while the right hand switch controls the hopper motor.
The safety glass door is hinged so it will swing outward. If it is opened
while the machine is in operation, a cam on its outer edge will contact and
release the clutch lever from the catch block, and spring action will return
the lever to its “off” position.
Lubrication of all moving parts is accomplished by Alemite-Zerk ﬁttings,
oil cups, oil holes or distribution of lubricant by oiler, swab, etc., over the
desired point. (See Lubrication Chart, page 43.)
[3l
CALIBER .30 FIRST DRAW CASE Machine Description

Motor, Counte rshaft This rear view of the cal. .30 First Draw press shows the motors, adjustable
and Flywheel and brackets, and belt drives contained within a guard. Each press is started
Cooling Solution and stopped by a clutch contained in the hub of the ﬂywheel.
Pump Below the motors in the frame of each press is a feed ﬁnger camshaft.
These shafts are driven separately by block chains and sprockets from
the inner end of each crankshaft. The camshafts drive the feed ﬁnger
mechanism which pulls the cups in from the rotary dials and locates them
under each punch.
The cooling solution pump motor is visible between the two frames. The
pump on the motor circulates the cooling solution from the reservoir in
the machine bed, through a pipe system, to the punches and dies. The
cooling solution serves both as a cooling and lubricating agent.


Adjustable _-
Bracket _.__ Adjustable
Bracket
Guard ...
Block Chains
REAR VIEW
l4l
CALIBER .30 FIRST DRAW CASE
Machine Description
\

Feed Fingers and
Fork Assembly

TOP FRONT VIEW AT FEEDING
MECHANISM
For each rotary dial there is a die assembly consisting of two sets of dies
and feed ﬁngers. The die and feed ﬁnger assembly are set at the rear of
the rotary dial. The die is mounted in the die block and the feed ﬁnger
assembly is mounted on the die block holder. The feed ﬁngers are actuated
by the feed ﬁnger camshaft. The forward position of the feed ﬁngers
places their hooks in line with the double feed track and two cups are
moved into their grasp. As the ﬁngers pull back they press the cups
against the forks and, thus held, the cups are carried back directly over
the dies and under the punches. In this “back” position the ﬁngers hold
the succeeding cups in the feed tracks.
When the punches descend, they push the cups down through the ﬁngers
and forks and through the draw die below. The ﬁngers and forks then
move forward for more cups.
CLOSE-UP OF CAM FOLLOWER
ASSEMBLY
I5]
CALIBER .30 FIRST DRAW CASE
Machine Description

Feed Finger
Camshaft
Push
Rod
Feed Finger
Camshaft
The feed ﬁnger camshaft is located on the rear of the machine and supports
the cam follower assembly. The camshaft is driven by a block chain from
a sprocket wheel on the crankshaft to a sprocket wheel on the feed ﬁnger
camshaft. This method of driving times the feed ﬁngers with the feed
ﬁnger camshaft. The feed ﬁnger cam on the camshaft forces the cam
follower and push rod forward allowing the cup to slide into the feed
ﬁnger. This action is referred to as a positive action.

CLOSE-UP OF FEED FINGER CAMSHAFT
A heavy coil tension spring pulls the assembly back, thus placing the cups
over the dies. This action is referred to as the negative action. The push
rod is connected to a lug on the feed ﬁngers on one end and to the camshaft
on the other end through a yoke which slips over the shaft and is actuated
by the cam through the camshaft follower. The feed ﬁngers transfer the
cups, two at a time, from the rotary dial to a position over the dies under
the punches.
I6]
CALIBER .30 FIRST DRAW CASE
Machine Description
Rotary Hopper
The rotary hopper is a feeding mechanism, set at an angle on the front
center of the press above the feed table. It is fed by a conveyor pipe from
an overhead hopper. A limited supply of cups is fed into the hopper and,
as the cups are rotated in the hopper, they escape “mouth up” through
the U-shaped openings in the lower edge of the hopper rim. As the
cases fall into the narrow channel in the hopper base around the outer
rim of the wheel, they slide down by gravity in a “mouth up” position.
From the channel the cases go down through the feed chute, below the
hopper base, and slide out on the feed table, “mouth up," in the proper
position for the punch.
The hopper is a bronze casting shaped like a pulley with four spokes. It
is located on a cast-iron base by means of a center shaft about which it
rotates. Through a V-type belt around the pulley rim, a pg h.p. geared
head motor furnishes the motive power. The lower edge of the pulley
rim is ﬁtted with a 18" x 2" bronze band, in which a series of U-shaped
openings are pierced.
The cast-iron base is stationary and mounted on brackets. The channel
around the outer edge of the base is concentric with the hopper stud shaft,
and the outlet at the bottom aligns with the opening in the feed chute.
U-Shaped
Opening

ROTARY HOPPER
l7l
CALIBER .30 FIRST DRAW CASE
Machine Description

Rotary Dial and
Cup Guide

A rotary dial is located at each end of the feed table. However, this des-
cription will refer to only one dial, since the two dials are identical.
The rotary dial feeds the cups into the feed ﬁnger mechanism as they come
from the feed chute and slide across the feed table. The rotary dial consists
of a steel dial set in a semi-circular opening in the rear edge and flush with
the feed table. The dial is mounted on a vertical shaft in a bearing
bracket on the machine bed. The rotary dial is belt-driven, through a short
horizontal shaft from its underside, by a bevel pinion and ring gear.
Cup guides direct the flow of cups to the rotary dial. As the dial turns, the
mass of cups is worked down to a double row. This action is accomplished
by the center cup guide, which is fastened to the dial center, and by the
cup guide agitator.
The cup guide agitator is driven by an agitator arm with a roller on its
end in contact with a cam on the drive pulley. As the rotary dial rotates,
the agitator jogs the cups into the double track.
Rotary Dial
Drive
ROTARY DIAL AND CUP GUIDE ASSEMBLY
[8]
CALIBER .30 FIRST DRAW CASE Tool Holder Description
TOOL HOLDER DESCRIPTION
Die Block Assembly Lock Pin: The lock pin is inserted through a small hole in the
rear of the die block. It holds the die block in place on the bolster
plate.
Die Block: The die block holds two die assemblies. They are
held in the channel of the bolster plate by the lock pin. The
bolster plate is adjustable to allow centering the dies under the
punches. The die assembly is inserted into the die block from
the bottom side. The large hole in the rear end of the block
assists the adjuster in inserting, locating, and removing the die
block.
Guide Ring: The guide ring is inserted ﬁrst in the die block
from below, with the large end of the tapered hole up. It centers
the cup in a vertical position over the draw die located immediately
below.
Draw Die: The draw die is inserted into the die assembly hole of
the die block under the guide ring and with the large end of its
tapered hole up. It forms and controls the outside diameter of
the cup as the cup is forced through it by the punch centered
above.
Stripper Holder: The stripper holder is inserted under the draw
die with the large end of the tapered hole down. It holds a three-
segmented stripper in position.
Stripper: The stripper, consisting of three segments held together
by a coiled spring, is inserted into the stripper holder with the
large end of the tapered hole up. The stripper unit strips the case
from the punch after the case has been forced through the die
on; BLOCK DISASSEMBLED assembly.
Die Block

Lock Pin


““““ _ \

Stripper


' Stripper Holder
Guide Ring
CROSS SECTION OF DIE BLOCK ASSEMBLY
l 9 l
CALIBER .30 FIRST DRAW CASE Tool Holder Description
Punch Block Anvil: The anvil is inserted into the top side of the punch
Assembly holder block in contact with the head of the punch and punch
holder. It protects the face of the ram from the thrust of the
punch.
Punch Holder Block: The punch holder block contains two
dowel pins for alignment and is bolted to the under side of the
ram by four Allen screws. It holds two punch assemblies.
Punch Holder: The punch holder is inserted in the punch
holder block from the top side, with the ﬂanged end up. The
lower end is threaded to receive a hexagon gland nut. It
retains the punch assembly in the punch holder block.
Split Collar: The split collar is composed of two halves which
are held in place by a coiled spring. It acts as a ﬂange on the
head end of the punch against which the sleeve is held by a
gland nut.
Sleeve: The sleeve is assembled on the punch from the head
end after the gland nut. It acts as a spacer in the alignment
of the punch.
Gland Nut: The gland nut threads on the outer surface of
the gland nut are screwed into the inner threads of the punch
; holder, forcing the sleeve against the split collar. It holds the
; 2 punch assembly to the punch holder.
Punch: The punch, with the gland nut, spacer sleeve, and
I / split collar in place, is inserted into the bottom side of the
punch holder, head end up. The gland nut is then screwed
into the punch block holder, which holds the assembly in a
PUNCH BLOCK DISASSEMBLED vertical position-


’ ‘V. ‘ Button Anvil
<,\g
§\ Punch Holder
/ /
R . Collar
Bl k Spring
oc .' \\ Bushing
Key Gland Nut
% 1/” Punch
CROSS SECTIONAL DRAWING or PUNCH
l 10 l
CALIBER .30 FIRST DRAW CASE
Tool Description


Punch


Guide Ring


Die


Stripper


Stripper
Holder


TOOL DESCRIPTION '
Tool Name: Punch—First Draw
Piece No.: D-1
Location: Held vertically in ram
Normal Life: 140,000 pieces
The punch is made of tool steel, hardened, ground
and polished. The shank is slightly softer than the
working end.
Tool Name: Guide ring—First Draw
Piece No.: .766
Location: Above die
Normal Life: 1,000,000 pieces
The guide ring is made of hardened tool steel, ground
and polished.
Tool Name: Die—First Draw
Piece No.: .655 x 16°
Location: Die block
Normal Life: 44,000 pieces
The die is made of tool steel, hardened, ground and
polished.
Tool Name: Stripper—First Draw
Piece No.: .622
Location: Die block—under die
Normal Life: 100,000 pieces
The stripper consists of three pieces held together
by a coiled spring. It is made of hardened tool steel,
ground and polished.
Tool Name: Stripper Holder~First Draw
Piece No.: 1.492 x 60°
Location: Between die and stripper
Normal Life: 10,000,000 pieces
The stripper holder is made of hardened tool steel,
ground on all surfaces.
[11]
CALIBER .30 FIRST DRAW CASE
Process Sequence

Overhead Hopper
Rotary Hopper
Flat Feed Chute
Feed Table
Turntable
Feed Finger
and Fork
Ram and Punch
The Draw
Stripper and
Disposal
Lubrication and
Cooling Solution
PROCESS SEQUENCE
The cups are fed by gravity from a truck or conveyor into the overhead
hopper. They drop through a feed pipe which has a control gate, into
the rotary hopper.
The cups are agitated in the rotary hopper and, as the hopper rotates,
the cups escape through U slots in the lower edge of the hopper rim
into the rotary hopper base channel, in a “mouth up” position. From
the hopper base channel they fall down into the ﬂat feed chute.
The cups are conveyed in an upright position by gravity through the
S-shaped flat feed chute, which breaks their fall and enables them to
emerge, mouth up, in a single layer, on the feed table.
The operator visually inspects the cups for defects, foreign matter, and
upside-down position, then pushes them along the feed table to the right
and left rotary dials.
The rotary dials carry the cups to the entrance of the feed tracks, past the
agitator and between the cup guides. The cups are carried in single ﬁle
past the counters to the feed ﬁngers.
On the upward stroke of the ram, each fe'ed ﬁnger moves forward and
allows a cup to enter each hook. As the ram descends, the ﬁngers start
to move back, pressing the cups ﬁrmly against the forks. As the cups
touch the fork, the whole assembly moves back together until the cups
are directly above the dies and under the punches.
The ram descends with the punches which force the cups through the
guide rings into and through the dies and strippers. The guide rings seat
the cups straight on the punches.
The forcing of the cups through the dies is known as the draw. The draw
reduces the wall thickness and diameter and increases the length of the
cups. Before the draw, the components are known as the cups and after
the draw, as the ﬁrst draw cases.
As the punches withdraw from the dies, the cases are stripped off by the
three-segmented strippers, located under the dies; then the cases fall into
a chute which guides them to a mechanical conveyor.
During the drawing operation, the cups are lubricated and the tools are
cooled by a cooling solution which ﬂows over the cups and dies, through
an opening in the die block.
CALIBER .30 FIRST DRAW CASE
Process Sequence

MACHINE FLOW CHART

Overhead Hopper
Cups are fed by gravity from truck or
conveyor into overhead hopper through


feed pipe.
I

Feed Pipe
Conveys cups by gravity past control gate

into rotary hopper.

Rotary Hopper
Rotates, and cups escape through U slots
into rotary hopper base channel, then
fall, mouth up, through ﬂat feed chute
down to feed table in a single layer.


Feed Table
Cups are visually inspected by the opera-
tor and pushed by hand to rotary dial.


Rotary Dial
Carries cups past agitator into feed track,
single ﬁle, past the counters to the feed

ﬁngers.
I

Feed Fingers
Pull the cups, one at a time, over the dies
and under the punches.
I
Hopper is powered by a %; h.p. reduc-
tion geared motor and a V-type belt.
Electric control is a toggle switch on
right side of press.


Power from ring gear to pinion gear, to
shaft, to pulley, to round leather belt, to
pulley on camshaft.


Ram and Punch
Ram descends and the punches force the
cups through the dies and strippers, in-
creasing the length, and decreasing the
diameter and sidewall thickness of the cup.
After this operation, the cups change
identity and are known as cases.

Power supplied by feed ﬁnger from
push rod, from cam follower, from cam,
from camshaft, from sprocket, from block
chain, from sprocket on crankshaft.


l
Stripper
After the punch forces the cup through the
dies, it withdraws and the case is stripped
off the punch by a three-segmented strip-
per under the die. Then the case falls into
a chute which guides the case into a me-
chanical conveyor.


Ram is powered by the connecting rod
from the crankshaft to the clutch, to the
ﬂywheel, by 4 V-type belts, from a 3
h.p. motor on side of the press.


CALIBER .30 FIRST DRAW CASE Product Description

PRODUCT DESCRIPTION
Product The component, when it is received by the ﬁrst draw press, is in the
Description , form of a cup, as shown in Fig. 1.
The cup is received from the Annealing Department, where it was
annealed, pickled and washed. When the cup is delivered to the Annealing
Department from the cupping press, the metal has a very bright, brassy
appearance and a smooth ﬁnish. After the cup has been annealed, the
metal appears dull and has a rough ﬁnish.
The cup is made of brass (70% copper, 30% zinc). The closed end of the
cup is the bottom and the open end is the mouth.
The dimensions of the cup are as follows:
Before lst Draw After lst Draw
Outside diameter .766i760” Outside diameter .662i659'
Inside diameter .560"-.558” Inside diameter .300i302’
Bottom thickness .135i129” Bottom thickness .129-5.135’
Sidewall variation .001”-.003” Sidewall variation .001i002”
Over-all length .46s’i.455” Over-all length .sszisss”
After the drawing operation, the cup, hereafter known as the case (see
Fig. 2), is delivered to the Annealing Department, where it is annealed,
pickled and washed before being delivered to the second draw.
FIG. 1—BEFORE 1st DRAW FIG. 2—AFTER ‘Isl DRAW
110
Before After Before After After Pickle
Annealing Annealing Annealing Annealing ' and Wash


I14]
CALIBER .30 FIRST DRAW CASE
Inspection
Visual
Gage Care
Gages
INSPECTION
A careful visual inspection of the case must be made. Inspect both the
inside and the outside of the case for scratches. Inspect the case for
crooked heads, crooked tops, or bodies that are not round. These defects,
call for adjustments on the machine. If a defect is found, the lot of which
it is a part must be taken from the machine and properly identiﬁed, so
that it will not be mixed up with lots composed of good cases.
Gages are expensive instruments machined to a ﬁne precision. Improper
use, or carelessness in gaging, may spring the gage or put a burr on it
which may affect its accuracy. Therefore, force should never be employed
in matching a case to a gage. A protected location should be used for
storage of gages to prevent their damage when not in use. The most
accurate checks are made when the cases are cool, since heat causes
expansion of the metal and results in a temporary variation in the case size.


The bottom thickness is checked
on a dial indicator, as variation in
this dimension greatly affects suc-
ceeding draws.
The body of the case is gaged with
a twin ring gage. Cases must pass
through the larger or “go” ring
and must not pass through the
smaller “no go” ring.
The above described inspection methods are those most commonly em-
ployed in the manufacture of Caliber .30 First Draw Cases. However,
other methods may be developed to maintain the manufacturing standards.
[15]
CALIBER .30 FIRST DRAW CASE
Adjustments
ADJUSTMENTS
Objective To maintain satisfactory production a machine must be adjusted to com-
Cautions
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than‘ the starting button to determine
whether the clutch is disengaged.
Make frequent inspection to determine whether proper and sufficient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
CALIBER .30 FIRST DRAW CASE
Adjustments
Die Replacement
Procedure:
The dies may become worn, causing the case to be too large in diameter,
or may become scratched, causing scratches on the outside of the case.
In either case the die must be removed and replaced with a new die.

1.
DIE BLOCK ASSEMBLY
Open the rear guard by releasing the latch and swinging the guard
door away from the machine.
Remove the die block lock pin.
. Remove the die block by placing ﬁngers in the large hole in the center
_ of the die block and pulling the die block out of the die block hole.

8.
Keep the other hand underneath the die block to hold the dies and
the stripper intact.
Allow the dies and the stripper to fall out in your hand; then turn the
die block over.
Inspect the dies and the stripper for defects. If any of the parts are
defective, replace with new parts.

Replace the guide rings, the dies, the stripper ring, and the stripper
in their respective order.
Caution: Be sure that the assembly is free of dirt and grit. Observe
that the hole in the die is tapered. The small part of the taper should
be at the bottom when the die block is placed in the die block holder.
. Turn the die block back over in its normal position, holding one hand on
the under side of the die block to keep the dies and the stripper from
falling out. Now slide thedie block back into the die block holder,
and replace the die block lock pin.
Close and latch the rear guard door.
I 17 I

CALIBER .30 FIRST DRAW CASE
Ad iustments

Punch The punch may become worn, causing the inside of the case to be too
small in diameter, or may become scratched, causing scratches on the
inside of the case. In either case the punch must be replaced.
1%” Wrench
Replacement
TOOIS:
Procedure:
1.
PUNCH BLOCK ASSEMBLY
Open the front guard by raising the latch and swinging the guard
door on its hinges.
Use a 13/8” wrench to remove the gland nut beneath the punch holder
by turning the wrench from right to left.
When the nut is clear of the punch holder, shake the punch from side
to side at the same time pulling down on the punch until the punch is
released from the punch holder.
Remove the split collar by spreading the two sections and slipping it
over the top of the punch.
Slide the sleeve and the gland nut from the top of the punch.
Slide the gland nut over the top of the new punch, the threaded side
up. Replace the sleeve following the nut and replace the split collar
with the wide part of the shoulder to the top.
Replace the punch assembly into the punch holder and start the gland
nut by turning it into the punch holder. Tighten the nut up as far as
possible with your ﬁngers; then use the 1%” wrench to tighten.
Swing the guard door into place and lock with a latch at the left side
of the door.
[18]
CALIBER .30 FIRST DRAW CASE
Adjustments

Agitator
(Feed Table)
T0Ols:
FEED TABLE SHOWING AGITATOR ADJUSTMENT
Procedure:
The feed table agitator agitates the cups before they begin their travel
through the feed tracks. If it is not properly adjusted, the cups will jam
before they begin their travel to the feed ﬁngers. The agitator should
be adjusted so that it is centered between the cup guide. Adjustment is
made by a set screw that changes the position of the agitator.
1/3" Wrench, 1/4" Wrench
1.
ENLARGED VIEW OF SET
SCREW ADJUSTMENT
Open the front guard door by releasing the latch and swinging it
away from the machine.
Use a 1/2” wrench to loosen the lock nut on the agitator adjusting
screw while holding the adjusting screw with a 1/4" wrench.
. Use a 1/4" wrench to turn the agitator adjusting screw until the
agitator ﬁnger is at the approximate center between the track guide
and the spring.
. Tighten the lock nut on the agitator adjustment screw while holding
the set screw in place.
Caution: Close and latch the front guard door.
Check by operating the machine and observing the action of the
agitator.
[19]
CALIBER .30 FIRST DRAW CASE
Adjustments

Fork and The camshaft that actuates the feed ﬁnger is connected by a block chain
to the ﬂywheel shaft. If the chain slips on the sprocket or is removed
for any reason, the chain must be replaced so that the action of the punch
is synchronized with the action of the feed ﬁnger. If they are improperly
timed, the cup in the feed ﬁnger would not be in position over the die in
time to be forced through the die by the punch.
Finger Timing
Tools:
FORK AND FINGER TIMING
Procedure:
7/§” Wrench, Flywheel Rod


1.


CLOSE-UP
OF CAM
AND YOKE
W Idler
Pulley
Cam


CLOSE-UP OF PUSH ROD SPRING
Open the rear guard door by releasing the latch and swinging it away
from the machine.
Release the push rod spring by pulling it towards the back of the
machine and unhooking it from the spring bracket.
Use a 78" wrench to loosen the bolt that holds the block chain idler
pulley, thus releasing the tension on the block chain.
Lift the chain clear of the dogs on the sprockets and remove the chain.
Turn the feed ﬁnger camshaft until the push rod cam follower is 1"
past the high side of the cam.
Replace the block chain on the crankshaft sprocket and then on the
camshaft sprocket holding the camshaft in the above position.
Use the left hand to raise the idler pulley ﬁrmly against the block
chain thus removing all slack. Hold the pulley in place and tighten
the studs with the 7/8" wrench.
Replace the push rod spring by pulling it toward the back of the
machine and booking it to the spring bracket.
Caution: Close the rear guard doors and latch.
[20]
CALIBER .30 FIRST DRAW CASE
Adjustments
Feed Finger
Push Rod
Tools:
The feed ﬁnger is carried forward by cam action on the feed ﬁnger push
rod. The push rod can be lengthened or shortened, thus changing the
forward position of the feed ﬁnger. The feed ﬁnger should be adjusted
so that it travels far enough forward to receive the cups from the cup
guide.
%" Wrench, Drift Punch


FEED FINGER PUSH ROD ADJUSTMENT
Procedure:
1.
ENLARGED VIEW OF
ADJUSTMENT ON PUSH ROD
Open the front guard by releasing the latch and swinging the guard
door away from the machine.
Engage the clutch and use a ﬂywheel rod to turn the ﬂywheel until the
feed fingers are at the end of their forward stroke.
. Place two cups in the cup guide against the feed ﬁnger.
Open the guard door in the rear of the machine by releasing latch and
swinging it away from the machine.
Use a %” wrench to loosen the two cap screws on the push rod (the
push rod is made up of two sections, the slotted portion of one section
allows the ﬁnger to be shifted forward or backward, when the cap
screws are loosened). Use a drift punch to pry the two sections of the
push rod a sufﬁcient distance to allow the cups to enter the feed ﬁnger
freely.
Hold the push rod in this position and tighten the cap screws.
Caution: Close and latch the rear guard.
Remove the cups from the cup guide.
Use a ﬂywheel rod to turn the ﬂywheel until the ram is at the top dead
center.
Caution: Close the front guard door and latch.
[21]
CALIBER .30 FIRST DRAW CASE
Adjustments

Feed Finger
Adjustment


FEED FINGER ADJUSTMENT
Procedure:
The feed ﬁnger carries the cup in line with the punch and die. The ﬁnger
is pushed forward by cam action and is pulled back in line with the die
by spring action. The back position is determined by the adjustment of
the two set screws in back of the feed ﬁnger assembly. If the set screws
are not properly adjusted, the cup will not be centered directly over the
die, causing the wall thickness to vary.
1%" Wrench, 3/16" Allen Wrench
10.
11.
12.


ENLARGED VIEW OF THE TWO
ADJUSTING SET SCREWS
Open the front and rear guards by releasing the latch and swinging
the guard door away from the machine. ,
Remove the safety glass from the front guard and close the door.
Place a cup in the feed ﬁnger, engage the clutch and use a ﬂywheel
rod to turn the ﬂywheel until the feed ﬁngers are in their farthest
backward position. Then continue to turn the ﬂywheel until the
punch almost touches the cup in the feed ﬁnger.
Use a 1%” wrench to loosen the lock nuts on the set screws in back
of the fork and ﬁnger assembly.
Use a %” Allen wrench to turn the feed ﬁnger adjustment set screws
until the cup is in line with the punch and die.
Use a 1%),’ wrench to tighten the lock nuts while holding the set
screw in place with an Allen wrench.
Remove the die block, holding one hand beneath the block to keep
the dies and stripper intact. Then turn the block over and set it
on the back part of the machine.
Use a ﬂywheel rod to turn the ﬂywheel until the cup drops through
the cap plate.
Reach into the die block holder and remove the cup from under the
cap plate.
Use a ﬂywheel rod to turn the ﬂywheel until the ram is about 3/1
of its distance to top dead center. Disengage the clutch and continue
to turn the ﬂywheel until the ram reaches top dead center.
Hold your right hand on the under side of the die block. Turn the
die block in its upright position and slide it back into the die holder.
Open the front guard and replace the safety glass.
Caution: Close and latch the front and rear guards.
I22}
CALIBER .30 FIRST DRAW CASE
Adjustments

Fork I
Tools:
The fork must be properly adjusted to allow clearance of the cup beneath
the punch and over the die. If the fork is too far forward or backward,
the cups will hang.
Two %" Wrenches, Pliers


Procedure:
1.
10.
11.
12.
13.
14.
FEED FINGER FORK ASSEMBLY
FORK ADJUSTMENT
Open the front guard by lifting the latch and swinging the door
forward.
Use pliers to remove the two cotter keys in the pins on the forward
end of the push rod.
Remove the ﬂat washer on the upper pin with the ﬁngers.
Using right hand, pull the spring forward to release the tension on
the upper pin. Remove the pin and release the spring.
Remove the bottom pin.
Remove the push rod.
Use two %” wrenches, one to hold the adjusting screw and the other
to loosen the lock nut.
Use a 1/2” wrench to turn the adjusting screw until the fork is ﬂush
with the back face of the cup slot in the cap plate.
Use a 1/9,” wrench to hold the adjusting nut in place and tighten the
lock nut.
Grasp the push rod assembly in the right hand and replace in position.
Insert the upper pin into the pin hole until the end of the pin is flush
with the inner edge of the slot.
Grasp the push rod spring firmly in both hands pulling forward until
in position for the pin to be inserted. Holding spring in this position,
drive the pin in place with heel of the hand.
Replace lower pin. Use the pliers to replace both cotter keys spread-
ing to lock in place.
Close the front guard by swinging forward into place and latch.
I23}
CALIBER .30 FIRST DRAW CASE
Adiustments

Hopper For proper agitation of the cups the agitator studs should be adjusted
about ‘X5’ from the inside face of the hopper.
1%" Wrench
Agitator Studs
TOOIS:
Procedure:
1.
2.


EN LARGED VIEW
HOPPER STUD
T T
I s
'1)
HOPPER WITH GUARD REMOVED
Release the hopper latch and open the hopper door.
Use an 146" wrench to loosen the lock nut on the threaded end of
the agitator stud.
Use ﬁnger to hold the stud and turn the nut on the inside of the spoke
of the hopper wheel, until the end of the stud is about 3/{6’' from the
inside face of the hopper.
Repeat this performance on each of the agitator studs, turning the
hopper by hand in order to bring the agitator studs to the opening.
Check the adjustment by turning the hopper by hand and observing
the action of the agitator studs.
[24]
CALIBER .30 FIRST DRAW CASE
Adjustments
Hopper
Agitator Stud
Replacement
TOOIS:
Procedure:
The hopper agitator studs are for the purpose of agitating the cups in the
rotary hopper. They may become bent or broken and will have to be
replaced. In order to replace the studs, the hopper must be disassembled
and the spoked wheel removed. ‘
Two “/16” Wrenches, 11/4" Wrench, 9/{6'' Wrench

HOPPER SHOWING AGITATOR STUDS
1. Empty the hopper of all cups.
2. Use a 91/6" wrench to remove the studs holding hopper belt guard;
remove the guard by lifting up and away from the hopper belt.
3. Use a %;" wrench to loosen the two studs on the back side of the
motor bracket.
4. Use a 1%,/’ wrench to loosen the lock nut on the motor bracket
adjusting studs.
5. Use a %” wrench to loosen the adjusting studs, lowering the motor
bracket.
6. Remove the belt from the motor pulley and hopper wheel.
7. Use a 11/4" wrench to loosen the hopper stud nut on front of the
hopper. Remove the nut and space washer.
[25]
CALIBER .30 FIRST DRAW CASE
Ad iustments
Procedure:
(Cont.)
8.
Remove the hopper door latch over the end of the stud.
9. Remove the hopper cover by lifting it clear of the hopper stud and
10.
11.
12.
13.
14.
15.
16.
17.
18.
place it on the ﬂoor out of the way.
Remove the hopper wheel by lifting the wheel clear of the stud.
Place it on the ﬂoor where the agitator studs may be removed.
Use an 1%” wrench to loosen and remove the adjusting nut on the
end of the damaged agitator stud.
Remove the damaged stud from the spoke of the hopper wheel.
Replace one of the nuts on the new or serviced agitator stud. Replace
the stud in the spoke of the hopper wheel and tighten the second nut
holding the agitator stud in place.
Reassemble the hopper wheel on theihopper stud, followed by the
hopper cover, then the hopper door latch and the space washer.
Use the 11/1” wrench to tighten the hopper stud nut in place.
Replace the hopper belt and adjust it to the proper tension by
tightening the adjusting screws on the motor frame.
Caution: Replace the hopper belt guard.
Use an 1%” wrench and adjust the agitator stud 1/33” from the
bottom of the hopper.
Reﬁll the hopper, close the hopper door and return the door latch to
locked position.
[26]
CALIBER .30 FIRST DRAW CASE Adjustments

Rotary Hopper The rotary hopper is driven by a V type belt. If the belt becomes loose
Belt and slips, it must be tightened by raising the hopper motor.
Tools: 19/32" Wrench, 9/16" Wrench, 1/2" Wrench


ENLARGED VIEW
ADJUSTMENT STUD BOLTS

HOPPER SHOWING ADJUSTABLE BRACKET,
MOTOR PULLEY AND V BELT DRIVE
Procedure: 1. Open the center rear guard by raising the latch and swinging the door
away from the machine.
2. Use a 9/16" wrench to loosen the stud bolts located in the rear of the
sliding hopper motor adjustment bracket.
3. Use a 1%2" wrench to loosen the lock nuts on the front of the sliding
hopper motor adjustment bracket.
4. Use a %" wrench to turn the adjustment screws evenly to raise the
sliding hopper motor adjustment bracket. This will tighten the motor
belt. Raise the motor, testing the belts for tautness by pressing your
hand against them.
5. Tighten the lock nuts on the front of the sliding hopper motor adjust-
ment bracket and the stud bolts on the rear of the bracket.
Caution: Close the center rear guard by swinging the door forward into
position. Lock with the latch.
6. Check the belt to see if it is taut. Operate the machine and observe
belt action.
[27]
CALIBER .30 FIRST DRAW CASE
Adjustments

Clutch Lever
Spring
Tools:
Procedure:
When the clutch lever is released it is pulled up by the clutch lever spring.
This action should disengage the clutch and release the brake lever so the
brake shoe can be pressed against the brake drum. If the spring does not
perform its function, the tension must be increased.
Two 7/8" Wrenches
ENLARGED VIEW OF
CLUTCH LEVER SPRING

CLUTCH LEVER SPRING
1. Use a 7 8" wrench to loosen the lock nut on the adjusting screw.
2. Use a V8” wrench to turn the adjusting nut until the tension on the
spring will draw the kick-out cam ﬁrmly against the clutch housing
when the clutch is disengaged.
3. Use a 7/8" wrench to hold the adjusting nut while tightening the lock
nut, using another 78" wrench.


[28]
CALIBER .30 FIRST DRAW CASE
Adjustments
Brake Spring
Tools:
Procedure:
The brake spring acts to close the brake shoe against the brake drum.
The spring must have sufﬁcient tension to press the brake shoe ﬁrmly
against the brake drum when the brake rod is released.
Two %" Wrenches .


ENLARGED VIEW
BRAKE SPRING

BRAKE SPRING ADJUSTMENT
1. Use two 78” wrenches, one to hold the adjusting nut and the other
to loosen the lock nut.
2. Use a %" wrench to turn the adjusting nut on the spring rod until
there is a ﬁrm pressure against the brake shoes.
3. Hold the adjusting nut in place with 78" wrench and tighten the
lock nut with another 7/8" wrench.
4. Check the adjustment by operating the clutch lever and observing
whether or not the brake shoe presses ﬁrmly against the drum when
the clutch is disengaged.
I29]
CALIBER .30 FIRST DRAW CASE
Adjustments

Brake Release Rod The brake release rod connects the brake lever to the clutch lever.
TOOIS:
Procedure:
Its
function is to synchronize the action of the brake and the clutch. When
the clutch is disengaged, the brake lever should be released so that the
brake is applied through the brake spring. Also when the clutch is en-
gaged, the rod should act to pull the brake lever sufficiently to release the
brake shoe from the brake drum. For proper adjustment the adjusting
nut should be about 1%" above the brake lever.
Two 1%” Wrenches

1.


ENLARGED VIEW
BRAKE RELEASE ROD
ADJUSTMENT
BRAKE RELEASE ROD ADJUSTMENT
Release the latch on the rear guard and swing the guard away from
the machine.
Use an M6” wrench to loosen the lock nut on the brake release rod
while holding the adjusting nut with another 1%," wrench.
Use an 1%" wrench to turn the adjusting nut until it is about 1%”
above the brake lever.
Tighten the lock nut with 1%” wrench while holding the adjusting nut
in place with another 11/16" wrench.
Caution: Close the guard by swinging it into place and latch securely.
To check for accuracy, engage the clutch, turn on the power, then
disengage the clutch and observe whether or not the brake lever is
released.
I30]
CALIBER .30 FIRST DRAW CASE
Troubles and Corrections
Objective
Scored or
Scratched Walls
Crooked Draw
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may con-
front an adjuster, but the production troubles that most commonly occur,
their causes and corrections are listed below.
The following troubles may be recognized by visual and gage inspection
of the component together with constant observation of the machine as it
operates.
Visual inspection will reveal if scratches are on the inside or outside walls
of the case. Scratches on the outside walls can be detected by ﬁnger nail
inspection.
The causes are: The corrections are:
1. Foreign matter (dirt, grit, shav- 1
. Remove the cooling solution,
ings etc.) in the cooling solution.
clean the reservoir, replace with
clean cooling solution.
. Send the cups to the Washing
Department to be rewashed.
2. Foreign matter (dirt, dried 2
soap etc.) on the cups.
3. Chipped punch—a piece is 3.
broken off the end of the punch.
Replace with a new punch.
4. Skinned punch—the punch sur- 4
face marred.
. Polish the punch if it is not too
badly skinned. If it is beyond
repair, replace with a new punch.
5. Cracked die—a fracture in the 5
cross section of the die.
. Replace with a new die.
6. Scratched die—a scratch on the 6
inside surface of die.
. Polish die if the scratch is not
too deep. Replace with a new
die if necessary.
7. Foreign matter (dirt, grit, etc.) 7.
on the feed table or in the
hopper.
Clean the table or hopper.
Gaging discloses uneven sidewall thickness, crooked tops, uneven bottoms.
The causes are: The corrections are:
1. Bent punch. 1. Straighten the punch in an ar-
bor press, or if it cannot be
straightened, replace with a new
punch.
2. Worn ,die—the drawing surface
too large or irregular.
2. Replace with a new die.
I31]
CALIBER .30 FIRST DRAW CASE
Troubles and Corrections
Crooked Draw 3. Foreign matter (dirt, shavings, 3.
(Cont.)
Thick Bottom
Thin Bottom
Punch Outs
Remove the die and the die
block; clean and replace the die
assembly.
burrs, etc.) under the die.
4. The die is too tight in the latch 4. Remove the die and adjust it.
block.
5. Defective cups. 5. Clear the hopper and check the
source of supply.
Remove the ring, reverse its
position and replace it.
6. The guide ring is upside down. 6.
Tighten the punch in the punch
holder properly.
7. Loose punch—the punch is loose 7.
in the holder.
Gaging discloses insufﬁcient material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by Metal-
lurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Not enough taper on the punch. 1. Replace with a new punch.
2. Radius on the end of the punch 2. Replace with a new punch.
insufﬁcient.
Gaging discloses too much material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by Metal-
lurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Too much taper on the punch. 1. Replace with a new punch.
2. The radius at the end of the
punch is too great.
2. Replace with a new punch.
Visual inspection discloses the bottom of the case is punched out or the
side of the case is deformed by the punch.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by Metal-
lurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Improper anneal~the cup me- 1. Send to the annealing room to
tal is too hard.
Improper anneal—~the cup me-
tal is too soft.
No radius on punch—the punch
is too large on the drawing end.
be reannealed.
. This cannot be corrected. The
cup will have to be salvaged.
Call the inspector.
. Replace the punch with a new
one.
I32}
CALIBER .30 FIRST DRAW CASE
Troubles and Corrections

Punch Outs (Cont.)
Short Case
Long Case
Uneven Feed of
Cups to Feed
Fingers
Hopper Stops
4. The die is inverted——the die is
not placed in the die block
properly.
4. Remove the die; replace the die
in the proper position.
Gaging discloses the case is not long enough and the walls are too thick
to meet speciﬁcations.
The causes are:
1. The die is too large—it is over-
size in the drawing surface.
2. Small punch——the punch is
undersize from’ wear or pol-
ishing.
The corrections are:
1. Replace with a new die.
2. Replace with a new punch.
Gaging discloses the case is too long and the walls too thin to meet speciﬁ-
cations.
The causes are:
1. Die too small-—it is undersize
in the drawing surface.
2. Punch too large—the punch is
oversize or does not have the
proper taper at the drawing end .
The corrections are:
1. Lap out the die to the proper
size.
2. Replace with a new punch.
Visual inspection discloses that feed ﬁnger is not receiving cups in proper
time as it moves in and out.
The causes are:
1. The counters are improperly
adjusted.
2. The agitators are improperly
adjusted.
3. The cup guides are bent or out
of adjustment.
4. The feed ﬁnger push rod is im-
properly adjusted.
5. The fork is improperly adjusted.
6. The belt is loose or oily.
The causes are:
1. Overloaded hopper—too many
cups in hopper.
2. There is an oversize cup in the
feed chute.
The corrections are:
1. Adjust the counters.
2. Adjust the agitators.
3. Straighten the guides if they
are bent or adjust them if neces-
sary.
4. Adjust the push rod.
5. Adjust the fork.
6. Tighten the belt if it is loose;
clean the belt if it is oily.
The corrections are:
1. Remove the excess supply of
cups from the hopper.
2. Clear the chute; check the
source of supply.
[33]
CALIBER .30 FIRST DRAW‘ CASE
Troubles and Corrections

Hopper Stops
(Cont.)
Smash Up
Dial Plate Stops
Slow Press
Uneven Flow of
Cooling Solution
Loose Ram
3. Clear the hopper—call the
Maintenance Department.
3. The hopper escape slots bent.
One or more tools are broken and have to be replaced.
The causes are: The corrections are:
1. Bent punch. 1. Replace with a new punch.
2. The machine is out of time or 2. Retime or adjust the machine.
adjustment.
8. Bent cups. 3. Clear the hopper and check the
source of supply.
4. Broken push rod spring. 4. Install a new spring.
5. Replace with new parts or call
the Maintenance Department.
5. Broken machine parts.
Visual inspection discloses lack of cups feeding to ﬁngers.
The cause is: The correction is:
1. Belt is too loose. 1. Adjustment will have to be
made by cutting the proper
amount from the belt and re-
clamping it.
A lowered production rate may indicate that the stroke of the press is
slowed down.
The causes are: The corrections are:
1. Loose Belt. 1. Adjust the belt.
2. Galled gibs. 2. Check the lubrication. (Call the
Maintenance Department.)
3. Dry bearings. 3. Check the lubrication. (Call
the Maintenance Department.)
Visual inspection discloses that pump is operating but the supply of cool-
ing solution is not being supplied properly to the drawing operation. This
condition may result in scores or scratches on the case or in damaged tools.
The cause is: The correction is:
1. Lack of cooling solution in the
reservoir.
1. Fill the reservoir with the proper
amount of solution.
Visual inspection discloses that the lock nut has become loose and ram has
lowered itself.
The correction is:
1. Adjust the ram stroke. Tighten
the lock nut.
The cause is:
1. Loose lock nut.
[34]
CALIBER .30 FIRST DRAW CASE
Troubles and Corrections

Clutch Clicks
Motor Stops
Visual inspection discloses the clutch does not operate properly.
The cause is: "The correction is:
1. Call the Maintenance Depart-
ment.
1. Bent or broken pins, rod or
springs. The dog will not re-
lease properly.
Visual inspection discloses that the motor is not running and the press is
stopped.
The cause is: The correction is:
1. An overload, or burnt out arm-
ature, bearings etc.
1. If there is an overload, clear the
cause of the overload; and press
the reset button to start the
machine. If there is any other
reason for the motor to stop,
shut off the power and call the
Maintenance Department.
CALIBER .30 FIRST DRAW CASE
Tool Servicing

TOOL SERVICING
Objective Proper tool servicing is essential to maintain standard quality in the
drawing of the bullet jackets and cartridge cases. Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters will be concerned primarily with the removal of brass and small
scratches that appear on working surfaces of dies and punches; and they
must be careful, when using an abrasive on any tool, not to alter ma-
terially its dimensions.
Servicing
New Dies
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1.
Dies as received from the tool room are normally undersize to allow
for expansion pressure, and for lapping to a desired size when necessary.
The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
As a precaution, before a test run is made, the die bore should be in-
spected for roughness and polished if necessary. If the bore is rough,
causing undue friction, more metal may be pulled from the bottom of
the jacket or case, at the start of the draw, than is necessary.
The product from the test run should be carefully gaged and in-
spected. Then, and then only, if an undersize or out of true die is
indicated, should the die be lapped.
If trial in the machine shows that the die is undersize, place it in a
three-jaw chuck on a speed lathe to lap it.

OVER-ALL VIEW OF SPEED LATHE
[36]
CALIBER .30 FIRST DRAW CASE Tool Servicing

6. Check the die to see that it is in the chuck straight and secure. (See
illustration below.)


FIG. 1 FIG. 2
CORRECT METHOD OF PLACING DIE IN CHUCK INCORRECT METHOD OF PLACING DIE IN CHUCK
Lapping Procedure 1. When lapping is necessary, proceed as follows: Use a lap stick made of
brass, lead, ﬁber or wood about the same diameter as the die hole.
2. Dip the lap stick in a solution of No. 120 emery dust and olive oil
or coal oil.
3. Hold the lap stick as nearly as possible in line with the angle of the
taper. When lapping the land, hold the stick at a right angle to the
mouth of the die to keep the land true. A land which is not true
causes irregular wall thickness and crooked tops on jackets and cases.
4. While holding the lap stick against the die, give the stick a rapid in
and out movement. This cuts down the ridges left by the grinder
wheel in the metal surface and makes it smoother. Repeat this
operation according to the amount of metal that must be taken out of
the die.
5. Wipe the die clean with a cloth.
6. Next, polish the die with the ﬁnest grade of emery cloth available,
not coarser than No. 220.
7. Finish the polishing operation with crocus cloth.
8. Wipe out the inside of the die again with a cloth.
9. Remove the die from the chuck and check the size of the die with a
plug gage.
10. Be sure the die is free of all emery dust before replacing it in the
machine for production.
[37]
CALIBER .30 FIRST DRAW CASE
Tool Servicing
Carboloy Dies
Servicing
Scratched Dies
Servicing
a New Punch
Lapping
To lap a carboloy die, follow the same procedure, with diamond dust
and olive oil instead of emery dust.
1. Before removing a die from a machine to look for scratches, remove the
stripper to determine whether the stripper, rather than the die, is
scratched.
2. Check the die or stripper visually to determine how badly it is scratched.
If the die or stripper has a very deep scratch, it should be sent to the
Tool Service Department.
3. If it is found that the scratch is in the die, check the die with a die
“wear limit” plug gage to determine how much metal can be worked
out of it without making the die too large.
4. To polish the die, place it in a three-jaw chuck on a speed lathe.
5. Polish it with ﬁne emery cloth, then with crocus cloth.
6. If the scratch can’t be removed by polishing, the die will have to be
lapped. See lapping procedure, or send to the Tool Service Department
if necessary.
7. Check the die size with the “wear limit” plug gage before putting it
into production. -
Before an abrasive of any kind is applied to a new punch its dimensions
should be carefully checked with micrometer or proﬁle gage; and its work-
ing surface should be examined for ﬁnishing or handling marks and lack of
polish. A highly polished punch aids in stripping and allows metal to
ﬂow freely thereby reducing the tendency of brass to pile up on the work-
ing surface.
An Adjuster will not be required to lap more than .0005” from a new
punch. If more than this must be removed to bring the punch to size, it
should be returned to the Tool Service Department for correction.
Lapping is done with a piece of abrasive cloth wrapped around and moved
back and forth along the axis of the punch as it revolves in a speed
chuck. If the abrasive were held stationary deep rings would be cut into
the surface, thereby ruining the ﬁnish.
The punch is shown in Fig. 1 correctly chucked and in Fig. 2 incorrectly
held. Avoid excessive overhang of the punch as this is a safety hazard,
and make sure that the jaws are correctly set, and tightened securely.
Do not allow the jaws to grasp the working surface of the punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with cross-hatched effect.
[38]
CALIBER .30 FIRST DRAW CASE
Tool Servicing

Polishing


Servicing
a Used Punch
The lapping operation must be followed by polishing. Polishing is done in
the same manner as lapping except that a ﬁner abrasive is used, as for ex-
ample crocus cloth, and a ﬁnal operation called draw polishing is done
with the chuck stopped. To draw polish a punch move the abrasive
cloth lengthwise over the entire working surface avoiding rotary motion
of the punch or the abrasive. Continue this ﬁnal operation until all
lapping marks are removed and the desired high polish or mirrorlike
ﬁnish is obtained.


FIG. 3
CORRECT METHOD OF PLACING
PUNCH IN CHUCK
FIG. 4
INCORRECT METHOD OF PLACING
PUNCH IN CHUCK
As a punch is used its working surface wears accumulating scratches and a
coating of brass. Excessive wear is determined by measuring with microm-
eter or checking with proﬁle gage. Obviously, an undersize punch must be
replaced with one of approved dimensions. Scratches, if not too severe,
may be removed by the lapping and polishing operations described above.
A light coating of brass may be removed by the polishing operation alone.
The question of how soon a new punch will need lapping or polishing can
be answered only from experience since many variable factors enter into
the problem.
[39]
CALIBER .30 FIRST DRAW CASE
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
MACHINE LLIBRICATION
The eﬂiciency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
8. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated suﬂiciently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap. '
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[40]
CALIBER .30 FIRST DRAW CASE
Machine Lubrication
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.'Q.@.<J‘r'>~.°°.N
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.‘q.@.°‘tI>‘.°°.l\'>
Frequency of lubrication.
I 41 I
CALIBER .30 FIRST DRAW CASE
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°.-q9=.°‘r'=~.w.l\°!-*
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the floor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I42]
CALIBER .30 FIRST DRAW CASE
Machine Lubrication
LUBRICATION CHART


. . N 0. of Fittings, Frequency of
Imbmcam Machine Part Grease Cups, etc. I/ubrication H ours
Crankshaft bearings . . . . 4 8
Pitman bearings . . . . . . 2 8
Drive shaft bearings . . . . 4 8
LIGHT GREASE §$’S ei, ' ' ' ' ' ' ' ' ' ' i 22
<B1ueGun> C1.‘2‘Zh..' 1 ; I L 1 I 1 1 I 2 16
Block chain idler pulleys 2 16
Ratchet pulley assembly 2 8
Main drive pulley . . . . . 1 8
HEAVY OIL ilitfiﬁifipin 3 it
(Yellow Oder) Coolant pump . . . . . . . 1 24
?RF; ‘3*Iéa(r:1)OMPOUND Drive pinion and gear 1 1 wk.
Revolving dial plate . . . . 2 8
Dial plate drive shaft . . . . 2 8
Dial plate agitator . . . . . 4 8
Camshafts . . . . . . . . 4 8
MEDIUM OIL Cam rollers . . . . . . . . . 2 8
(Red Oiler) Clutch lever . . . . . . . . 2 24
Idler pulleys for hopper belt . . 2 8
Dial Plate agitator cams 2 8
Cam for ﬁnger assembly 2 8
Ring and pinion gears . . 2 8


I43]
CALIBER .30 FIRST DRAW CASE
Index
Abrasives, 38
Accurate Checks, 15
Adjustable Brackets, 4
Adjusting Screw, 19
Adjustment, Brake Release Rod, 30
Brake Spring, 29
Clutch Lever Spring, 28
Die Replacement, 17
Feed Finger, 22
Feed Finger Push Rod, 21
Feed Table Agitator, 19
Fork, 23
Fork and Finger Timing, 20
Hopper Agitator Stud Replace-
ment, 25
Hopper Agitator Studs, 24
Punch Replacement, 18
Rotary Hopper Belt, 27
Adjustment Bracket, Hopper Motor,
27
Adjustment Stud Bolts, 27
After Annealing, 14
Pickle and Wash, 14
Agitator, 12, 34
Adjusting Screw, 19
Arm, 8
Studs, 24
Alemite-Zerk Fittings, 4
Annealed, 14
Annealing Department, 14
Anti-Friction Bearings, 40
Anvil, 10
Base, 7
Bearings, 35
Before Annealing, 14
Belt Drives, 4
Block Chain, 6
Chain Idler Pulley, 20
Chains, 4
Bolster Plate, 9
Bottom Thickness, 15
Variation, 14
Brake, 30
Action, 3
Drum, 3, 28, 29
Lever, 28, 30
Release Rod, 30
Release Rod Adjustment, 30
Rod, 29
Shoe, 3, 28, 29
Spring, 29
Spring Adjustment, 29
Cam Follower, 6
Follower Assembly, 5, 6
Follower Yoke, 5
Camshaft, 3, 13, 20
Follower, 6
Cap Plate, 22, 23
Carboloy Dies, 38
INDEX
Case, 14
Bottom, 14
Mouth, 14
Sidewall, 14
Cast-Iron Base, 7
Center Cup Guide, 8
Chuck, 37
Clutch, 4, 30
Action, 3
Clicks, 36
Housing, 28
Lever, 2, 28, 30
Lever Spring, 26, 28
Lever Spring Adjustment, 28
Coil Tension Spring, 6
Coiled Spring, 9
Component, 12
Control Gate, 12
Controls, 3
Conveyor Pipe, 7
Cooling Solution, 3, 12
Solution Pump, 1, 4
Solution Pump Motor, 4
Counters, 12
Countershaft, 4
Crankshaft, 2, 6
Speed, 1
Sprocket, 20
Crooked Draw, 32
Heads, 15
Bodies, 15
Tops, 15, 32
Crocus Cloth, 37
Cup Bottom, 14
Guide, 5, 19, 21
Guide Agitator, 8
Guides, 8, 12, 34
Jam, 19
Mouth, 14
Slot, 23
Cups, 3-9, 12, 14, 34, 35
Dial Indicator, 15
Plate, 35
Diameter, 12
Diamond Dust, 38
Die, 5, 6, 11, 12, 17, 23, 32, 34
Assembly, 5
Block, 5, 9, 12, 17, 22
Block Assembly, 9
Block Hole, 17
Block Holder, 5
Block Lock Pin, 17
Bore, 36
Plug Gage, 36
Life, 3
Replacement Adjustment, 17
Dies, 36
Disposal, 12
Double Feed Track, 5
Draw, 12
Die, 9
Polish, 39
Drive Pulley, 8
Emery Cloth, 37
Excess Oil, 42
Feed Chute, 6, 7, 8
Finger, 12, 20, 21, 22
Finger Adjustment, 22
Finger Assembly, 5, 22
Finger Cam, 6
Finger Camshaft, 4-6, 20
Finger Fork Assembly, 23
Finger Mechanism, 8
Finger Push Rod, 21, 34
Finger Push Rod Adjustment, 21
Fingers, 5, 6, 13, 19
Fork, 12
Motor, 1
Feed Pipe, 12, 13
Table, 3, 7, 8, 12, 13
Table Agitator, 19
Table Agitator Adjustment, 19
Track, 5
Tracks, 12
Feeding Mechanism, 5
Finger Assembly, 5
First Draw Case, 12
Flat Feed Chute, 3, 12
Floor Space, 1
Flywheel, 4, 21
Hub, 2
Pulley, 2
Shaft, 20
Foreign Matter, 32, 33
Fork, 34
Fork and Finger Timing Adjustment,
20
and Finger Assembly, 22
Adjustment, 23
Assembly, 5
Friction, 40
Front Guard, 18
Guard Door, 19
Gage Care, 15
Gages, 15
Gaging, 32, 33
Geared Head Motor, 7
Gland Nut, 10, 18
“Go” Ring, 15
Grease, 41
Guide Ring, 9, 11, 12, 17, 33
Hints on Lubrication, 42
Hook, 12
Hopper, 24, 34
Adjustable Bracket, 27
Agitator Stud Replacement Adjust-
ment, 25
Agitator Studs Adjustment, 24
l44l
CALIBER .30 FIRST DRAW CASE
Index
Hopper, Cont.
Base, 7
Belt Guard, 25
Bracket, 7
Center Shaft, 7
Door Latch, 25
Latch, 24
Motor, 3
Motor Adjustment Bracket, 27
Rim, 7, 12
Stops, 34
Stud, 24
Stud Shaft, 7
Wheel, 24
Idler Pulley, 20
Inside Diameter, 14
Inspection, Visual, 15
Key Clutch, 2
Kick-Out Cam, 28
Lapping, 36, 38
Lap Stick, 37
Large Diameter, 17
Lock Pin, 9
Long Case, 34
Loose Ram, 35
Lubricant, 4
Lubricating Film, 40
Lubrication, 4, 12, 40
Chart, 43
Methods, 41
Machine Motors, 1
Main Drive Motors, 3
Micrometer, 38
Motor, 36
Bracket, 25
Bracket Adjusting Studs, 25
Cooling Solution Pump, 4
Geared Head, 7
Hopper, 3
Motor Pulley, 25, 27
Motor Stops, 36
Motors, 4
Main Drive, 3
“No Go” Ring, 15
Oil Cups, 4
Holes, 4
Oiler, 4
Outside Diameter, 14
Over-All Height, 1
Length, 14
Overhead Hopper, 7, 12, 13
Pickled, 14
Pinion Gear, 13
Pitman, 13
Polished Punch, 38
Polishing, 39
Power, 2
Production, 1
Proﬁle Gage, 38
Pulley Rim, 7
Punch, 4, 5, 10-13, 18, 23, 32—35
Assembly, 18
Block Assembly, 10, 18
Cuts, 33
Holder, 10, 18
Holder Block, 3, 10
Life, 3
Push Rod, 6, 20, 23
Replacement Adjustment, 18
Rod Assembly, 23
Rod Spring, 20
Ram, 3, 12, 13
Rear Guard, 17
Ring Gear, 13
Rotary Dial, 3, 5, 8, 13
Dial Shafts, 3
Dials, 12
Hopper, 3, 7, 12, 13
Hopper Base Channel, 12
Hopper Belt Adjustment, 27
Safety Glass Door, 4
Guard, 4
Scored Walls, 32
Scratched, 17
Dies, 38
Walls, 32
Scratches, 15, 18, 32
Second Draw, 14
Selecting Lubricant, 41
Servicing New Dies, 36
New Punch, 38
Used Punch, 39
Set Screw, 19
Short Case, 34
Sidewall Thickness, 14
Sleeve, 10, 18
Slow Press, 35
Small Diameter, 18
Smash Up, 35
Speed Chuck, 38
Lathe, 36
Split Collar, 10, 18
Sprocket, 4
Wheel, 6
Storage of Gages, 15
Stripper, 9, 11-13, 17
Holder, 9, 11
Ring, 17
Stroke, 1
Swab, 4
Switches, 3
Toggle, 3
Thick Bottom, 33
Thin Bottom, 33
Three-J aw Chuck, 36
Toggle Switches, 3
Switch, 13
Tools, 1
Tool Service Department, 36
Servicing, 36
Track Guide, 19
Transmission, 2
Turntable, 12
Twin Ring Gage, 15
Type of Feed, 1
Undersize Punch, 39
Uneven Bottoms, 32
Feed of Cups, 34
Flow of Cooling Solution, 35
Sidewall Thickness, 32
Visual Inspection, 15, 32. 33
Wall Thickness, 12
Washed, 14
Worn Punch, 18
Yoke, 6
[45]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Second Draw Case
BY
Training Department

Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public N o. 443, 76th Congress, 3rd Session).
II
MANUAL CORRECTlONS—CALlBER .30 SECOND DRAW CASE
LOCATION
Page 18—Fig
Page 13—Fz'g
Page 1./,, ‘I6 & 9'
Page 1 6—Spec
Page 1 6-Spec
Page 16-Spec
Page 26—Pr0c 3
ERROR
Guide Ring
Die
Guide Ring
Inside diameter before 2nd Draw .300-.302
Inside diameter after 2nd Draw .274—.276
Bottom Thickness after 2nd Draw .135-.143
3/8 ” Wrench
CORRECTION
Top Die
Bottom Die
Top Die
Inside diameter before 2nd Draw .551—.553
Inside diameter after 2nd Draw .518—.520
Bottom Thickness after 2nd Draw .137 —.141
% ” Wrench
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Process Sequence . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
III

DRAW PRESS—CALIBER .30 SECOND DRAW CASE
IV
CALIBER .30 SECOND DRAW CASE
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Feed Motor
Production
Crankshaft Speed
Stroke
Cooling Solution
Pump
Tools
Floor Space
Over-all Height
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, New York
Vertical Straight Side Single Crank Press
E. W. Bliss No. 304 6 V Belt Drive Motor to
Crankshaft
71/2 h.p.; 3 phase; 60 cycle; 220/440 volts;
23.5/11.8 amps.; 865 R.P.M.
Automatic Pin Wheel Hopper (6 R.P.M.)
Gearhead ys h.p., 1 phase, 60 cycle
115/230 volts, 3.4/1.7 amps., 1725 R.P.M. Coun-
tershaft 48 R.P.M.
360 per minute.
90 r.p.m.
8!!
Centrifugal (Gusher) Model 1 P3 3450 R.P.M.,
1/10 h.p. 1 phase, 60 cycle, 1.1 amp., 110 volt
Piece No.:
Punch D-2
Top Die .588x14°
Bottom Die .5665x14°
Stripper .574
Stripper Holder 1.492x60°
4 ft. x 7 % ft.
10 ft. x 1% ft.
Ill
CALIBER .30 SECOND DRAW CASE
Machine Description

Crankshaft
Brake Assembly
Hopper Box
Hopper
Feed Tubes


Switch
Switch
Glass Guard
Pump Motor
Power and
Transmission


MACHINE DESCRIPTION
Connecting Rod
' Guard
Clutch Handle
-4‘ ww '-as-. em .
FRONT VIEW
The E. W. Bliss single draw press No. 304, illustrated above, is powered by
a 7% h.p. motor, through six V belts, to the ﬂywheel mounted on a
horizontal crankshaft.
Incorporated in the flywheel hub is a rolling key clutch for control of power
to the crankshaft through linkage to an individual clutch lever.
A conventional brake drum is located on the end of the crankshaft oppo-
site the ﬁywheel. A lined brake shoe secured and located by a bracket
attached to the machine frame provides the friction necessary to hold the
crankshaft in position when the clutch is disengaged.
The clutch and brake action are synchronized through the clutch lever.
When the clutch is engaged, the brake is released, and when the clutch
is disengaged, the brake is applied.
I2]
CALIBER .30 SECOND DRAW CASE
Machine Description
Power and
Transmission
(Cont.)
Pin Wheel Hopper
Feed Tracks
Ram
Detector Stems
Cooling Solution
Controls
In normal operation, if the clutch is disengaged for any reason, the crank-
shaft will always stop at the maximum upward position of the crank. For
inspection or adjustment purposes, the machine may be rotated by hand
and the crankshaft stopped and held in any desired position.
The pin wheel hopper receives cases from an overhead source and through
feed tubes deposits the cases, “mouth up,” in the feed tracks on the bed of
the machine.
The motive power for the pin wheel hopper is supplied by a % h.p. reduc-
tion gear-head motor, on an adjustable mounting bracket at the left
side of the hopper, through a V belt to the pin wheel.
The feed tracks, with the assistance of the feed ﬁngers, transfer the cases
from the feed tubes to the punch and die stations.
The ram is a heavy cast-iron block. Its mass assists the power stroke of
the punch and absorbs the shock of impact and subsequent vibration.
The lower surface is machined for the attachment of a punch holder block.
The ram, the sides of which are ﬁtted into V grooves to guide it in its
vertical motion, is connected to the crankshaft throw by a non-adjustable
connecting rod.
Two coil springs are attached between the back side of the ram and a
spring bracket mounted on the machine frame above the crankshaft. The
springs act as a counter balance and assist in dissipating the vibration set
up by the punches’ contact with the cases during the drawing process.
The detector system, which is mounted on the front of the ram, is a
mechanism which detects inverted cases, cases on their sides, and foreign
objects within cases as they travel through the feed tracks.
Above each feed track is located a detector stem. If a detector stem en-
counters an improperly positioned case or a foreign object in a case, the
stem will be forced upward, and will move the knockoff bar to the right.
The knockoff bar will strike and move the clutch lever latch pin to the
right, tripping the clutch lever; thus the clutch is disengaged, the brake
is applied, and the machine is stopped.
To prolong die and punch life, each case is bathed by a cooling solution,
which acts both as a cooling and a lubricating agent.
The base of the machine forms a reservoir for this cooling solution which
is pumped through a pipe system to the die. The pump is driven by a 1/ 10
h.p. vertical, direct drive motor.
The main motor control switch is of the push button “start and stop” type.
An overload switch, with a “reset” pushbutton is also provided for pro-
tection of the main drive motor.
Two toggle type switches contained in the same case are provided for con-
trol of the hopper and pump motors. The right hand switch is for the
pump motor, and the left hand switch controls the hopper motor.
[3]
c/sussa .30 SECOND DRAW CASE Machine Description

Lubrication Lubrication of all moving parts is accomplished by Alemite-Zerk ﬁttings,
oil cups, oil holes, or distribution of lubricant by oiler, swab, etc., over de-
sired point. (See Lubrication Chart, page 40.)
Rear View of This rear view of the caliber .30 draw case press shows the motors and ad-
Caliber .30 justable brackets. The press is started and stopped by a clutch in the-
Draw Case Press crankshaft ﬂywheel.
Below the frame is shown the %; h.p. motor that drives the cooling solu-
tion pump which circulates the cooling solution from the reservoir in the
machine bed through the pipe system to the punches and dies. The cooling
solution serves as both a cooling and a lubricating agent.
Motor
V Bells
Brake Assembly
Hopper Box


Guard _ Hopper Motor
H opper Wh eel
Brake Release Rod
Shall
Die Blocks S"’"“"
Cooling Pipe
REAR VIEW
[4]
CALIBER .30 SECOND DRAW CASE Machine Description

Detector System The detector system is a mechanism which detects cases which are not in
their proper positions and foreign objects within cases as they travel
through the feed tracks. The detector system, which is bolted to the front
of the ram, consists of a detector stem for each feed track. If a stem en-
counters a foreign object in a case or locates an improperly positioned
case, the detector stem will be forced up, and its upper end will move the
knockoff bar to the right. The knockoff bar will strike the clutch lever
latch, tripping the clutch lever which disengages the clutch, and applying
the brake, thereby stopping the action of the ram.
Detector System
Assembly
Knockout Bar
Detector Stems
Clutch Lever Latch
Clutch Lever

VIEW OF THE DETECTOR SYSTEM
[5]
CALIBER .30 srcono DRAW CASE Machine Description
Connecting A connecting rod connects the ram to the crankshaft. The ﬂywheel on the
Rod and Ram end of the crankshaft transmits power to the ram from the motor. There
are two heavy coil springs which cushion the impact of the ram on its
downward stroke and help in a small way to lift the ram on its upward
stroke.
The clutch lever is used to start and stop the press. In the running position
it is hooked onto the latch pin catch. For automatic stop, the latch pin
kicks the lever off its hook. The rod on the clutch lever connects the lever
to the clutch.


Crankshalt
Connecting Rod
‘
-
.-
-1&-
Qt
-_
~Q~
.
_
-
~
‘
‘
-Q»
v
RAM AND COUNTERBALANCE
SPRINGS (REAR VIEW)
[6]
CALIBER .30 secoma DRAW CASE Machine Description
Pin Wheel Hopper The pin wheel hopper and hopper box are located at the top and to the
Description left of the machine.
The pin wheel hopper box is a cast-iron reservoir with the bottom sloping
toward an opening which leads into the pin wheel hopper. The pin wheel
hopper, attached to the front of the hopper box, is mounted on a project-
ing cast-iron bronze lined bearing, into which is ﬁtted the pin wheel
shaft and hub.
The pin wheel hopper consists of an inner and an outer dish-shaped rim
and a mid-section of pin rings and spacer rings, bolted to form a hopper
assembly. The outer rim has three spokes attached to a hub shaft on
which the entire hopper revolves. The hopper is driven by a V type belt
from a gear reduction %; h.p. motor.
Hopper Box
Hopper Motor
Hopper Door
Spacer and Pin
Rings
Dish-shaped
Rim

FRONT VIEW OF PIN WHEEL HOPPER
I7l
CALIBER .30 SECOND DRAW CASE
Machine Description
Pin Wheel Hopper


The pin rings have a series of steel pins, spaced approximately 1" apart on
their inner circumference, set at an angle with the radii. The spacer
rings are wider than the pin rings and are chamfered on their inner edges.
This chamfer forms a channel between each of the spacers to guide the
components onto the pins.
As the pin wheel hopper rotates clockwise, some of the pins pick up cases
and convey them upward. Contacting each row of pins as they rotate
upward is a spring steel strip, called a rake-off spring, which rakes off all
cases that are not properly seated on the pins. As the cases continue their
upward travel, they contact a pin wheel bridge which holds them on the
pins as they reach the top of the circle. There is one pin wheel bridge for
each row of pins. When the cases reach their nearly vertical “head down”
position, they come to the end of the pin wheel bridge, where they slide off
into the mouth of the feed tube.
The door for the front of the pin wheel hopper is dish-shaped to match the
pin wheel rim, and is hinged at the left of the hopper box. The door is held
shut by a rotary latch.
Hopper Bridge
-_ Feed Tube Mouth
Rake-off Spring
Spacer Rings
Steel Pins
INSIDE VIEW OF PIN WHEEL HOPPER
I8]
CALIBER .30 SECOND DRAW CASE
Machine Description
Feed Tracks

The machine has a series of two-piece feed tracks that hold the cases in a
mouth up position. Each track is bolted to the bolster plate of the machine.
On the inner face of each track is a series of ball-spring stops spaced to
hold the cases in an upright position. On the rear of each track is a brass
back-stop to prevent the cases from being forced past the dies.
As the ram ascends, an arm fastened to the ram lifts a plunger rod which
actuates a rocker arm assembly which, in turn, furnishes motive power to
the feed ﬁngers.
The case, which has just emerged from the feed tube, is forced against the
others in the feed tracks by the feed ﬁngers. This causes the case, in the
rear of the tracks to be forced past the ball-spring stops to a position over
the dies where the punch descends and forces the case through the die.
Rocker Arm
' Shaft
Feed Finger
Trac It
Backstop
Bolster Plate
VIEW OF THE FEED TRACKS
I9]
CALIBER .30 SECOND DRAW CASE Machine Description

Feed Tubes The feed tube mouth is connected to the upper end of the feed tube by
and Bridge means of a bushing. A bayonet type of bushing is used to connect the
lower end of the tube to the feed tube bridge.
The feed tube bridge is bolted to the bolster plate above the feed tracks.
The feed tube bridge holds the feed tubes in position over the case tracks.
The cases slide head down from the feed tube mouth, down the feed tubes,
to a position on the feed ﬁngers in the feed tracks.
Feed Tube Mouth Bushing Feed Tubes
> ‘
‘-
b
’ '

VIEW OF THE PIN WHEEL HOPPER BRIDGE
Feed Tubes.-.
Bayonet Bushing.__
Feed Tube Bridge-~ . - ‘
\ "\
. W . .
\ ’ .-


Bolster Plate
FEED TUBES, BAYONET BUSHING, FEED TUBE
BRIDGE, BOLSTER PLATE
[10]
CALIBER .30 SECOND DRAW CASE Tool Holder Description

TOOL HOLDER DESCRIPTION
Punch Block Anvil: The anvil is inserted in the top side of the punch holder
Assembly / block in contact with the head of the punch and the punch
holder. It protects the face of the ram from the thrust of the
‘ punch.
/ Punch Holder Block: The punch holder block has two dowel
’ ' I " -' pins for alignment and is bolted to the under side of the ram
by four Allen screws. It holds the punch holder assemblies.
Punch Holder: The punch holder is placed into the punch
holder block from the top side by “Press ﬁt," ﬂanged end up.
The lower end is threaded to receive a hexagon gland nut. It
holds the punch assembly in the punch holder block.
Split Collar: The split collar is composed of two halves which
are held in place by a coiled spring. It acts as a ﬂange on the
head end of the punch against which the sleeve is held by the
gland nut.


Punch: The punch, with the gland nut, spacer sleeve and
split collar in place, is inserted into the bottom sides of the
punch holder, head end up. This gland nut is then screwed into
the punch block holder.
Sleeve: The sleeve is placed on the punch from the bottom end
before the gland nut. It acts as a spacer in the assembling of
the punch.
Gland Nut: The gland nut, which has threads on its outer
surface, is screwed into the inner threads of the punch holder,
VIEW OF THE forcing the spacer against the split collar. The gland nut thus
PUNCH BLOCK h Id th h bl , th h h M r
ASSEMBLY 0 s e punc assem y m e punc o e .
Button Anvil
W / ry-.\
§::;:'z::rJ:“'
I Bushing
Gland Nut
Punch


CROSS SECTIONAL DRAWING OF PUNCH BLOCK ASSEMBLY
[ 11 I
CALIBER .30 SECOND DRAW CASE Tool Holder Description
Die Block Assembly Top Draw Die: The top draw die is placed in the die hole of the die block
from the top side to rest on the bottom die. It forms the outside diameter
of the case as the case is forced through it by the punch.
.':?- Bottom Draw Die: The bottom draw die is inserted ﬁrst from the top
side of the die holder into the die assembly hole of the die block. It sizes
the case to the speciﬁed diameter.
_>
Die Block: The die block holds the die assembly. It is held in the chan-
nel of its bolster plate by a lock pin. The bolster plate is adjustable to
allow centering of the die assembly contained in the die block under the
punch. The vertical lip on the rear end of the die block assists the adjuster
in inserting, locating and removing the die block. There is one die assem-
bly for each punch.
Lock Pin: The lock pin is inserted through a small hole in the rear end of
0 Q the die block. It holds the die block in place on the bolster plate.
\
Stripper Holder: The stripper holder is inserted in the die assembly hole
\\ from the bottom side and rests on the bolster plate.


Stripper: The stripper consists of three segments held together by a
coiled spring. It is inserted in the stripper holder with the large side of the
tapered hole up. It strips the case from the punch after it has been forced
\ through the die assembly.
VIEW OF THE DIE Die Block Base Plate: The die block base plate serves as an anvil for
BLOCK ASSEMBLY the die block. The bottom projection guides the cases onto the conveyor.


Top Die
‘ . .9. 1 _
CROSS SECTIONAL DRAWING OF DIE BLOCK ASSEMBLY
Bottom Die
Stripper Holder


.-‘I.-‘_. ".'."-.‘..._.
S - 'o:O:O:0...o.o.o'0:0:Q:O.‘
pI'l I19 ‘. A . x\_o_0_0‘0‘ K ‘ ,0;


Stripper
‘N


I12]
CALIBER .30 SECOND DRAW CASE
Tool Description
TOOL DESCRIPTION


Guide Ring


Die


Stripper


Stripper Holder
VIEW OF ALL TOOLS


Punch—~Second Draw
D-2
Held vertically in the ram
770,000 pieces
Tool Name:
Piece No.:
Location:
Normal Life:
The punch is made of tool steel, hardened, ground
and polished. The shank is slightly softer than the
working end.
Top die—Second Draw
.588 x 14°
Die block above the bottom die
112,000 pieces
Tool Name:
Piece No.:
Location:
Normal Life:
The die is made of tool steel, hardened, ground and
polished.
Bottom die—Second Draw
.5665 x 14°
Die block—below the top die
42,000 pieces
Tool Name:
Piece No.:
Location:
Normal Life:
The die is made of tool steel, hardened, ground and
polished.
Tool Name: Stripper—Second Draw
Piece No.: .574 -
Location: Die block—under the die
Normal Life: 100,000 pieces
The stripper is hardened tool steel, ground and pol-
ished. It consists of three pieces held together by a
coiled spring band.
Tool Name: Stripper holder~—Second draw
Piece No.: 1.492 x 60°
Location: Between the die and stripper
Normal Life: Indeﬁnite
The stripper holder is made of tool steel, hardened
and ground on all surfaces.
I13]
CALIBER .30 SECOND DRAW CASE
Process Sequence
Overhead Hopper
Pin Wheel Hopper
Box
Pin Wheel Hopper
Feed Tube
Feed Finger and
Feed Track
Ram and Punch
The Draw
Stripper
and Disposal
Lubrication
PROCESS SEQUENCE
The cases are fed by gravity from a truck or conveyor into the overhead
hopper and drop through a feed pipe, into the pin wheel hopper box.
Cases flow from the pin wheel hopper box through an opening past the
agitator into the bottom part of the pin wheel hopper.
As the pin wheel hopper rotates, cases are agitated and picked up by pins
on the inside circumference of the pin wheel and carried up past the rake-
off springs which knock off misaligned cases and push partly set cases all
the way on pins. As the cases are carried to the top of the pin wheel they
are held on the pins by the bridge. At the end of the bridge they drop off
one at a time into the open end of the feed tube mouth up.
Cases fall by gravity down through the coil spring feed tube into a bushing
mounted on the feed tube bridge and rest momentarily on the feed ﬁnger.
On the downward stroke of the ram the feed ﬁnger moves back permitting
the case to fall into the feed track. On the upward stroke of the ram the
feed ﬁnger moves forward pushing the cases along the feed track past the
spring buttons. The ball spring stop keeps the cases in an upright posi-
tion and prevents them from falling over. Cases pass by the counter
under and past the detector stems which detect foreign matter and in-
verted cases.
They pass to the rear of the feed tracks where they drop into the guide
ring directly over the dies and under the punch.
The ram descends with the punch and forces the case through the guide
ring into and through the die and stripper.
The forcing of the case through the die reduces the wall thickness and
diameter and increases the length of the case. This is known as the draw.
Before the draw, the component is known as the ﬁrst draw case and, after
the draw, as the second draw case.
As the punch withdraws from the dies, the cases are stripped off by a three-
segmented stripper located under the die, then falls onto a slide down a
chute through a rotary washer to a mechanical conveyor.
During the drawing operation the cases are lubricated and tools cooled by
a cooling solution which ﬂows over the cases through an opening under the
work plate.
CALIBER .30 sscouo DRAW CASE Process Sequence

FLOW CHART

Overhead Hopper
Cases are fed by gravity from truck or conveyor
into overhead hopper through feed pipe.
I


Feed Pipe
Conveys cases by gravity down into pin wheel
hopper box.

I
Pin Wheel Hopper Box
Cases flow through opening in pin wheel hopper
box past agitator into bottom of pin wheel hopper.
I
Pin Wheel Hopper
Rotates and cases are picked up by pins and car-


ried up past rake-off springs to top of pin wheel __ H0PPe_I‘ is P0Wered by a 1/8 h-P-
where they are held by the bridge. At the end of reductwn motor through a V-
the bridge they drop off, one at a time, into open type belt-


end pf coil spring feed tube, mouth up.


I
Coil Spring Feed Tube
Conveys cases by gravity, mouth up, into the
bushing mounted in the feed tube bridge, where
they rest momentarily on the feed hammer.
I
Feed Finger
Moves backward, allowing the case to drop into
feed track. It then moves forward pushing the
case along the feed track.


Feed ﬁnger is powered from the
— rocker arm shaft through the push
rod through the ram.


Feed Track
Guides the cases, single ﬁle, past and under the
detector stem to rear of track, where cases drop
into the dies and under the punch.


Dies and Punch
As the ram descends, the punch forces the case

Ram is powered from the Pitman
connecting rod through the crank-
through the dies and stripper increasing the length, __ shaft clutch and ﬂywheel by 6
and decreasing the diameter and the sidewall V_tyI')e belts to 7% h_p_ motor
thickness of the case. mounted on top of press,


Stripper
After the punch forces the case through the dies, it
withdraws and the case is stripped off by a three-
segmented stripper under the dies and falls onto a
slide and drops down a chute through a rotary
washer to a mechanical conveyor.

[15]
CALIBER .30 SECOND DRAW CASE
Product Description

Alter
Fmt
Draw
FIG. 1 BEFORE SECOND DRAW


PRODUCT DESCRIPTION
The component, when it is received by the second draw, is in the form of
a hollow cylinder with one end closed as shown in Figure No. 1.
The case is received from the Annealing Department, where it was anneal-
ed, pickled and washed. When the case is delivered to the Annealing De-
partment from the ﬁrst draw press, the metal has a very bright, brassy
appearance and a smooth ﬁnish. After the case has been annealed, the
metal appears dull and has a rough ﬁnish. The case is made of brass
(70% copper, 30% zinc). The closed end of the cylinder is the bottom
and the open end is the mouth.
The dimensions of the case are as follows:
Before second draw After second draw
Outside diameter .662l.659" Outside diameter .572‘; .570"
Inside diameter .300"-.302" Inside diameter .274"- .276"
Sidewall variation .002" Sidewall variation .002"
Bottom thickness .129”—.135" Bottom thickness .135L .143"
Over-all length .832'—'.838" Over-all length 1.595l1.608"
After the drawing operation, the cases are delivered to the Washing De-
partment where they are washed and dried before they are delivered to
the ﬁrst trim machine.
FIG. 2 AFTER SECOND DRAW


Alter After After Alter Alter
Annealing Washing Second Annealing Washing
Operation Operation Draw Operation Operation
[16]
CALIBER .30 SECOND DRAW CASE
Inspection

Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the drawing operation, a careful visual inspec-
tion of the cases must be made. The cases should be inspected for scratches
on the inside and outside walls, for crooked heads, crooked tops, and bodies
that are not round. These defects when found require an immediate ad-
justment of the machine in order to correct the fault. Whenever defective
cases are found, the lot from which they come must be removed from the
machine and properly identiﬁed so the bad lot will not get mixed up with
the good cases.
Gages are expensive instruments machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool since heat causes expansion of the
metal and results in a temporary variation in the case size.
The outside diameter of the case
is gaged with a twin ring gage.
Cases must pass through the
larger or “go” ring and must
not pass through the smaller
“no go” ring.


The bottom thickness of the case is checked on
a dial indicator as variation in this dimension
greatly affects succeeding draws.


The inside diameter is checked with
a plug gage.
[17]
CALIBER .30 SECOND DRAW CASE
Adjustments
ADJUSTMENTS
Objective To maintain satisfactory production a machine must be adjusted to com-
Cautions
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the ‘manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than the starting button to determine
whether the clutch is disengaged.
Make frequent, inspection to determine whether proper and sufficient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
CALIBER .30 SECOND DRAW CASE
Adjustments
Brake Release Rod
Tools:
Procedure:
The brake release rod connects the brake lever to the clutch lever. Its
function is to synchronize the action of the brake and the clutch. When
the clutch is disengaged, the brake lever should be released so that the
brake is applied through the brake spring. Also when the clutch is engaged,
the rod should act to pull the brake lever sufficiently to release the brake
shoe from the brake drum. For proper adjustment the adjusting nut should
be about 11/4" above the brake lever.


Brake Release
Rad Adjustment
ENLARGED VIEW
OF BRAKE RELEASE
ROD ADJUSTMENT
REAR VIEW OF MACHINE
Two 1%” Wrenches.
1. Use an 1%” wrench to loosen the lock nut on the brake release rod
while holding the adjusting nut with another 13-1/6” wrench.
2. Use an 1%” wrench to turn the adjusting nut until it is about 11/4"
above the brake lever.
3. Tighten the lock nut while holding the adjusting nut in place.
4. To check for accuracy, engage the clutch, turn on the power, and then
disengage the clutch and observe whether or not the brake lever is
released.


[19]
CALIBER .30 SECOND DRAW CASE
Adjustments
Brake The brake should be so adjusted as to prevent the ram from falling when
the clutch is disengaged. It must be adjusted so that the brake drum is
gripped ﬁrmly when the brake is applied, but must not be so tight that it
drags when the drum is in motion.

REAR VIEW SHOWING BRAKE
ADJUSTMENT CIRCLED
Tools:
Procedure:
Brake Spring


I \ Set Screws
Brake Release
Rod
SKETCH OF BRAKE ASSEMBLY
V3" Wrench, %" Wrench
1.
Use a V3" wrench to loosen the lock nuts on both of the adjusting screws
on the brake shoes.
Use a V2” wrench to loosen the adjusting screw a fraction of a turn,
bringing the shoe closer to the brake drum.
Tighten the lock nuts on the adjusting screws.
Operate the machine and observe the action of the brake.
Note: The above procedure should be repeated until the brake drags
slightly when the machine is in motion. Then the adjusting
screws should be tightened just enough to free the shoe from the
drum.
I20]
CALIBER .30 SECOND DRAW CASE Adjustments
Brake Spring The brake spring acts to close the brake shoe against the brake drum. The
spring must have sufficient tension to press the brake shoe ﬁrmly against
the brake drum when the brake rod is released.


ENLARGED VIEW
OF BRAKE SPRING
ADJUSTMENT


\ Brake Spring
Adjustment
REAR VIEW OF MACHINE
Tools: 1%," Wrench
Procedure: 1. Use a 1%¢;” wrench to loosen the lock nut on the brake spring rod.
2. Use a 1%” wrench to turn the adjusting nut on the spring rod until
there is a ﬁrm pressure against the brake shoes.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Check the adjustment by operating the clutch lever and observing
whether or not the brake shoe presses ﬁrmly against the drum when
the clutch is disengaged.
I21]
CALIBER .30 SECOND DRAW CASE
Ad iustments
Detector Stem
Tools:
Procedure:
The detector stem actuates the knockout bar which in turn actuates the
clutch lever trip. If the knockout bar is adjusted properly and the detector
system fails to trip the clutch when there is an inverted case or foreign
material in the case on the feed track, the stems must be adjusted. They
should be adjusted so that they almost touch the bottom of the case when
the ram is in its bottom dead center.


ENLARGED VIEW
DETECTOR STEM
ADJUSTMENT
Detector Stem
Adjustment
FRONT VIEW DETECTOR SYSTEM
1%" Wrench, V2” Wrench
1.
2.
3.
5.
6.
7.
Raise the front guard until the latch engages the bottom of the guard.
Place test cases under the detector stem, mouth up.
Engage the clutch and turn the ﬂywheel until the ram is at bottom
dead center.
Hold the stem with a %” wrench and loosen the lock nut with an 1%”
wrench.
Adjust the detector stem until it touches the bottom of the case lightly.
Use an 14;" wrench to tighten the lock nut on the detector stern.
Turn the ﬂywheel with a ﬂywheel rod until the ram is about three-
fourths its upward travel, then disengage the clutch and continue
turning the ﬂywheel until it has reached the top dead center.
Lower the glass guard before resuming production.
[22]
CALIBER .30 SECOND DRAW CASE
Adjustments

Feed Fingers
Tools:
Procedure:
The feed ﬁngers push the cases along the feed track to the punch and die.
If it is not properly adjusted, the case may fail to drop from the feed
socket into the feed track, or if the feed ﬁnger is set too far back, the cases
will not travel smoothly along the feed track.’ The position of the feed
ﬁngers is adjusted by adjusting the nuts on top of the push rod. They
should be adjusted so that the case just clears the feed ﬁnger when the
case drops from the feed socket into the feed track.


( .\


ENLARGEMENT OF
FEED FINGER
ADJUSTMENT
I
o
.
I
U
_
.
-
.
.
-
U
I
Feed Finger
Adjustment
Two 1%" Wrenches
1.
2.
3.
Lift the guard by hand until the latch engages the bottom of the guard.
Place three or four cases in the feed track against the feed ﬁnger.
Disconnect the feed tubes by turning with your hand until the bayonet
ﬁtting is disengaged. Then place a case in the feed tube socket.
Turn the ﬂywheel one complete turn and continue until the ram is at
its lowest position. This places the feed ﬁngers at the extreme back
stroke.
Lower the front guard.
Use two 11/4” wrenches to loosen the lock nut on top of the push rod..
Use a 11/4" wrench to turn the adjusting nut on top of the push rod
until the case in the feed tube socket drops into the feed track.
Tighten the lock nut while holding the adjusting nut in place.
Turn the ﬂywheel until the ram is at the top dead center.
Caution: Make sure all guards are in place before starting the machine.
I23]
CALIBER .30 SECOND DRAW CASE
Adjustments

Knockout Bar
Tools:
Procedure:
The purpose of the detector system is to disengage the clutch if there is
an inverted case or foreign material in the case on the feed track. If it
fails to perform its function, either the knockout bar or the detector stem
is out of adjustment. The knockout bar should be checked ﬁrst by bring-
ing the ram to bottom dead center and checking the clearance between
the knockout bar and the clutch lever trip. A clearance of about .004”
should exist at this point. If the clearance is not correct, the knockout
bar must be adjusted.

.
-
.
If
’ .
.:_~D
_.


ENLARGED VIEW
KNOCKOUT BAR AND
ADJUSTMENT
VIEW OF KNOCKOUT ASSEMBLY
Two %” Wrenches, Feeler Gage
1.
2.
Raise the front guard until the latch engages the bottom of the guard.
Lower the ram with a ﬂywheel rod until it is at the bottom of the
stroke.
Use a 78" wrench to loosen the lock nuts on top of the bottom part
of the knockout bar.
Use a %" wrench to adjust the knockout bar by turning the bottom
adjusting screws until there is a .004" clearance between the knockout
bar and the emergency release pin.
. Tighten the lock nuts against the knockout bar.
Raise the ram by turning the ﬂywheel with the ﬂywheel rod.
. Release the latch on the bottom of the guard and allow the guard to
drop back into position.
I 24 l
CALIBER .30 SECOND DRAW CASE Adjustments
Clutch Lever Spring When the clutch lever is released, it is pulled up by the clutch lever spring.
This action should disengage the clutch and release the brake lever so the
brake shoe can be pressed against the brake drum. If the spring does not
perform its function, the tension must be increased.


V .- .i
ENLARGEMENT OF
BRAKE SPRING


REAR VIEW: CLUTCH LEVER
SPRING CIRCLED
Tools: Two 78" Wrenches
Procedure; 1. Use a %” wrench to loosen the lock nut on the adjusting screw.
2. Use a %;” wrench to turn the adjusting nut until the tension on the
spring will draw the kick-out cam ﬁrmly against the clutch housing
when the clutch is disengaged.
3. Use a %” wrench to hold the adjusting nut while tightening the lock
nut, using another 78" wrench.
I25}
CALIBER .30 SECOND DRAW CASE
Adjustments
Friction Ball Spring
Replacement
The friction balls backed up by springs form the stations for the cases in
the feed track. If the springs become worn or dirty, the cases will not
travel smoothly along the feed track. This necessitates removal of feed
track guides, cleaning of the springs, and the replacing of worn springs.
TOOIS:
Procedure: 1.


FEED TRACK DISASSEMBLED
%” Allen Wrench, 5%” Allen Wrench, %" Wrench, 8" Screwdriver
Raise front guard until latch engages on the bottom of the guard.
2. Remove the feed tubes from the bridge by turning the bayonet
10.
11.
ﬁttings by hand until disengaged.
Use a 1%” wrench to remove the nuts from each end of the bridge
and remove the bridge from the machine.
Use a %" Allen wrench to remove all of the Allen screws in each side
of the feed track, also the screws in the back stop. Lift the feed
tracks and the back stops from the machine.
Use an 8" screwdriver to remove the screws from the sides of the feed
track. Lift the plate from the feed track.
. Remove the ball bearings from the top of the springs.
. Lift the springs out, and inspect for tension and breakage.
Put a drop of oil on the springs and replace in the feed track. Place
the ball bearings on top of the springs and replace the feed track plate.
Caution: Watch that the ball bearings do not bind while the plate is
being replaced.
Replace the tracks in the machine and tighten the Allen screws.
Replace the back stops and tighten the Allen screws.
Release the catch on the guard and lower it in place.
I 26 I
CALIBER .30 SECOND DRAW CASE
Adjustments

Die Replacement
Tools:
Procedure:
The dies may become worn causing the case to be too large in diameter
or may become scratched causing scratches on the outside of the case.
In either case the die must be removed and replaced with a new die.

DIE BLOCK DISASSEMBLED
Screwdriver
1.
2.
3.
Remove the rear guard by lifting up and pulling out on the bottom.
Lift out the die block lock pin.
Pull out the die block keeping one hand underneath to prevent stripper
from dropping out.
Turn the die block upside down allowing the dies to fall out into your
hand. Turn the die block right side up.
Slide the die block back in the machine part way while getting new dies.
Replace the dies in the die block making sure that the bottom die is
on the bottom with the tapered end down.
Push the die block back in the machine and replace the die block lock
pin.
Replace the guard.
Check for accuracy by drawing a case.
[27]
CALIBER .30 SECOND DRAW CASE
Adjustments

Punch Replacement
Tools:
Procedure:
The punch may become worn causing the inside of the case to be too small
in diameter or may become scratched causing scratches on the inside of
the case. In either case the punch must be replaced.

as
PUNCH DISASSEMBLED
1%" Wrench
1.
Remove the rear guard by lifting it up and pulling it out away from
the machine.
Use a 1%” wrench to remove the gland nut in the punch holder while
holding the punch with the other hand. ~
Pull down on the punch removing the assembly from the punch holder.
Remove the bushing, gland nut, and the split collar from the worn or
broken punch and place these parts on the new punch making sure
the wide shoulder on the split collar is up.
Insert the punch assembly in the punch holder and tighten the gland
nut.
Caution: Be sure that the punch is clean.
Replace the rear guard.
Check the replacement for accuracy by drawing a case.
[28]
CALIBER .30 SECOND DRAW CASE Adjustments
Pin wheel Bridge In order to adjust the position of the bridges in relation to the pins on
the pin wheel, each bridge can be adjusted by the vertical bolts connected
to the bridges. Each bolt adjusts one of the bridges and should be adjusted
so that the cases will travel along the bridge to the feed mouth. If the
bridges are not properly adjusted, the cases will fall from the pins before
arriving at the feed mouth, or will jam along the bridge.

_ Four Bridge -
I ‘ _: Adjustment
I ‘ "uh
HOPPER BRIDGE AND FEED TUBE MOUTH ASSEMBLY
Tools: Two 1%" Wrenches
Procedure: 1. Open the hopper inspection gate by pulling down on the gate.
2. Use two 1%.” wrenches to hold the top nut with one wrench and
loosen the bottom lock nut on the vertical adjusting bolt with the
other wrench.
3. Turn the adjusting nut until the bridge is approximately %" from the
pins on the pin wheel.
4. Tighten the lock nut while holding the adjusting nut in place and close
the hopper inspection gate.
5. Check the adjustment for accuracy by turning on the power and
observing whether or not the cases fall properly down through the
feed tube.
[29]
CALIBER .30 secono DRAW CASE Adjustments
Hopper Feed Tube The feed tube mouth receives the cases after they travel the length of the
Mouth pin wheel bridge. The mouth should be in line with the pins on the pin
wheel so that the cases will drop from the pins into the feed tube mouth.
If the mouth is not properly adjusted, the cases will jam at the feed
mouth. Adjustment is made on the adjusting bolt that connects the feed '
tube mouth to the pin wheel bridge.


INSIDE VIEW SHOWING THE BRIDGES AND FEED TUBE MOUTH
Tools: %” Wrench
Procedure: 1. Open the hopper inspection gate by pulling down on the gate.
2. Use a %" wrench to loosen the set screw on the bottom of the feed
tube bridge.
3. Adjust the feed tube mouth by hand until it is in alignment with the
pins on the pin wheel, and tighten the set screw.
4. Check by turning on the hopper motor and observing the action of the
cases.
5. When accuracy has been attained, close the inspection gate.
[30]
CALIBER .30 SECOND DRAW CASE
Troubles and Corrections

Objective
Scored or Scratched
Walls
Crooked Draw
TROUBLES AND CORRECTIONS
The adjuster will meet many troubles and defects in the operation of this
machine. It is impossible to anticipate all the problems that may con-
front an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
Recognition of the following troubles is made by visual and gage inspection
of the component together with constant observation of the machine as
it operates.
Visual inspection will reveal scratches on the inside or outside walls of
the case. Finger nail inspection is especially valuable in detecting
scratches on the outside wall.
The causes are:
The corrections are:
1. Foreign matter (dirt, grit, shav- 1. Remove the cooling solution,
ings, etc.) in the cooling solution. clean the reservoir, replace with
clean cooling solution.
2. Foreign matter (dirt, dried soap, 2. Send the cups to the Washing
etc.) on the cases. Department to be rewashed.
3. Chipped punch—a piece broken 3. Replace with a new punch.
off the end of the punch.
4. Skinned punch—punch surface 4. Polish the punch if it is not too
marred. badly skinned. If it is beyond
repair, replace with new punch.
5. Cracked die—fracture in the 5. Replace with new die.
cross section of the die.
6. Scratched die—scratched on the 6. Polish the die if the scratch is
inside surface of the die.
not too deep, or replace with a
new die if necessary.
Gaging discloses uneven sidewall thickness, crooked tops, or uneven
bottoms.
The causes are:
The corrections are:
1. Bent punch. 1. Straighten the punch in an arbor
press. If it cannot be straight-
ened, replace with a new punch.
2. Worn die—drawing surface too 2. Replace with a new die.
large or irregular.
3. Foreign matter (dirt, shavings, 3. Remove the die and the die
burrs, etc.).
block. Clean with a rag and
replace.
[311
CALIBER .30 SECOND DRAW CASE
Troubles and Corrections
Crooked Draw 4. Improper anneal—cups either 4. If too hard, return to Annealing
(Cont.)
Thick Bottom
Thin Bottom
Punch Outs
Department to be reannealed; if
too soft, call inspector and check
source of supply.
annealed too hard or too soft.
Gaging discloses insufficient material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Not enough angle on taper of 1. Replace with new punch.
punch.
2. Radius on end of punch insuffi- 2. Replace with new punch.
cient.
Gaging indicates too much material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Too much angle on the taper of 1. Replace with new punch.
the punch.
2. Radius at the end of the punch 2. Replace with new punch.
too great.
Visual inspection discloses that the bottom of the case is punched out or
the side of the case is deformed by the punch.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by,
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Improper anneal—the case met- 1. Send to the annealing room.
al is too hard.
This cannot be corrected. Check
source of supply and call in-
spector.
2. Improper anneal—the case met- 2.
al is too soft.
3. There is no radius on the punch. 3. Replace with a new punch.
The punch is too large on the
drawing end.
4. The die is upside down. The die 4.
is not placed in the die block
properly.
Remove the die and replace it in
the proper position.
[32]
CALIBER .30 sscono DRAW CASE Troubles and Corrections

Short Case Gaging discloses the case is not long enough and the walls are too thick
to meet speciﬁcations.
The causes are: The corrections are:
1. The die is too large—it is over- 1. Replace with a new die.
size in the drawing surface.
2. Punch is too small. 2. Replace with a new punch.
Long Case Gaging discloses the case is too long and the walls too thin to meet
speciﬁcations.
The causes are: The corrections are:
1. The die is too small—undersize 1. Lap out the die to the proper
in the drawing surface. size.
2. The punch -is too large. 2. Replace with a new punch.
Sheared Tops Visual inspection discloses that the mouth of the case is torn or uneven.
The causes are: The corrections are:
1. Improper annealing——-case metal 1. Send to the Annealing Depart-
too hard. ment to be reannealed.
2. Faulty stripper——stripper bro- 2. Repair, or replace with new
ken. stripper.
3. No stripper. 3. Insert stripper.
Undersile Diameter Gaging discloses diameter of case undersize.
The cause is: The correction is:
1. The die is too small—undersize 1. Lap out the die to proper size.
in the drawing surface.
Qversile Diﬂmeler Gaging discloses diameter of case is oversize.
The cause is: The correction is:
1. The die is too large——it is over- 1. Replace with a new die.
size in the drawing surface.
Wrinkled MQUII1 Visual inspection discloses mouth of case wrinkled and uneven.
The causes are: The corrections are:
1. Rough punch—surface of punch 1. Polish and remove brass from
has excess coating of brass. punch.
2. Faulty stripper—-stripper bro- 2. Repair or replace with new
ken. stripper.
3. Rough or ringed die———rough spot 3. Lap die if possible, or replace
or brass coating on drawing with new die.
surface of die.
4. No stripper. 4. Insert stripper.
I33]
CALIBER .30 SECOND DRAW CASE Troubles and Corrections
Uneven Flow of Visual inspection discloses that cases are not ﬂowing through the feed
Cases from Hopper tube and feed tracks.
The causes are: The corrections are:
1. Defective or long cases—cases 1. Remove cases from hopper and
from previous draw to long or check source of supply.
defective.
2. Cases jammed in feed tube. 2. Clear feed tube.
3. Foreign matter (dirt, shavings, 3. Clean and check source of slip-
etc.). ply.
4. Feed ﬁnger burred. 4. Repair feed ﬁnger or replace
with new feed ﬁnger.
5. Broken feed ﬁnger operating rod 5. Replace with new springs.
springs.
6. Arm in pin wheel hopper loose. 6. Tighten arm.
Case Tracks Visual inspection discloses cases not properly traveling along case tracks.
Damaged
The causes are: The corrections are:
1. Improper adjustment. 1. Proper adjustment.
2. Broken springs. 2. Replace with new springs.
Hopper Jam Visual inspection discloses cases are not feeding through hopper to feed
tube properly.
The causes are: The corrections are:
1. Over1oaded——too many cases in 1. Remove excess cases.
hopper. >
E“
2. Cases stuck to pins in pin wheel Clear hopper and check pins for
hopper. burrs.
3. Bolt slips-—loose belt, oily belt. 3. Tighten belt; if oily, clean.
Slow Press A lowered production rate may indicate that the stroke of the press is
slowed down.
The causes are: The corrections are:
1. Dry bearings. 1. Check the lubrication. Call
Maintenance Department.
2. Galled gibs. 2. Check the lubrication. Call
Maintenance Department.
3. Loose belt. 3. Adjust the motor on the slides.
I34]
CALIBER .30 SECOND DRAW CASE Troubles and Corrections

Clutch Clicks Visual inspection discloses that the clutch does not operate properly.
The cause is: The correction is:
1. Bent or broken pins, rods or 1. Call Maintenance Department.
springs. The clutch dog will not-
release properly.
Motor Stops Visual inspection discloses the motor is not running and the press is
stopped.
The cause is: The correction is:
1. Overload or burnt out armature, 1. If the machine is overloaded,
bearings, etc. clear the cause of the overload;
press the reset button to start
the motor. If there is any other
cause for the motor to stop, shut
off the power; call the Main-
tenance Department.
[35]
CALIBER .30 SECOND DRAW CASE
Tool Servicing
Objective
Servicing New Dies
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the
drawing of the bullet jackets and cartridge cases. Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters will be concerned primarily with the removal of brass and
small scratches that appear on working surfaces of dies and punches, and
they must be careful, when using an abrasive on any tool, not to alter
materially its dimensions.
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1. Dies as received from the tool room are normally undersize to allow
for expansion pressure and for lapping to a desired size when necessary.
2. The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
3. As a precaution, before a test run is made, the die bore should be
inspected for roughness and polished if necessary. If the bore is rough
causing undue friction, more metal than is necessary may be pulled
from the bottom of the jacket or case at the start of the draw.
4. The product from the test run should be carefully gaged and inspected.
Then, and then only, if an undersize or out-of-true die is indicated,
should the die be lapped.
5. If trial in the machine shows that the die is undersize, place it in a
three jaw chuck on a speed lathe to lap it.

OVER-ALL VIEW OF SPEED LATHE
I36]
CALIBER .30 SECOND DRAW CASE
Tool Servicing

CORRECT METHOD OF PLACING
Lapping Procedure
6.
Check the die to see that it is straight and secure in the chuck.

FIG. 1 FIG. 2
INCORRECT METHOD or PLACING
DIE IN CHUCK DIE IN CHUCK
1. When lapping is necessary, proceed as follows: Use a lap stick made
of brass, lead, ﬁber or wood about the same diameter as the die hole.
2. Dip the lap stick in a solution of #120 emery dust and olive oil or
coal oil.
3. Hold the lap stick as nearly as possible in line with the angle of the
taper. When lapping the land, hold the stick at a right angle to the
mouth of the die to keep the land true. A land which is not true
causes irregular wall thickness and crooked tops on jackets and cases.
4. While holding the lap stick against the die, give the stick a rapid in
and out movement. This cuts down the ridges left by the grinder
wheel in the metal surface and makes it smoother. Repeat this
operation according to the amount of metal that must be taken out
of the die.
5. Wipe the die clean with a cloth.
6. Next, polish the die with the ﬁnest grade of emery cloth available,
not coarser than #220.
7 . Finish the polishing operation with crocus cloth.
8. Wipe out the inside of the die again with a cloth.
9. Remove the die from the chuck and check the size of the die with a
plug gage.
10. Be sure the die is free of all emery dust before replacing it in the
Carboloy Dies
machine for production.
To lap a carboloy die, follow the same procedure, with diamond dust
and olive oil instead of emery dust.
I37]
CALIBER .30 SECOND DRAW CASE
Tool Servicing

Servicing Scratched
Dies
Servicing a New
Punch
Lapping
1. Before removing a die from a machine to look for scratches, remove
the stripper to determine whether the stripper, rather than the die, is
scratched.
2. Check the die or stripper visually to determine how badly it is
scratched. If the die or stripper has a very deep scratch, it should be
sent to the Tool Service Department.
3. If it is found that the scratch is in the die, check the die with a die
“wear limit” plug gage to determine how much metal can be worked
out of it without making the die too large.
4. To polish the die, place it in a three jaw chuck on a speed lathe.
5. Polish it with ﬁne emery cloth, then with crocus cloth.
6. If the scratch can’t be removed by polishing, the die must be lapped.
See lapping procedure, or send to the Tool Service Department if
necessary.
7. Check the die size with the “wear limit” plug gage before putting it
into production.
Before an abrasive of any kind is applied to a new punch its dimensions
should be carefully checked with micrometer or proﬁle gage, and its
working surface should be examined for ﬁnishing or handling marks and
lack of polish. A highly polished punch aids in stripping and allows metal
to ﬂow freely thereby reducing the tendency of brass to pile up on the
working surface.
An Adjuster will not be required to lap more than .0005” from a new
punch. If more than this must be removed to bring the punch to size, it
should be returned to the Tool Service Department for correction. Lap-
ping is done with a piece of abrasive cloth wrapped around and moved
back and forth along the axis of the punch as it revolves in a speed chuck.
If the abrasive were held stationary, deep rings would be cut into the
surface, thereby ruining the ﬁnish.
The punch is shown in Fig. 1 correctly chucked, and in Fig. 2 incorrectly
held (See page 37). Avoid excessive overhang of the punch as this is a
safety hazard; make sure that the jaws are correctly set and tightened
securely. Do not allow the jaws to grasp the working surface of the punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with cross-hatched effect.
[38]
CALIBER .30 SECOND DRAW CASE
Tool Servicing
Polishing


Servicing a Used
Punch
The lapping operation must be followed by polishing. Polishing is done
in the same manner as lapping except that a ﬁner abrasive is used, as for
example, crocus cloth. A ﬁnal operation called draw polishing is done with
the chuck stopped. To draw polish a punch move the abrasive cloth
lengthwise over the entire working surface avoiding rotary motion of the
punch or the abrasive. Continue this ﬁnal operation until all lapping
marks are removed and the-desired high polish or mirror like ﬁnish is
obtained. '
FIG. 3
CORRECT METHOD OF PLACING
PUNCH IN CHUCK
FIG. 4
INCORRECT METHOD OF PLACING
PUNCH IN CHUCK
As a punch is used its working surface wears accumulating scratches and
a coating of brass. Excessive wear is determined by measuring with
micrometer or checking with proﬁle gage. Obviously, an undersize punch
must be replaced with one of approved dimensions. Scratches, if not too
severe, may be removed by the lapping and polishing operations described
above. A light coating of brass may be removed by the polishing operation
alone. The question of how soon a new punch will need lapping or
polishing can be answered only from experience since many variable factors
enter into the problem.


[39]
CALIBER .30 SECOND DRAW CASE
Machine Lubrication
Friction
lntrod ucing
Lubricating
Film Reduces Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efﬁciency of all machines depends, to a great extent, upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction as far as we are concerned
here, is the force that resists the sliding of one surface over another. It
makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
(1) Petroleum oils and greases. Petroleum oil or crude oil is a mineral
oil that is pumped from the earth.
By various degrees of reﬁning, oils of different properties are obtained for
the thousands of different types of lubrication needed in industry.
Lubricating grease is a compound of petroleum oil and soap.
(2) Vegetable oils and animals oils are mixed with petroleum oils for
many applications.
(3) Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction. We thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts. ‘
I40]
CALIBER .30 SECOND DRAW CASE
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.*9°P‘F‘9°P°
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed
of the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage, and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive Oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable, where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen, good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs sp that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.*?*P‘P‘P°P°
Frequency of lubrication.
[41]
CALIBER .30 SECOND DRAW CASE
Machine Lubrication
Methods of Getting
Lubricant to Bearing
Surface
Hints on Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
2. Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
P°.'q.°‘.¢"tl>‘°°
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
. Screw down cups.
. Compression cups.
1
2
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5
. Grease packing.
A systematic control of all lubrication is important. Lubrication must
be done periodically and lubrication cups must be kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubri-
cation.”
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁttin , before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the floor.
A grease gun should be in one of two places—in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times except when
the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way into a
grease barrel can be easily forced into a bearing and cause the machine
to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think that it
should be changed, take it up with your supervisor.
I42]
CALIBER .30 SECOND DRAW CASE Machine Lubrication


‘ LUBRICATION CHART
No. of Fittings, Frequency of
Lubricant Machine Part Grease Cups, Lubrication
Etc. Hours
Crankshaft Bearings 2 8
Pitman Bearing 1 8
LIGHT GREASE Gibs 4 8
(Blue Gun) Clutch Assembly 1 8
Hopper 1 24
Connecting Screw Knuckle 1 8
Flywheel and Clutch 1 8
Feed Finger Assembly 4 8
Feed Finger 6 8
MEDIUM OIL Detector Punch Assembly 5 8
(Red Oiler) Clutch Lever 7 24
Brake Assembly 6 24
Brake Shaft 2 24
HEAVY OIL Wrist Pin Reservoir 1 24
(Yellow Oiler) Worm Gear Drive for Hopper 1 1 wk.

[43]
CALIBER .30 SECOND DRAW CASE
Index
Adjustable Bracket, 3, 4
Adjustment, Brake Release Rod, 19,
20
Brake Spring, 21
Clutch, Lever Spring, 25
Detector Stem, 22
Die Replacement, 27
Feed Fingers, 23
Friction Ball, Spring Replacement,
26
Hopper Feed Tube Mouth, 30
Knockout Bar, 24
Pin Wheel, Bridge, 29
Punch Replacement, 28
Annealing Department, 16
Anvil, 11
Back Stops, 9
Ball Spring Stops, 9
Bayonet Bushing, 10
Fitting, 23
Bolster Plate, 9, 10
Bottom Die, 13
Draw Die, 12
Thickness, 16, 17
Brake, 3, 5, 19
Action, 2
Adjustment, 20
Assembly, 2, 20
Drum, 2, 20, 21, 25
Lever, 19, 25
Release Rod, 19, 20
Release Rod Adjustment, 19
Rod, 21
Shoe, 2, 20, 21, 25
Spring, 20
Spring Adjustment, 21
Spring Rod, 21
Bridge, 26, 29
Bushing, 28
Button Anvil, 11
Case Tracks Damaged, 34
Cautions, 18
Clutch, 2, 3, 5, 19, 20, 22
Clicks, 35
Handle, 2
Lever, 2, 3, 5, 6, 19, 21
Lever Adjustment, 25
Lever Latch, 3
Lever Spring, 25
Lever Trip, 22, 24
Coating of Brass, 39
Coil Springs, 3
Component, 16
Connectmg Rod, 2, 6
Controls, 3
Cooling Solution, 1, 3
Counterbalance Springs, 6
Crankshaft, 2, 6
INDEX
Crankshaft——Cont.
Speed, 1
Crocus Cloth, 39
Crooked Draws, 31
Heads, 17
Tops, 17, 37
Defect, Case Tracks, Damaged, 34
Clutch Clicks, 35
Crooked Draw, 31
Hopper Jam, 34
Long Cases, 33
Motor Stops, 35
Oversize Diameter, 33
Punch Outs, 32
Scored Walls, 31
Scratched Walls, 31
Sheared Tops, 33
Short Cases, 33
Slow Press, 34
Thick Bottoms, 32
Thin Bottoms, 32
Undersize Diameter, 33
Uneven Flow of Cases from Hop-
per, 34
Wrinkled Mouths, 33
Defective Cases, 17
Defects, 17
Detector Stem, 3, 5, 24
Stem Adjustment, 22
System 3, 5, 22, 24
Dial Indicator, 17 -
Die, 23
Block, 12, 27
Block Assembly, 12
Block Base Plate, 12
Block Lock Pin, 27
Plug Gage, 36
Replacement Adjustment, 27
Dies, 27
Disposal, 14
Draw Polishing, 39
Emery Cloth, 38
Dust, 37
Excessive Wear. 40
Feed Finger, 9, 14
Fingers Adjustment, 23
Motor, 1
Mouth, 29
Socket, 23
Track, 5, 14, 22, 23, 26
Track Guides, 26
Tracks, 3, 9
Tube, 2, 14, 29
Tube Bridge, 10
Tube Mouth, 30
Tubes, 3, 10, 23
First Trim Machine, 16
Floor Space, 1
Flow Chart, 15
Flywheel, 2, 6, 22
Rod, 22
Foreign Material, 22, 24
Friction, 40
Balls, 26
Ball Spring Replacement Adjust-
ment, 26
Gage Care, 17
Gages, 17
Gaging, 33
Gland Nut, 11, 28
Glass Guard, 2
Go Ring, 17
Graphite, 41
Greases, 41, 42
Guard, 2
Heavy Oil, 40
Hints on Lubrication, 43
Hopper, 1, 2
Box, 2, 7
Door, 7
Feed Tube Mouth Adjustment, 30
Inspection Gate, 29, 30
Jam, 34
Motor, 3, 7, 30
Inside Diameter, 16, 17
Inverted Case, 22, 24
Irregular Wall Thickness, 37
Key, 11
Knockoff Bar, 3, 5
Knockout Bar, 22, 24
Knockout Bar Adjustment, 24
Lap Stick, 37
Lapping, 37, 38, 39
Latch Pin, 6
Pin Catch, 6
Light Grease, 40
Lock Pin, 12
Long Cases, 33
Lubricating Grease, 41
Lubrication, 4, 14, 41
Methods, 42
Machine Motor, 1
Maintenance Costs, 40
Department, 18
Manufacturers Name, 1
Medium Oil, 40
Micrometer, 39
Motor, 2, 3
Stops, 35
No Go Ring, 17
Oil Cups, 4
Holes, 4
Outside Diameter, 16, 17
Overall Height, 1
Overall Length, 16
Overhead Hopper, 14
[44]
CALIBER .30 SECOND DRAW CASE
Index
Oversize Diameter, 33
Petroleum Oils, 41
Pin Rings, 8
Wheel, 30
Wheel Bridge, 8, 30
Wheel Bridge Adjustment, 29
Wheel Hopper, 3, 7, 14
Wheel Hopper Box, 14
Plug Gage, 17
Plunger Rod, 9
Polishing, 39
Operation, 37
Power, 2
Production, 1
Proﬁle Gage, 39
Pump, 1
Motor, 2, 3
Punch, 3, 11, 13, 14, 23, 28, 38
Block Assembly, 11
Holder, 11, 28
Holder Block, 11
Outs, 32
Punch—Cont.
Replacement Adjustment, 28
Push Rod, 23
Ram, 3, 5, 6, 14, 20, 22, 23, 24
Reservoir, 3
Rocker Arm Assembly, 9
Shaft, 9
Scored Walls, 31
Scratched Walls, 31
Scratches, 17, 39
Selecting a Lubricant, 41
Servicing a New Punch, 38
A Used Punch, 39
New Dies, 36
Scratched Dies, 38
Sheared Tops, 33
Short Cases, 33
Sidewall Variation, 16
Sleeve, 11
Slow Press, 34
Speed Lathe, 36
Split Collar, 11, 28
Stripper, 12, 13, 14, 27
Holder, 12, 13
Stroke, 1
Switch, 2
Test Run, 36
Thick Bottoms, 32
Thin Bottoms, 32
Three Jaw Chuck, 36
Toggle Type Switches, 3
Top Die, 13
Top Draw Die, 12
Transmission, 2
Twin Ring Gage, 17
Type of Feed, 1
Undersize Diameter, 33
Die, 36
Punch, 39
Uneven Flow of Cases, Hopper, 34
V Belt, 2
Visual Inspection, 17 , 31
Washing Department, 16
Wrinkled Mouths, 33
I45]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Bumping Machine

BY
Training Department
Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 194-1
United States Government Contract
W-ORD-481, Title II

PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminolo.gy for the
machines and machine parts used in the manufacture of _small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAL CORRECTlONS—CALIBER .30 BUMPING MACHINE
LOCATION
Page 11 -—Fig
and 115
Page 20—Fig
Page 1 7 —
Cautions
Page 20--Fig
Page 21 —Fig
Page 23—P1-oc 3
Page 18- 1] 2
ERROR
Flat Punch
Wrong Figure
Locknuts
Adjusting Screw Locknuts
Tighten the Spanner nuts against the brake
Case is headed
CORRECTION
Convex Punch
Figure of Bump die block assembly
Omit 4 and 7
Adjusting Screw
Lockscrew Adjusting Screws
Tighten the Spanner nuts against the bracket
Case is bumped
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . .~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tool Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjustments . . . . . . . . .- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
III

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.30 BUMPING MACHINE
VIEW OF CALIBER
IV
CALIBER .30 BUMPING MACHINE
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Feed Motor
Production
Crankshaft Speed
Stroke
Tools
Height
Weight
Floor Space
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, N. Y.
E. W. Bliss Co. Horizontal Crank and Toggle
press 5V, belt drive motor to ﬂywheel on crank-
shaft.
5 h.p.; 3 phase; 60 cycle; 220/440 volt; 870 R.P.M.
Pedestal type pin wheel hopper mounted on ma-
chine. Belt driven from motor. 7 R.P.M.
Gear head % h.p. ; 1 phase; 60 cycles; 1725 R.P.M.
105 per minute.
105 R.P.M.
Front ram 8", back ram 6%".
Piece No.:
Punch E- 9
Die E-10
Injecting Stem E- 1
7 ft. 2 in.
8,000 lbs.
7 ft. 9 in. x 3 ft. 10 in.
[1]
CALIBER .30 BUMPING MACHINE Machine Description
MACHINE DESCRIPTION
The caliber .30 Bumping Machine Bumps the bottom of the case to pro-
duce a ﬂattened or slightly concave bottom. This operation is necessary
to change the contour of the bottom and produce a uniform bottom
thickness on each case.
Hopper
H
opper / Box
Motor


Machine ,_.;
Mom‘ _____‘__—- Pin Wheel
' Hopper
Guard
Covering
Flywheel
CALIBER .30 BUMPING MACHINE
Power and The E. W. Bliss Horizontal Crank and Toggle Press, illustrated above, is
Transmission powered by a 5 h.p. motor through ﬁve V-type belts connecting the motor
to the ﬂywheel.
The Horizontal Crank and Toggle Press presses the convex surface of the
case head inward so that the head of the case is concave after the bumping
operation. This operation is performed to distribute the metal evenly
throughout the case head.
The motor is mounted directly above the ﬂywheel on an adjustable
bracket, which allows proper adjustment of belt tension. The ﬂywheel is
mounted to the front or bumper ram crankshaft at the front of the ma-
chine.
[2]
CALIBER .30 BUMPING MACHINE
Machine Description

Power and
Transmission
(Cont.)
Brake
Bumper Ram
Knockoff Wire
Stem Ram
Eccentric Cam and
Rocker Arms
Pin Wheel Hopper
Lubrication
The motor is controlled by a push button type switch; the red button
breaks the circuit and the black button closes the circuit. As no clutch is
employed on this type machine, the machine is started by releasing the
manually operated brake and pressing the starter switch.
The brake is manually controlled through linkage from the brake operating
arm to the brake shoes. The brake operating arm is held in a horizontal
position directly above the die holder. The brake linkage is equipped with
an arm which acts to break the electrical circuit to the motor when the
brake is applied. As the electrical circuit is broken, the shoes are applied
to the front and rear face of the ﬂywheel to stop the machine action.
The front or bumper ram is supported by and travels on two 45° angle gib
plates. The bumper ram is connected to and actuated by a connecting rod
attached to the front crankshaft throw. The face of the ram is machined
to hold the tool holder.
A knockoff wire is attached to an operating arm which is actuated by a
cam roller attached to the bumper ram, and extends out from the rear
edge of the machine frame to a position directly above the case as it is
discharged from the die. The discharged case is knocked into the bottom
of the machine bed where it passes out onto a conveyor belt leading to
the elevator by means of a knockoff wire, which is actuated by the bumper
ram on every stroke of the ram.
The stem ram or back ram is connected to and actuated by a connecting
rod attached to the rear crankshaft. The ram face is machined to hold the
working tools. The ram is supported by and travels on two 45° angle gib
plates which are bolted to the machine frame in a horizontal position.
The power is transferred from the front crankshaft to the rear crankshaft
through two rocker arms and an eccentric cam.
The pin wheel hopper is mounted on a supporting bracket located at the
rear center of the machine. The cases are fed into the hopper box from an
overhead chute, and are agitated in the hopper by a manually oper-
ated lever, which extends through the bottom of the hopper to a posi-
tion within easy reach of the operator. The cases are fed to the machine
through a feed tube, to the feed sleeve, from the feed sleeve into the die.
As each case is fed into the die, it discharges the preceding case from the
die.
The machine is lubricated by means of Alemite-Zerk ﬁttings attached to
the various working parts.
The gibs and other exposed parts which have a tendency to overheat
quickly should be oiled frequently with an oil can containing the appro-
priate grade and viscosity of lubricant.
CALIBER .30 BUMPING MACHINE Machine Description


Stem Bumper
Crankshaft‘ 7r I Y l I ‘L > "hi :5 '_ .“.. '~ it .'.1_ ‘ \?' il§‘CrankshaIt
....
Rocker
Rocker I _
Arm
Arm ,,
Eccentric ’
Cam
ECCENTRIC CAM AND ROCKER ARMS
Eccentric Cam and The power is transmitted from the front, or bumper crankshaft, through
Rocker Arms two rocker arms and an eccentric cam to the back or stem ram crankshaft.
The bumper crankshaft turns 360° or, in a complete revolution. A rocker
arm leads from the crankshaft to a point off center on the eccentric cam.
The eccentric cam is mounted on a stub shaft at the back center of the
machine. A second rocker arm shaft, attached to the off center point on
the cam, leads to the back or bumper stem crankshaft. The motion of the
bumper crankshaft, by use of the rocker arms and eccentric cam, is trans-
formed from a 360° revolution to a 90° are at the bumper stem crankshaft.
[4l
CALIBER .30 BUMPING MACHINE Machine Description


Spanner ‘B’ - __. g I t . I’
NUIS .; --
, ~' f‘ . _ Knockoff
. - ﬁg . ~ k ,_ . v‘ Wire
Set
Screw
, Springs
Feed
/ Tube
Allen
I _ Set Screw
RAMS, TOOL HOLDERS AND CRADLE
Rams The face of each ram is machined to hold a tool holder. The bumper ram
contains the tool holder which holds the bumping punch. The tool holder
incorporates two spanner nuts, which allow an adjustment to be made on
the bumper tool. The stem ram contains the tool holder which holds the
injecting stem. Two spanner nuts are incorporated in the tool holder which
allow an adjustment to be made on the injecting stem.
[5]
CALIBER .30 BUMPING MACHINE Machine Description

~ ova-*
1 la '1‘-


Brake shoe
pt.
1%” Lock Nut
3%" Adjusting
Screw
11/4" Lock Nuts
3/4" Adjusting
Screws
BRAKE ASSEMBLY
Brake The brake shoes are attached to a bracket, which holds the shoes in posi-
tion against the inner and outer surface of the ﬂywheel. The brake shoe
operating lever, which is connected to the brake shoes by a series of con-
necting links, applies the brake shoes against the ﬂywheel to stop the ma-
chine, when the brake lever is pulled back. A small trip arm, attached at a
right angle to the vertical brake shaft, breaks the electrical circuit by con-
tacting an auxiliary switch when the brake is applied. The switch is at-
tached to the back side of the frame at the right end of the machine.
[6]
CALIBER .30 BUMPING MACHINE Machine Description

Spanner H
Nuts - _ Knockoff
Wire
Set
Screw ’ smmgS
Bumper
Tool ’
Holder Feed
/ Tube
Ram /
Allen
_ Set Screw
Cap
Die Screw
Block
Ram
Stem Front
Tool __ - i|panner
Holder "‘
Back
- Spanner
Nut
RAMS, ~TOOL HOLDERS AND CRADLE
Die Block and The die block is incorporated in the machine frame and is located between
Feed Slide the two rams. The feed cradle is attached to the top surface of the die
block. The feed tube leads to the cradle from which the cases are fed into
the feed sleeve. The cases drop through the feed sleeve in alignment with
the inserting stem on the stem ram, which injects them into the die. The
bumper punch travels forward to bump the head of the case and form the
concave surface. The next case, as it is inserted into the die, ejects the
preceding case from the die into the chute leading to the conveyor.
[7]
CALIBER .30 BUMPING MACHINE
Machine Description
Pin Wheel Hopper
and Hopper Box


The pin wheel hopper box is a one-piece casting with a bottom sloping
toward an adjustable gate, which leads into the pin wheel hopper. The
pin wheel hopper is attached to the front of the hopper box. The pin wheel
consists of a pin ring, an inner and an outer dish-shaped rim bolted to-
gether to form a hopper assembly. The outer dish-shaped rim has three
spokes attached to a hub shaft on which the entire hopper revolves. The
hopper is driven by a V-type belt connected to a %; h.p. motor. The motor
is supported by an adjustable bracket to maintain proper belt tension.
The pin ring has a series of steel pins, spaced approximately 1" apart on its
inner circumference and set at an angle to the radii. A steel band rake-off
keeps the components that are not properly seated on the pins from enter-
ing the bridge. As the hopper revolves clockwise, the cases slide onto the
steel pins, and approach a vertical position, with the mouth end down.
When the components approach the upper arc of the circumference, they
contact and are held on the pins by the bridge. In this position they are
nearly mouth end up. At the end of the pin wheel bridge they are in a
vertical position and slide off the pins into an adjustable feed tube mouth,
and are carried by gravity down the feed tube to the feed sleeve.
Hopper Box
Steel Pins

Hopper Door
____-—- Latch
Dish-shaped
Hopper Door


Y ‘ ~ irllu-i.|'u\;n‘
U‘!
2
=
n
:-
__.___-—— Feed Tu be
CLOSE UP or PIN WHEEL HOPPER
[8 l
CALIBER .30 BUMPING MACHINE
Tool Holder Description

Die Block
Assembly
TOOL HOLDER DESCRIPTION
Die: The die is cylindrical, approximately 4" long and 3" in diameter,
with a longitudinal hole through the center, which tapers from the mouth
to the head of the die.
Bushing: The bushing is a hollow cylinder that ﬁts in the die block and is
used as a spacer between the die block and the die.
Anvil: The shape of the anvil is similar to a washer with a hole through
the center to permit the passage of the case through it as the case is fed
into the die. The anvil ﬁts in the die block directly behind the bushing.
It absorbs shock and prevents wear on the die block.

§\\\\\\\\\\\\\W
7
/
'\
V%%/////////J
/
W
/////%z
Anvil

/
.\\\l
e\\\\\‘
CROSS-SECTIONAL DRAWING OF DIE BLOCK ASSEMBLY
Bushing
CALIBER .30 BUMPING MACHINE Tool Holder Description
Injecting Stem Rear Spanner Adjusting Nut: The rear spanner ad-
Assembly / justing nut determines the forward adjustment of the
V injecting stem holder, and is the same as the front span-
ner nut with the exception that it is thicker. Care must
be exercised in assembling the injecting stem holder to
get the spanner nut placed properly.


Front Spanner Adjusting Nut: The front spanner
adjusting nut determines the backward adjustment of
the injecting stem holder. It contains equally spaced
holes to facilitate adjustment with a spanner wrench.
Injecting Stem Holder: The injecting stem holder is a
threaded bar that ﬁts in the back ram and is held in
place by two spanner adjusting nuts. The front end is
hollow to accommodate the anvil, bushing and injecting
stem.
Anvil: The anvil is a solid circular piece that ﬁts inside
the end of the injecting stem holder. The stem seats
against the anvil, which helps to absorb the shock on the
stem.
Bushing: The bushing is cylindrical with a hole
through the center through which the shouldered part of
the injecting stem ﬁts.
Cap Nut: The cap nut is a hexagonal shouldered nut
which is beveled inside to ﬁt the bevel on the shoulder
of the stem. The nut is placed on the injecting stem to
rest on the injecting stem shoulder. The stem is inserted
in the injecting stem holder and the nut is screwed in
place on the injecting stem holder.
Injecting Stem: The injecting stem is tapered on the
working end and has a beveled shoulder on the other
end. It ﬁts in a bushing in the injecting stem holder.
Cap N ut Injecting Stem
Tool Holder
Injecting Stern


s.
. I
' mt 'c“'As
.\


Anvil
Rear Spanner
Nut


Bushing Front Spanner
Nut


CROSS-SECTIONAL DRAWING or INJECTING STEM
I 10]
CALIBER .30 BUMPING MACHINE
Tool Holder Description
Punch Holder
Assembly

Rear Spanner Adjusting Nut: The rear spanner adjusting nut,
located on the bumping punch holder, determines the forward ad-
justment of the bumping punch. The spanner nut contains
equally spaced holes around its circumference to facilitate its ad-
justment with a spanner wrench.
Front Spanner Adjusting Nut: The front spanner adjusting
nut determines the backward adjustment of the bumping punch
and is identical to the rear spanner nut with the exception that it is
thinner.
Punch Holder: The bumping punch holder is a threaded bar
that ﬁts in the front ram. It is held in place by the two spanner
nuts and a set screw which screws through the front of the ram
into a slot in the bumping punch holder.
Bushing: The bushing is cylindrical, with a hole through the
center. It ﬁts in the front of the bumping punch holder against the
anvil and acts as a spacer between the bumping punch holder and
the bumping punch.
Bumping Punch: The working end of the bumping punch is
ﬁat; it is approximately half as large as the cylindrical body of the
punch. The working end of the punch curves back to the shoulder.
The punch ﬁts in the bushing and seats against the anvil. It is
held in place by a set screw through the front of the bumping
punch holder.


Q
-\\\\\\\\\\\\\\\~\\\\\t\\\‘
Bump Punch I -j


s
!
§


Tool Hulda, Bushing Anvil
Front Spanner Rear Spanner
Nut NM
CROSS-SECTIONAL DRAWING OF PUNCH HOLDER ASSEMBLY
I11]
CALIBER .30 BUMPING MACHINE
Tool Description
2-£23
STEM
‘.
,-


DIE


PUNCH
TOOL DESCRIPTION
Tool Name: Stem
Piece No.: E-1
Location: Held horizontally in back crosshead
ram.
Normal Life: 833,000 pieces.
Stem is made of tool steel, hardened, ground and pol-
ished. Point of stem is rounded and tapered.
Tool Name: Die
Piece No.: E-10
Location: Die block
Normal Life: 357,000 pieces
Die is made of tool steel, hardened, ground and pol-
ished. Mouth end of die is rounded and tapered.
Tool Name: Punch
Piece No.: E-9
Location: Held horizontally in front crosshead
ram.
Normal Life: 1,250,000 pieces
Bumper is made of tool steel, hardened, ground and
polished. Point is convex.
I12]
CALIBER .30 BUMPING MACHINE
Process Sequence

Overhead Hopper
Pin Wheel Hopper
Box
Pin Wheel Hopper
Coil Spring Feed
Tube
Cradle
Injecting Stem
Bumper
Punch
Bumped Case
Knockoff and
Disposal
PROCESS SEQUENCE
The cases are gravity fed from an overhead source into the overhead
hopper, and drop down through a feed pipe into the pin wheel hopper box.
The cases ﬂow from the pin wheel hopper box through an opening, past the
agitator into the lower part of the pin wheel hopper.
As the pin wheel hopper rotates, the cases are agitated and picked up by
pins on the inner circumference of the pin wheel and are carried up past
the rake-off springs which knock off misaligned cases, and push partly set
cases all the way onto the pins. As the cases are carried to the top of the
pin wheel, they are held on the pins by the bridge. At the end of the bridge
they drop off, one at a time, head down into the mouth of the coil spring
feed tube.
The cases fall by gravity through the coil spring feed tube into a curved
steel feed pipe. The curved feed pipe prevents long cases from entering the
feed block, and stopping the ﬂow. These long cases are removed by the
operator so the ﬂow can continue into the feed block. The cases then drop
into the cradle. '
The cradle moves forward conveying the case into the feed sleeve in front
of the stem and in alignment with the die.
The injecting stem, moving from right to left, enters the case, pushes it
into the die and holds it there to wait for the bumper punch.
The bumper punch moves in from left to right to strike the case and put
a concave surface on its bottom end.
As the bumper and stem move back from the die, another case is moved
into the sleeve by the cradle and the above bump operation is repeated.
As the succeeding case is pushed into the die by the stem, it pushes the
previously bumped case out of the die.
The bumped case is pushed out to a point where the knockoff wire strikes
it, knocking it downward quickly, through a metal chute onto a conveyor
belt underneath the press.
CALIBER .30 BUMPING MACHINE
Process Sequence

FLOW CHART

Overhead Hopper
The cases are gravity fed from an overhead source
into the overhead hopper and drop through a feed
pipe into the pin wheel hopper box.


I
Pin Wheel Hopper Box
The cases ﬂow from the pin wheel hopper box through
an opening in the bottom, past the agitator, into the
lower part of pin wheel hopper.

1
Pin Wheel Hopper
Rotates and cases are picked up by pins and carried
up past the rake-off springs to top of the pin wheel
where they are held by the bridge. At the end of the
bridge they drop off, one at a time, head down into
mouth of coil spring feed tube.


Hopper is powered by a %
h.p. reduction gear motor
and driven by a V-type belt.
Control is by a toggle switch.


l
Coil Spring Feed Tube
Conveys the cases into curved feed tube through the
feed block into the cradle.


J
Cradle
Moves forward, conveying cases into the feed sleeve
in front of the stem and in alignment with the die.

J
Injecting Stem
The injecting stem, moving in from right to left,
enters the case, pushes it into the die and holds it there
to wait for the bumper.
I
Bumper
Moves in from left to right, striking the case, and
putting a concave surface on its bottom end.
I
Cradle is powered by push
rod and slide from cam on
eccentric wheel from rocker
arm connected to ﬂywheel
crankshaft.


Injecting stem is powered by
ram through connecting rod,
from back toggle shaft, from
rocker arm, from eccentric
wheel, from rocker arm, from
crankshaft.


Bumper and Injecting Stem
Move back from the die. Another case is moved
into the sleeve by the cradle and the above bump
operation is repeated. As the succeeding case is
pushed into the die by theinjecting stem, it pushes the
bumped case out of the die.

Bumper powered by ram
through connecting rod from
crankshaft.


L
Bumped Case
Is pushed out to a point where the knockoff wire
strikes the case, knocking it downward through a
metal chute, onto a conveyor underneath the press.


Knockoff wire powered by
cam in cam track on the
bumper ram, through the con-
necting rod from crankshaft.


[14]
CALIBER .30 BUMPING MACHINE
Product Description

Product
Description
PRODUCT DESCRIPTION
The component, when it is received by the bumping machine, is in the
form of a case as shown in Fig. 1.
The case is made of brass (70% copper, 30% zinc). The closed end of the
case is known as the bottom and the open end as the mouth.
The cases are received at the bumping machine from the Washing Depart-
ment, where they were washed and dried. The cases were delivered to the
Washing Department from the second draw press. There is no annealing
process between the second draw and the bumping operation.
The dimensions of the case are as follows:
Before bumping operation After bumping operation
Outside diameter .570—.572 Outside diameter .571—.574
Bottom thickness .137—.141 Bottom thickness .136—.140
Sidewall variation .002 Sidewall variation .002
After the bumping operation, the case is delivered to the Annealing De-
partment where it is annealed, pickled and washed before being delivered
to the third draw.
FIG. 1 FIG. 2


r V ‘ V ' H ‘ ,_ \-5-J
».<.<i‘=“.;15>_'¢ -~ Hi‘
BEFORE BUMP AFTER BUMP
I15]
CALIBER .30 BUMPING MACHINE
Inspection
Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the bumping operation, a careful visual in-
spection of the cases must be made. The cases should be inspected for
scratches on the inside and outside walls, for deposits of metal on the bot-
tom, wrinkles on the side and mouth, and dents on the bottom. These
defects indicate an immediate adjustment of the machine is necessary to
correct the fault. Whenever defective cases are found, the lot from which
they come must be removed from the machine and properly identiﬁed so the
bad lot will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use, or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their being damaged when not in use. The most ac-
curate checks are made when the cases are cool, since heat causes expan-
sion of the metal and results in a temporary variation in the case size.
TWIN RING GAGE
The outside diameter of
the case is gaged with a
twin ring gage. Cases
must pass through the lar-
ger or “go” ring but must
not pass through the smal-
ler “no go” ring.


DIAL INDICATOR GAGE
The bottom thickness of the case is
checked on a dial indicator; variation
in this dimension greatly affects suc-
ceeding operations.


The above described inspection methods are those most commonly em-
ployed in the bumping of a Caliber .30 case. However, other methods may
be developed to maintain the manufacturing standards.
[16]
CALIBER .30 BUMPING MACHINE
Adjustments
Objective
Cautions
ADJ LISTMENTS
To maintain satisfactory production, a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any trouble may be de-
tected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
N o adjustments are to be made while the machine is in motion, or until the
ﬂywheel has stopped.
To insure proper adjustment of the machine, always turn the ﬂywheel over
by hand before applying power.
Inspect the machine periodically to determine whether or not all connec-
tions and adjustments are secure.
Turn off the power before applying the foot brake.
The brake should be applied in such a manner as to cause the ram to stop
on its back stroke.
Do not permit the ﬂywheel to make a complete revolution in reverse, since
this will throw the machine out of time and cause it to jam.
Before making adjustments on the machine, always lock the electric motor
stop button with the locking set screw.
No adjustments are to be made on the die block until after it has been
ﬁrst determined that the components entering the machine are accep-
table, and second, that the punch and / or die is not defective.
The concave indentation produced in the bottom of the case by the
bumping punch must be positioned in the center of the case bottom. If
this indentation is off center (out of concentricity), the die block must be
adjusted. This adjustment is rarely necessary and is to be made only
by an experienced adjuster, or under his supervision.
[17]
CALIBER .30 BUMPING MACHINE Adjustments

Concentricity The die block should be adjusted so that the case is in direct line with the
punch. If the punch and the case are not perfectly aligned, the head of the
case will not be concentric with the side wall.
Concentricity is attained by moving the die block either vertically or hori-
zontally, or both. In order to know which way the die block should be
adjusted, it is necessary to place a test case in the machine and operate the
machine until the case is headed. The machine is stopped before the case
is ejected from the die, and the case and the die are marked with a vertical
line across the face of the case head and the die, so that the position of the
case in the die is known after the case has been removed from the die.
Remove the case from the die and test the head for concentricity with a
dial gage. Mark the high point of the head and replace the case in the die
in its original position.
If the high point is either to the right or left horizontally, the die block
must be adjusted correspondingly as shown by the arrows in the sketches
below. -

%
I
I
I
I
I
I
I
I
I
I
I


HIGH POINT TO RIGHT HIGH POINT TO LEFT
If the high point of the head is on either the top or bottom of the case when
it is placed back into the die, vertical adjustment of the die block is neces-
sary as shown by the arrows in the sketches below:

Pt
~


\\
IIIIIIIIIIIIIIIIIIIIIIIIIII
\\\\


III
_ .-___________t


HIGH POINT TO TOP HIGH POINT TO BOTTOM

I 18 I
CALIBER .30 BUMPING MACHINE
Adjustments
The die block may be out of adjustment both vertically and horizontally.
If this is the case, the die block is adjusted as shown by the arrows in the
sketches below:


' IIII Illlllllllllllllii‘


HIGH POINT TO THE LEFT HIGH POINT TO THE RIGHT
AND TOP AND TOP


HIGH POINT TO THE BOTTOM HIGH POINT TO LEFT AND
BOTTOM
AND RIGHT
I19]
CALIBER .30 BUMPING MACHINE
Adjustments
Die Block The die block is adjusted horizontally by turning the three adjusting screws
on the machine at the side of the die block holder. One of the adjusting
screws is threaded into the die block and is used to move the block toward
the left. The other adjusting screws are threaded into the machine, are
forced against the die block, and are adjusted to move the die block to the
right.
(Horizontal)

Die Block
Lock Nuts
Three—-5/15" Allen
Set Screws
Throo—1l/3" Lock
Nuts
1" Lock Screws
Loclt Nut:
TOOIS:
Procedure: 1.
2.
we
DIE BLOCK ASSEMBLY
%” Allen wrench, 1%” wrench, screwdriver.
Use a screwdriver to remove the four screws from the guard and remove
the guard.
Use a 1%” wrench to loosen the lock nuts on the adjusting screws in the
machine at the side of the die block while holding the adjusting screws
in place with a %” Allen wrench.
To move the die block to the right, use a 5/{6" Allen wrench to loosen the
two outside adjusting screws a fraction of a turn.
. To move the die block to the left, loosen the center adjusting screw a
fraction of a turn.
Tighten the lock nuts on the adjusting screws against the machine.
Check the adjustment by operating the machine and inspecting the
cases on a dial gage.
Note: The above procedure should be repeated until concentricity of
the head of the case is attained.
Replace the guard; insert and tighten the screws holding the guard in
place.
[20]
CALIBER .30 BUMPING MACHINE
Adjustments
Die Block The die block is adjusted vertically by turning the four adjusting screws
on top of the die block holder. The adjusting screws are hollow, permitting
the lock screws to pass through the center and screw into the machine bed.
(Vertical)

TOOIS:
Procedure:
Die Block
R-1;.\,‘7*q~§:#."-.‘\\ .
\
DIE BLOCK
2" wrench, 1 ” wrench, 7%" wrench, screwdriver.
1.
Use a screwdriver to remove the four screws from the guard and remove
the guard.
Lift the cotter key from the pin connecting the push rod to the cradle.
Remove the connecting pin.
Use a 78" wrench to remove the cap screws that hold the carriage to
the machine. Remove the carriage.
Use a 1 " wrench to loosen the four lock screws on top of the die block.
To raise the die block holder, use a 2 " wrench to tighten the four adjust-
ing screws a fraction of a turn.
To lower the die block, use a 2” wrench to loosen the four adjusting
screws a fraction of a turn.
Caution: Each of the four adjusting screws must be turned a like
amount to keep the die block level.
[21]
CALIBER .30 BUMPING MACHINE Adjustments
Procedure: 7. Tighten the four lock screws while holding the adjusting screw in place.
(Com-I Note: The above procedure must be repeated until concentricity of
the case head is attained.
8. Replace the carriage, the connecting pin and the cotter key.
9. Place the guard back on the machine; insert and tighten the screws
holding the guard in place.
[22]
CALIBER .30 BUMPING MACHINE
Adjustments
Injecting Stern
The injecting stem pushes the case out of the die just far enough that the
head of the case is bumped by the action of the bumper punch. If the case
is pushed too far out of the die, a ring will be formed on the case by the
outside edge of the die. If the case is not pushed far enough out of the die,
the bumper punch will not bump the head of the case hard enough to pro-
duce a concave surface. Adjustment is made by adjusting the two spanner
nuts on the injecting stem tool holder. The stem must be adjusted so that
the head of the case projects out of the die about $65”.
Injecting
Stem
Spanner
Nut

Tools:
Procedure:
INJECTING STEM AND HOLDER
V2" steel rod, screwdriver.
1.
2.
3.
Use a screwdriver to remove the four screws that hold the guard in
place, and remove the guard.
Place a test case in the magazine and turn the ﬂywheel by hand until
the head of the case protrudes from the die.
If the head of the case does not protrude at least .146" from the die, use a
%" steel rod to loosen slightly the spanner nut closer to the stem.
Tighten the other spanner nut against the brake.
If the head of the case protrudes more than 1/16”, use a 1/2" steel rod to
loosen slightly the spanner nut farther from the stem. Tighten the other
spanner nut against the bracket.
(In either of the above cases the adjustment must be repeated until
the head of the case protrudes 1%” from the die).
Remove the test case from the die and turn the flywheel by hand until
the ram is at its normal position.
Place the guard back on the machine; insert and tighten the screws
which hold the guard in place.
[23]
CALIBER .30 BUMPING MACHINE Adjustments
Bumper Punch The bumper punch bumps the head of the case to the desired thickness.
The head thickness of the case depends, therefore, upon correct adjustment
of the punch. If the case head is too thick, the punch must be adjusted
closer to the stern; if the head is too thin, the punch must be adjusted so
that there is more clearance between the stem and the punch. The punch
is adjusted by turning the spanner nuts on the bumper punch holder.
Before any work is done on the bumper punch, the stem must be checked
to see that it is properly adjusted.

Spanner
Nut
RAMS, TOOL HOLDERS AND CRADLE
Tools: 1/2" steel rod, screwdriver.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place and remove the guard.
(If the case head is too thick, the punch must be moved closer to
the stem. If the head is too thin, the punch must be moved away
from the stem).
2. If the case head is too thick, use a %" steel rod to loosen slightly
the spanner nut which is closer to the punch. Tighten the other
spanner nut against the bracket.
3. If the case head is too thin, loosen slightly the spanner nut farther
from the punch. Tighten the other spanner nut against the bracket.
4. The above procedure must be repeated and the head thickness tested
after each setting until the desired head thickness is attained.
5. Replace the guard; insert and tighten the screws holding the guard in
place.
[24]
CALIBER .30 BUMPING MACHINE Adiustments

Cradle The cradle receives the case from the feed tube and places it in line with
the die. In order to adjust the cradle so that it is in alignment with the
feed tube and socket, it is necessary to loosen the cap screws holding the
carriage to the machine and to turn the part that connects the cradle to the
push rod one complete revolution.


Spanner --
Nuts I
Knockoff
Wire
Set __
Screw ' Springs
Bumper
Tool "
Holder Feed
-. / Tube
Ram
Allen
_ Set Screw
Die _
Block
_ Ram
Fr t
Stew; - S::InnrIer
Hol?l?er — Nut
Back
- Spanner
RAMS, TOOL HOLDERS AND CRADLE
Tools: 7/8" wrench, %2” Allen wrench.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place, and remove the guard.
2. Remove the cotter key from the pin that connects the feed ﬁnger to the
push rod.
3. Use a 7/8" wrench to loosen the two cap screws, one on each side of the
carriage.
4. Remove the feed tube and observe whether or not the cradle is in line
with the feed socket.
5. Turn the part that connects the cradle to the push rod one complete
revolution, clockwise if the cradle is too far forward, or counterclock-
wise if the cradle is too far back to be in line with the feed socket.
Tighten the cap screws that hold the carriage to the machine.
Replace the connecting pin, the cotter pin and the feed tube. .
Replace the guard; insert and tighten the screws which hold the guard
in place.
.0<>.~19=
l25l
CALIBER .30 BUMPING MACHINE
Adjustments
Hopper Feed As the cases are carried upward by the pin wheel, the case heads contact
Bridge (Horizontal)
the hopper bridge which holds the cases on the pins until they reach the
feed tube mouth and fall down through the feed tube. The bridge should
be close enough to the seating spring that the cases do not fall from the
pins before they begin their travel on the bridge. The bridge can be moved
to the desired position by loosening the cap screw which holds the bridge to
the hopper.
Feed
Mouth
Hori-
zontal
Adju8t- T‘
moat
Feed
Tube
Bridge ‘
AdiUﬂ- -'\rf
mont '
Hop er
Fee
C)pening
TOOI:
Procedure: 1.
2.

INTERIOR OF PIN WHEEL HOPPER
11/4 ' wrench.
Release the latch and open the hopper door.
Use a 11/4' wrench to loosen the cap screw on the lower left end of the
hopper bridge.
Move the bridge close to the seating spring and in line with the bottom
of the pins on the pin wheel.
Hold the bridge in position and tighten the cap screw.
Close and latch the hopper door.
Check the adjustment by operating the hopper and opening the hopper
inspection gate to see whether or not the cases remain on the pins until
they begin their travel on the bridge.
I26]
CALIBER .30 BUMPING MACHINE Adjustments
Hopper Feed The feed bridge can be adjusted vertically by adjusting the nuts on the
Bridge (Vertical) vertical bolt connected to the bridge. ,
Tools: Two ll/i'i5" wrenches.
Procedure: 1. Use an 1%” wrench to loosen the lock nut on the vertical bolt while
holding the adjusting nut.
2. Use an 1%,” wrench to turn the adjusting nut, either raising or lowering
the feed bridge until it is about 3/4' from the pins on the pin wheel.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Close and latch the hopper door.

ENLARGEMENT OF INTERIOR OF PIN WHEEL HOPPER
Feed Tube Mouth The cases should fall from the pins into the feed tube mouth and down
through the feed tube. If they fail to do this, the feed mouth must be
aligned with the pins on the pin wheel.
Tool: L4’ wrench.
Procedure: 1. Release the latch and open the hopper door.
2. Use a 1/4" wrench to loosen the set screw on the front of the hopper
bridge.
3. Align the feed tube mouth with the pins on the pin wheel.
4. Hold the feed mouth in alignment and tighten the set screw.
[27]
CALIBER .30 BUMPING MACHINE Adjustments

Pin Wheel Hopper When the pin wheel hopper motor belt becomes too loose through being
Motor Belt stretched, it is necessary to tighten the belt to assure proper operation of
the pin wheel.
Hopper
Ad-
iusting
Screw
HOPPER MOTOR BELT ADJUSTMENT
Tools: %” wrench, V2" wrench.
Procedure: 1. Use a V8” wrench to loosen the lock nut on the motor adjusting set
screw.
2. Use a V2” wrench to turn the adjusting set screw, moving the motor
away from the hopper pulley, thus tightening the belt.
3. Tighten the lock nut.
[28]
CALIBER .30 BUMPING MACHINE Adjustments
Flywheel Motor When the motor belt becomes too loose, through being stretched, it is
Belt necessary to tighten the belt by raising the motor, to insure proper opera-
tion of the machine.

Machine
Motor
Top Nut
Nut
FLYWHEEL MOTOR BELT ADJUSTMENT
Tool: 2 " wrench.
Procedure: 1. Use a 2" wrench to loosen the three top nuts on the motor supporting
studs.
2. Use a 2" wrench to turn the three lower nuts to raise the motor, moving
it away from the ﬂywheel, thus tightening the belts.
3. Tighten the three top nuts.
[29]
CALIBER .30 BUMPING MACHINE Adjustments
Flywheel Brake Two brake shoes press against the side of the ﬂywheel when the brake is
applied. If the ﬂywheel does not stop almost immediately upon applica-
tion of the brake, the brake shoes should be adjusted so that they press
more ﬁrmly against the ﬂywheel. Both shoes should be adjusted a like
amount.
II It ~
T


I
Brake shoe


/


1%" Lock Nut
3%" Adjusting
Screw
11/4” Lock Nuts—-
3/4" Adjusting
Screws
BRAKE ASSEMBLY
Tools: 1%” wrench, 3/1" wrench.
Procedure: 1. Use a 11/4” end wrench to loosen the lock nuts on the brake shoes.
(The brake shoes are located at the bottom of the ﬂywheel.)
2. Use a 34 " wrench to tighten each of the adjusting screws about one-half
turn.
3. Hold the adjusting screws in place and tighten the lock nuts.
4. Check the adjustment by operating the machine and applying the
brake.
I30]
CALIBER .30 BUMPING MACHINE Troubles and Corrections

TROLIBLES AND CORRECTIONS
Objective The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles may be recognized by visual and gage inspection
of the component, together with constant observation of the machine as it
operates.
Scratched or Visual inspection will reveal scratches on the inside or outside walls of the
Scored Walls case. Scratches on the outside wall can be detected by ﬁnger nail inspec-
tion.
The causes are: The corrections are:
1. Rough die—die has excess brass 1. Lap and polish die if possible,
coating on inside surface. or replace with a new die.
2. Chipped die—edge on inner 2. Replace with a new die.
surface of die has become chip-
ped.
3. Scratched die—scratch on the 3. Polish the die if the scratch is
inside surface of the die. not too deep, or replace with a
new die if necessary.
4. Foreign matter—dirt, dried 4. Send the cases to the Washing
soap, etc. on the cases. Department to be rewashed.
Crooked Head Gaging discloses that the head of the case is irregular.
The causes are: The corrections are:
1. Bent injecting stem. 1. Replace with a new injecting
stem.
2. Worn injecting stem ; stem un- 2. Replace with a new injecting
dersize. stem.
Case Head Visual inspection discloses dents, scratches, or metal accumulation on the
Marred head of the case.
The causes are: The corrections are:
1. Worn bumper punch—-punch 1. Replace with a new bumper
is undersize. punch.
2. Chipped bumper punch—-a 2. Replace with a new punch.
piece is broken off the end of
the punch.
3. Broken bumper punch. 3. Replace with a new punch.
I 31 I
CALIBER .30 BUMPING MACHINE
Troubles and Corrections

Case Head
Ma rred
(Cont.)
Wrinkles in Case
Dented Mouth
Metal Deposit
Under Head
Metal Deposit on
Inside of Case
Oversize Diameter
Concave Shape in
Head Irregular
4. Skinned bumper punch—punch
surface marred or has excessive
brass coating.
4. Polish the punch if not too
badly skinned. If it is beyond
repair, replace with a new
punch.
Visual inspection discloses wrinkles on the outside near the mouth of the
case.
The causes are:
1. Undersize die—the mouth of
the die is too small.
2. Excessive oil or lubricant on
cases.
3. Insufficient lubricant.
The corrections are:
1. Lap and polish the die to the
proper speciﬁcation.
2. Remove cases and send to
Washing Department to be re-
washed, or reduce ﬂow of lubri-
cant.
3. Increase the ﬂow to required
amount.
Visual inspection discloses that the mouth of the case is dented.
The cause is:
1. Knockoff wire is out of time.
The correction is:
1. Adjust properly.
Visual inspection discloses that there is a deposit of metal under the head.
The causes are:
1. Cracked die——there is a crack
on the inside surface of the die.
2. Chipped die—edge on inner
surface of die has become chip-
ped.
The corrections are:
1. Replace with a new die.
2. Replace with a new die.
Visual inspection discloses that there is a deposit of metal inside the case.
The causes are:
1. Cracked injecting stem.
2. Chipped injecting stem.
The corrections are:
1. Replace with a new injecting
stem.
2. Replace with a new injecting
stem.
Gaging discloses that the body of the case is too large.
The cause is:
1. The die is too large.
The correction is:
1. Replace with a new die.
Gaging discloses that the concave head of the case is not concentric with
outside of the case.
The causes are:
1. Die block is out of adjustment.
The corrections are:
1. Adjust properly.
l32l
CALIBER .30 BUMPING MACHINE
Troubles and Corrections

Concave Shape in
Head Irregular
(Cont.)
Pocket Out of
Concentricity
Cases Cut Off
Cases Fed
Improperly
in Machine
2. Loose gibs.
3. Bent injecting stem.
2.
3.
Refer to and call Maintenance
Department.
Replacewith newinjectingstem.
Gaging discloses that the pocket is not concentric with the outside of the
case.
The causes are:
1.
The die block is out of align-
ment.
Cases are crooked and defec-
tive.
3. Bent injecting stern.
Die bushing is undersize.
5. Loose gibs.
. Cases have variable sidewall
thicknesses.
The corrections are:
1.
oso1ii>~_oo
Adjust the die block properly.
Check source of supply; call the
inspector.
Replace with a new stem.
. Replace with a new bushing.
. Call Maintenance Department.
. Check source of supply.
Visual inspection discloses that the case has become bent, cut in half, or
severed by the injecting stem.
The causes are:
1.
Cases feeding into feed box too
long.
Case is injected into die im-
properly.
. Case pulled out of die.
The corrections are:
1.
2.
Remove the long case and check
the source of supply.
Remove the case and check the
source of supply.
. Adjust properly.
Visual inspection discloses that the cases are not properly feeding through
the feed block and cradle.
The causes are:
1.
The cases are too long or too
short.
. Foreignmatter—dirt,scrap,etc.
in feed block or cradle.
. Bent cases in feed block.
. Cradle out of adjustment.
The corrections are:
1.
Remove the cases and check
the source of supply.
. Remove the feed block or cra-
dle and clean.
. Remove bent case and check
source of supply.
. Adjust cradle properly.
[33]
CALIBER .30 BUMPING MACHINE
Troubles and Corrections

Uneven Flow of
Cases from
Hopper
Machine Stops on
Dead Center
Visual inspection discloses that hopper is not feeding cases to machine
properly.
The causes are:
1.
Defective or long case—cases
from second draw are too long
or defective
Case is jammed in feed tube.
. Foreign matter—dirt, shavings,
etc. in the hopper.
Overloaded hopper—too many
cases in hopper.
5. Bridge is out of adjustment.
6. Belt slips———-loose belt, oily belt.
The corrections are:
1.
05
Remove the cases from the hop-
per and check the source of
supply.
. Remove the case and clear feed
tube.
. Clean the hopper and check the
source of supply.
. Remove excess cases from the
hopper.
Adjust the bridge properly.
. Tighten the belt if it is loose;
clean the belt if oily.
Visual inspection discloses that the machine has stopped on dead center.
The cause is:
1.
The injecting stem and the
bumper punch are locked
against the case in the die.
The correction is:
1.
Adjust the machine properly.
[34]
CALIBER .30 BUMPING MACHINE
Tool Servicing

Objective
Servicing of
New Dies
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the bump-
ing, pocketing, and heading of the cases. Dies and punches are costly and
great care must be exercised in the servicing of these tools. Adjusters will
be concerned primarily with the removal of brass and small scratches that
appear on working surfaces of dies and punches; they must be careful,
however, when using an abrasive on any tool, not to alter its dimensions
materially.
All tools that cannot be corrected by polishing or minor straightening must
be returned to the Tool Service Department.
1. Dies as received from the tool room are normally undersize to allow for
expansion pressure, and for lapping to a desired size when necessary.
2. The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
3. As a precaution, before a test run is made, the die bore should be in-
spected for roughness and polished if necessary.
4. The product from the test run should be carefully gaged and inspected.
Then, and then only, if an undersize or out of true die is indicated,
should the die be lapped.

FIG. 1
OVER-ALL VIEW OF SPEED LATHE
I35]
CALIBER .30 BUMPING MACHINE Tool Servicing
Lapping Procedure 1. When lapping is necessary, proceed as follows: Use a lap stick made of
ﬁber or wood about the same diameter as the die hole.
2. Tear off strips of 220 emery cloth about 1" wide and wrap the emery
around the end of the lap stick until it makes a snug ﬁt in the head of
the die.

FIG. 2 FIG. 3
CORRECT WAY TO PLACE DIE INCORRECT WAY TO PLACE
IN CHUCK DIE IN CHUCK
3. Chuck the die in the speed lathe, head out. Care must be taken to get
the die in the lathe properly. See Fig. 2.
Insert the lap stick in the head of the die.
Run the lathe on low speed, holding the lap stick in your hand and
move it in and out to prevent cutting grooves in the die.
6. Extreme care must be taken to guard against cutting too much metal
out of the die thus making it too large.
7. Remove the die from the lathe, wipe out with a cloth and gage with a
plug gage.
Servicing When a die becomes scratched on the inside, the above procedure will be
Scratched Dies used for eliminating the scratch providing the scratch is not too deep. In
case of exceptionally deep scratches the die must be returned to the tool
room.
9‘?
Servicing the When theinjecting stem has an accumulation of brass on it, remove the stem
Injecting Stern and polish it with 220 emery cloth, by hand, until the brass is completely
removed. Then polish the stem off with crocus cloth.
I36]
CALIBER .30 BUMPING MACHINE
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
MACHINE LLIBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[37]
CALIBER .30 BUMPING MACHINE
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.<.@.°‘tl>‘.°°.l\°
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.S9‘.°‘b‘>‘?*°.l\'>
Frequency of lubrication.
I 38 I
CALIBER .30 BUMPING MACHINE
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°.q9“-’$"!‘°‘.°°.“"l"‘
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I39]
CALIBER .30 BUMPING MACHINE Machine Lubrication

LUBRICATION CHART


. . N 0. of Fittings, Frequency of
I/ubmcant Machine Part Grease Cups, etc. Lubrication Hours
Crankshaft bearings . 4 8
Connecting rod 7 8
LIGHT GREASE Rocker wheel . 1 8
(Blue Gun) Ram . 4 8
Hopper . 1 24
Knockoff Cam 1 8
Flush gibs 4 4
Rocker arms 4 8
Cam on eccentrics . 1 8
Knockoff pin shaft . 2 8
MEDIUM OIL Brake lever . . . . . 6 24
(Red Oiler) Push block conveyor . 4 8
Cam roller . . . . . 1 8
Push blocks and parts 3 8

CALIBER .30 BUMPING MACHINE
Index
Adjustment, Bumper Punch, 24
Concentricity, 18
Cradle, 25
Die Block, Horizontal, 20
Die Block, Vertical, 21
Feed Tube Mouth, 27
Flywheel Brake, 30
Flywheel Motor Belt, 29
Hopper Feed Bridge, Horizontal, 26
Hopper Feed Bridge, Vertical, 27
Injecting Stem, 23
Pin Wheel Hopper Belt, 28
Anti-friction Bearings, 37
Anvil, 9, 10, 11
Bottom Thickness, 15
Brake, 3, 6
Assembly, 6
Lever, 6
Shoe, 3, 6
Bumped Case, 13, 14
Bumper, 13, 14
Punch Adjustment, 24
Ram, 3
Stem, 14
Bumping Punch, 11
Bushing, 9, 10, 11
Cap Nut, 10
Case Head Marred, 31, 32
Cases Cut Off, 33
Fed Improperly, 33
Out of Concentricity, 33
Coil Spring Feed Tube, 13, 14
Concave Shape in Head Irregular, 32
Concentricity Adjustment, 18
Cradle, 13, 14
Adjustment, 25
Crankshaft, 2, 4
Crooked Head, 31
Defects, 16
Dented Mouth, 32
Dial Indicator Gage, 16
Die, 3, 9, 12
Block, 18, 19
Block Assembly, 9
INDEX
Die Block, Horizontal, Adjustment, 20
Block, Vertical, Adjustment, 21
Holder, 3
Disposal, 13
Eccentric Cam, 3, 4
Elevator, 3
Feed Motor, 1
Sleeve, 3
Tube, 3, 25
Tube Mouth Adjustment, 27
Floor Space, 1
Flow Chart, 14
Flywheel, 2, 3, 6
Brake Adjustment, 30
Motor Belt Adjustment, 29
Friction, 37
Front Spanner Adjusting Nut, 10, 11
Gage Care, 16
Gages, 16
Grease, 38
Height, 1
Hopper Box, 7
Feed Bridge, Horizontal, Adjust-
ment, 26
Feed Bridge, Vertical, Adjustment,
27
Injecting Stem, 10, 13, 14
Stem Adjustment, 23
Stem Assembly, 10
Stem Holder, 10
Knockoff, 13
Wire, 3
Lap Stock, 36
Lapping, 35
Procedure, 36
Lubricating Film, 37
Lubrication, 3, 37
Chart, 40
Hints on, 39
Methods, 38
Machine Motor, 1
Stops on Dead Center, 34
Manufacturer, 1
Metal Deposit on Inside of Case, 32
Deposit Under Head, 32
Methods of Getting Lubricant to
Bearing Surface, 39
Motor, 2
Outside Diameter, 15
Overhead Hopper, 13, 14
Oversize Diameter, 32
Pin Wheel Hopper, 3, 7, 8, 13, 14
Wheel Hopper Box, 13, 14
Wheel Hopper Motor Belt Adjust-
ment, 28
Power, 2, 14
Production, 1
Punch, 12
Holder, 11
Holder Assembly, 11
Ram, 3, 5
Rear Spanner Adjusting Nut, 10, 11
Rocker Arm, 3, 4
R.P.M. of Crank, 1
Scored Walls, 31
Scratched Walls, 31
Selecting a Lubricant, 38
Servicing Ejecting Stem, 36
New Dies, 35
Scratched Die, 36
Sidewall Variation, 15
Speed Lathe, 35
Stem, 12
Ram, 3
Stroke, 1
Switch, 2
Tools, 1
Transmission, 2
Twin Ring Gage, 16
Type of Feed, 1
Uneven Flow of Cases, 34
V Belt, 7
Visual Inspection, 16
Washing Department, 15
Weight, 1
Wrinkles in Case, 32
[41]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Third Draw Case

BY
Training Department
Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 194]
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 7 6th Congress, 3rd Session).
II
MANUAL CORRECTIONS—CALIBER .30 THIRD DRAW CASE
LOCATION
Page 10— 1] 3
Page 11 — 1] 1,
Page 13-
Spacer Location
Page 1 6—Spec
Page 11,—— ‘I 8
Page 30—Proc 3
ERROR
Latch Pin Catch
Die Block Holder
“above die”
Outside diameter before 3rd Draw .571—.574
Inside diameter before 3rd Draw .270—.272
Bottom thickness before 3rd Draw .140-.136
Inside diameter after 3rd Draw .228—.226
1st Draw
2nd Draw
%" Wrench
CORRECTION
Clutch Lever Catch
Die Block
“below die”
Outside diameter before 3rd Draw .57 0—.57 2
Inside diameter before 3rd Draw .518—.520
Bottom thickness before 3rd Draw .137 —.141
Inside diameter after 3rd Draw .480—.482
2nd Draw
3rd Draw
%" Wrench
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
III

DRAW PRESS—CALlBER .30 THIRD DRAW CASE
IV
CALIBER .30 THIRD DRAW CASE
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Feed Motor
Production
Crankshaft Speed
Stroke
Cooling Solution
Pump
Tools :
Floor Space
Over-all Height
Weight
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, New York
Vertical straight side single crank press E. W.
Bliss No. 304 6 V-belt drive motor to crankshaft
7% h.p.; 3 phase; 60 cycle; 220/440 V; 23.5/11.8
amps.; 865 R.P.M.
Automatic pin wheel hopper 6 R.P.M.
Gearhead % h.p.; 1 phase; 60 cycle; 115/230
V; 3.4/1.7 amp.; 1725 R.P.M. co. shaft 48 R.P.M.
270 components per minute
90 r.p.m.
8/!
Centrifugal (Gusher) model 1—P3 1/10 h.p.
1 phase; 60 cycle; 110 volt
Punch
Die
Guide ring
Spacer
Stripper
Stripper holder
Stripper spring
Split bushing
Split bushing spring
Bushing sleeve
4/8//X7/3”
10 ft. x 10% in.
8,000 lbs.
Piece No.:
D-3
.515x16
.580x3/16” radius
.580x3/16” radius
.520
1.492x60°
.520
AE—8
21/2”x10"x.016
AE—5
[1]
CALIBER .30 THIRD DRAW CASE
Machine Description
Motor
Hopper Box
Power and
Transmission

MACHINE DESCRIPTION


FRONT VIEW
The E. W. Bliss single draw press No. 304, illustrated above, is powered
by a 7 X; h.p. motor, through six V belts, to the ﬂywheel mounted on a
horizontal crankshaft.
Incorporated in the ﬂywheel hub is a rolling key clutch for control of
power to the crankshaft through linkage to an individual clutch lever.
A conventional brake drum is located on the end of the crankshaft op-
posite the ﬂywheel. A lined brake shoe secured and located by a bracket
attached to the machine frame provides the friction necessary to hold the
crankshaft in position when the clutch is disengaged.
The clutch and brake action are synchronized through the clutch lever.
When the clutch is engaged, the brake is released, and when the clutch is
disengaged, the brake is applied.
[21
CALIBER .30 THIRD DRAW CASE ‘
Machine Description

Power and
Transmission (Cont.)
Pin Wheel
Hopper
Feed Tracks
Ram
Detector Stems
Cooling Solution
Controls
In normal operation, if the clutch is disengaged for any reason, the crank-
shaft will always stop at the maximum upward position of the crank. For
inspection or adjustment purposes, the crankshaft may be stopped and
held in any desired position while the machine is rotated by hand.
The pin wheel hopper receives cases from an overhead source and through
feed tubes deposits the cases, “mouth up,” in the feed tracks on the bed
of the machine.
The motive power for the pin wheel hopper is supplied by a 1/8 h.p. reduc-
tion gear head motor, on an adjustable mounting bracket at the left side
of the hopper, through a V belt to the pin wheel.
The feed tracks, with the assistance of the feed ﬁngers, transfer the cases
from the feed tubes to the punch and die stations.
The ram is a heavy cast-iron block. Its mass assists the power stroke of
the punch and absorbs the shock of impact and subsequent vibration.
The lower surface is machined for the attachment of a punch holder
block. The ram, the sides of which are ﬁtted into V grooves to guide
it in its vertical motion, is connected to the crankshaft throw by a non-
adjustable connecting rod.
Two coil springs are attached between the back side of the ram and a
spring bracket mounted on the machine frame above the crankshaft. The
springs act as a counter balance and assist in dissipating the vibration set
up by the punches’ contact with the cases during the drawing process.
The detector system, which is mounted on the front of the ram, is a
mechanism which detects inverted cases, cases on their sides, and foreign
objects within cases as they travel through the feed tracks.
Above each feed track is located a detector stem. If a detector stem en-
counters an improperly positioned case or a foreign object in a case, the
stem will be forced upward, and will move the knockoff bar to the right.
The knockoff bar will strike and move the clutch lever latch pin to the
right, tripping the clutch lever; thus the clutch is disengaged, the brake
is applied, and the machine is stopped.
To prolong die and punch life each case is bathed by a cooling solution
which acts both as a cooling and a lubricating agent.
The base of the machine forms a reservoir for this cooling solution which
is pumped through a pipe system to the die. The pump is driven by a 1/10
h.p. vertical, direct drive motor.
The main motor control switch is of the push button “start and stop”
type. An overload switch, with a “reset” push button is also provided
for protection of the main drive motor.
Two toggle switches, contained in the same case, are provided for control
of the hopper and pump motors. The right hand switch is for the pump
motor, and the left hand switch controls the hopper motor.
[3]
CALIBER .30 THIRD DRAW CASE
Machine Description

Lubrication
Pin Wheel Hopper
Description
Ho per
oor
Hopper
Spokes

Lubrication of all moving parts is accomplished by Alemite-Zerk ﬁttings,
oil cups, oil holes, or distribution of lubricant by oiler, swab, etc., over
desired point. (See special lubrication chart, page 44.)
The pin wheel hopper and hopper box are located at the top and to the
left of the machine.
The pin wheel hopper box is a cast-iron reservoir with the bottom sloping
toward an opening and leading into the pin wheel hopper. The pin wheel
hopper, attached to the front of the hopper box, is mounted on a project-
ing cast-iron, bronze-lined bearing, into which is ﬁtted the pin wheel shaft
and hub.
The pin wheel hopper consists of an inner and an outer dish-shaped
rim and a midsection of pin rings and spacer rings, bolted to form the
hopper assembly. The outer rim has three spokes attached to a hub shaft
on which the entire hopper revolves. This shaft extends through the
hopper box. The shaft has a pinion gear on the ﬁat end that meshes with
a ring gear and pulley that is driven by a V belt from a gear reduction
V8 h.p. motor.
Hopper Box
tiub
and
Shatt
Feed
Tubes
FRONT VIEW OF PIN WHEEL HOPPER WITH DOOR OPEN
[4]
CALIBER .30 THIRD DRAW CASE
Machine Description

Pin Wheel Hopper
The pin rings have a series of steel pins, spaced approximately 1" apart
on their inner circumference, and set at an angle with the radii. The
spacer rings are wider than the pin rings and are chamfered on their inner
edge. This chamfer forms a channel between each of the spacers, to guide
the components onto the pins.
As the pin wheel hopper rotates clockwise, some of the pins pick up the
cases and convey them upward. Contacting each row of pins as they rotate
upward is a spring steel strip, called a rake-off spring, which rakes off all
cases that are not properly seated on the pins. As the cases continue their
upward travel, they contact a pin wheel bridge which holds them on the
pins. There is a pin wheel bridge for each row of pins. As the cases reach
their nearly vertical “head down” position, they come to the end of the
pin wheel bridge, where they slide off into the mouth of the feed tube.
The door for the front of the pin wheel hopper is dish-shaped to match the
pin wheel rim, and is hinged at the left of the hopper box. The door is
held shut by a rotary latch.
Pin Wheel Bridge
Pin Wheel Adjustment
Bridge Steel Pins
INTERIOR OF PIN WHEEL HOPPER
l5I
CALIBER .30 THIRD DRAW CASE
Machine Description
Detector System

DETECTOR SYSTEM
The detector system is a mechanism which detects cases not in proper
position and foreign objects within feed tracks. The detector system
which is bolted to the front of the ram consists of a detector stem for
each feed track. If a detector stem encounters a foreign object in a case or
locates an improperly positioned case, the detector stem will be forced up,
and by cam action on its upper end will move the knockoff bar to the
right. The knockoff bar will strike the clutch lever latch pin tripping the
clutch lever which disengages the clutch and applies the brake, thereby
stopping the action of the ram. The clutch lever returns to an “off”
position by spring action.
Push Rod
Clutch
Lever
Knockout
Assembly

SIDE VIEW OF DETECTOR SYSTEM
[6]
CALIBER .30 THIRD DRAW CASE
Machine Description
Feed Tubes and
Bﬁdge
The lower end of the feed tube mouth is connected to the upper end of
the feed tube by means of a bushing. A bayonet type of bushing is used
to connect the lower end of the tube to the feed tube bridge.
The feed tube is bolted to the work plate above the feed tracks. The feed
tube bridge holds the feed tubes in position over the case tracks.
The cases slide, head down, from the feed tube mouth, down the feed
tubes, to a position on the feed ﬁngers in the feed tracks.
Feed Tubes
Bayonet
Connection \
\ .
Latch Pin Feed
Tube
\ Bridge

'.-+
I
Feed _/
Track
Bolster
Plate
FEED TUBE ASSEMBLY
I7]
CALIBER .30 THIRD DRAW CASE
Machine Description
Feed Tracks
The machine has a series of two-piece feed tracks that hold the cases in
a mouth-up position. Each track is bolted to the bolster plate of the
machine. On the inner face of each track is a series of ball spring tension
stops, spaced to hold the cases in an upright position. On the rear of each
track is a brass back-stop to prevent the cases from being forced past the
dies. '
As the ram ascends, an arm fastened to the ram lifts a plunger rod which
actuates a rocker arm assembly which, in turn, furnishes motive power
for the feed ﬁngers.
The case, which has just emerged from the feed tube, is forced against the
others in the feed tracks by the feed ﬁngers. This causes the case, in the
rear of the tracks, to be forced past the ball spring stops to a position over
the dies where the punch descends and forces the case through the die.
Feed Tracks


Plunger
Rod
Case
Counters
Feed
Finger Rocker
— Arm


FRONT VIEW OF FEED TRACKS
I8]
CALIBER .30 THIRD DRAW CASE Machine Description
Rear of Press The rear view of the Caliber .30 Third draw press shows the motors and
adjustable brackets. The press is started and stopped by a clutch in the
crankshaft ﬂywheel.
Below the frame is a V8 h.p. motor (not shown in picture) which drives
the cooling pump and circulates the cooling solution from the reservoir,
in the machine bed, through the pipe system to the punches and dies.
The cooling solution serves as both a coolant and a lubricant.
Motor
‘ V Belts Bracket
Hopper
Box


Clutch '
Lever \
Cooling Solution
Feed Pipes
REAR VIEW
[9]
CALIBER .30 THIRD DRAW CASE Machine Description
Connecting Rod The ﬂywheel on the end of the crankshaft transmits power to the ram,
and Ram through the crankshaft and connecting rod.
There are two heavy coil springs which cushion the impact of the ram on
its downward stroke and help in a small way to lift the ram on its upward
stroke.
REAR VIEW

FRONT VIEW
The clutch lever is used to start and stop the press. In the running posi-
tion it is hooked onto the latch pin catch. For automatic stop, the latch
pin kicks the lever off its hook. The rod on the clutch lever connects the
lever to the clutch.
I10]
CALIBER .30 THIRD DRAW CASE Tool Holder Description

TOOL HOLDER DESCRIPTION
Guide Ring: The guide ring is inserted into the die block
from the top side above the draw die. It centers the com-
ponent in a vertical position over the draw die.
:73 _ ‘ Draw Die: The draw die is placed in the die hole of the die
M / holder from the top side under the guide ring. The draw
III die forms and controls the outside diameter of the com-
ponent.
I -PU~ , I 1 - . .
. Spacer Rmg. The spacer r1ng, Wl1ICh 1s assembled 1n the
die block below the die, acts as a build-up for the die.
Die Block Holder: The die block holder holds the die as-
sembly. It is held in the channel of its bolster plate by a
lock pin. The bolster plate is adjustable to allow centering
the die assembly under the punch. A vertical lip on the rear
end of the die block assists the adjuster in inserting, locating
and removing the die block.
Stripper Ring: The stripper holder holds the assembled
stripper. It is inserted into the die assembly hole from the
under side and rests on the base plate.
Die Block Assembly
Stripper: The stripper consists of three segments held to-
gether by a coiled spring. The stripper is inserted in the
stripper ring with the large end of the tapered hole up. It
strips the case from the punch after the case has been
forced through the die assembly.

Die Block BasePlate: The die block base plate serves as
an anvil for the die block. The projection on the bottom of
the plate guides the component onto the conveyor.


Guide Ring
Die


Spacer Ring
Stripper Holder
Spﬁng
Stripper


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CROSS-SECTIONAL DRAWING or ASSEMBLED DIE BLOCK
I 11 l
CALIBER .30 THIRD DRAW CASE , Tool Holder Description

Punch Holder Anvil: The anvil is inserted in the top side of the punch
Assembly / holder in contact with the head of the punch and punch
holder. It protects the face of the ram from the thrust of the
' punch.
I
j Punch Holder: The punch holder is placed in the punch
holder block from the top side by “press ﬁt," ﬂanged end up.
T’ The lower end is threaded to receive a hexagon gland nut.
‘I Punch Holder Block: The punch holder block is bolted to
the under side of the ram by four Allen screws. It holds the
punch assembly.
Split Collar: The split collar acts as a ﬂange on the head
end of the punch. It is held in place by a coil spring. The
spacer bushing is held in place against the split collar by a
gland nut.
Punch: The punch, assembled with a gland nut, sleeve and
split collar is inserted in the bottom side of the punch holder,
and is held in a vertical position.
Sleeve: The sleeve is place on the punch from the bottom
end before the gland nut. It acts as a spacer in the alignment
of the punch.
Gland Nut: The gland nut, which has threads on its outer
surface, is screwed into the inner threads of the punch
holder, forcing the spacer against the split collar. The gland
nut holds the punch assembly in the punch holder.

Button Anvil
\ /
,/
_ Punch Holder
H \\ Split Collar
Bushing


\


‘
\\
Key


V/'


~\\\
s\\
Gland Nut
Punch
CROSS-SECTIONAL DRAWING OF ASSEMBLED PUNCH BLOCK
I 12 I
CALIBER .30 THIRD DRAW CASE
Tool Description


- Guide Ring
Die


TOOL DESCRIPTION
Tool Name: Punch~Third Draw
Piece No.: D-3
Location: Held vertically in ram
Normal Life: 1 tool, 312,000 pieces
The punch is made of tool steel, hardened, ground
and polished. The shank is slightly softer than the
working end.
Tool Name: Guide ring—Third Draw
Piece No.: .580x3/1%” radius
Location: Above die
Normal Life: 1 tool, 1,000,000 pieces
The guide ring is hardened tool steel. The hole is ground
and polished. The top and bottom surfaces are only
ground.
Tool Name: Die—Third Draw
Piece No.: .515xl6
Location: Die block
Normal Life: 1 tool, 5,000 pieces
The die is made of tool steel, ground, hardened and
polished.
Tool Name: Spacer—Third Draw
Piece No.: .580x%/6” radius
Location: Above die
Normal Life: 1 tool, 1,000,000 pieces
Tool Name: Stripper—Third Draw
Piece No.: .520
Location: Die block—under die
Normal Life: 1 tool, 100,000 pieces
The stripper consists of three segments held together
with a coiled spring band ;it is made of tool steel, ground,
hardened and polished.
Tool Name: Stripper holder—Third Draw
Piece No.: 1.492x60°
Location: Between die and stripper
Normal Life: 1 tool, 10,000,000 pieces
The stripper holder is hardened tool steel, ground on
all surfaces.
[13]
CALIBER .30 THIRD DRAW CASE
Process Sequence
Overhead Hopper
Pin Wheel Hopper
Box
Pin Wheel Hopper
Feed Tube
Feed Finger and
Feed Track
Ram and Punch
The Draw
Stripper
and Disposal
Lubrication
PROCESS SEQUENCE
The cases are fed by gravity from a truck or conveyor into the overhead
hopper and drop through a feed pipe, into the pin wheel hopper box.
Cases ﬂow from the pin wheel hopper box through an opening past the
agitator into the bottom part of the pin wheel hopper.
As the pin wheel hopper rotates, cases are agitated and picked up by pins
on the inside circumference of the pin wheel and carried up past the rake-
off springs which knock off misaligned cases and push partly set cases all
the way on pins. As the cases are carried to the top of the pin wheel they
are held on the pins by the bridge. At the end of the bridge they drop off
one at a time into the open end of the feed tube mouth up.
Cases fall by gravity down through the coil spring feed tube into a bushing
mounted on the feed tube bridge and rest momentarily on the feed ﬁnger.
On the downward stroke of the ram the feed ﬁnger moves back permitting
the case to fall into the feed track. On the upward stroke of the ram the
feed ﬁnger moves forward pushing the cases along the feed track past the
spring buttons. The ball spring stop keeps the cases in an upright posi-
tion and prevents them from falling over. Cases pass by the counter
under and past the detector stems which detect foreign matter and in-
verted cases.
They pass to the rear of the feed tracks where they drop into the guide
ring directly over the dies and under the punch.
The ram descends with the punch and forces the case through the guide
ring into and through the die and stripper.
The forcing of the case through the die reduces the wall thickness and
diameter and increases the length of the case. This is known as the draw.
Before the draw, the component is known as the ﬁrst draw case and, after
the draw, as the second draw case.
As the punch withdraws from the dies, the cases are stripped off by a three-
segmented stripper located under the die, then falls onto a slide down a
chute through a rotary washer to a mechanical conveyor.
During the drawing operation the cases are lubricated and tools cooled by
a cooling solution which ﬂows over the cases through an opening under the
work plate.
[14]
CALIBER .30 THIRD DRAW CASE
Process Sequence

FLOW CHART

Overhead Hopper
Cases are fed by gravity from truck or conveyor
into overhead hopper through feed pipe.


Feed Pipe
Conveys cases by gravity down into pin wheel
hopper box.

I
Pin Wheel Hopper Box
Cases ﬂow through opening in pin wheel hopper
box past agitator into bottom of pin wheel hopper.

I
Pin Wheel Hopper
Rotates and cases are picked up by pins and car-
ried up past rake-off springs to top of pin wheel
where they are held by the bridge. At the end of
the bridge they drop off, one at a time, into open
end of coil spring feed tube, mouth up.


Hopper is powered by a %; h.p.
reduction motor through a V-
type belt.


I
Coil Spring Feed Tube
Conveys cases by gravity, mouth up, into the
bushing mounted in the feed tube bridge, where
they rest momentarily on the feed hammer.


Feed Finger
Moves backward, allowing the case to drop into
feed track. It then moves forward pushing the
case along the feed track.


Feed ﬁnger is powered from the
rocker arm shaft through the push
rod through the ram.


Feed Track
Guides the cases, single ﬁle, past and under the
detector stem to rear of track, where cases drop
into the dies and under the punch.

I
Dies and Punch
As the ram descends, the punch forces the case
through the dies and stripper increasing the length,
and decreasing the diameter and the sidewall
thickness of the case.


Stripper
After the punch forces the case through the dies, it
withdraws and the case is stripped off by a three-
segmented stripper under the dies and falls onto a
slide and drops down a chute through a rotary
washer to a mechanical conveyor.

Ram is powered from the
connecting rod through the crank-
shaft, clutch and ﬂywheel by 6
V-type belts to 7 % h.p. motor
mounted on top of press.


CALIBER .30 THIRD DRAW CASE
Product Description


After
Second
Draw
Product
Description
FIG. 1. BEFORE THIRD DRAW


PRODUCT DESCRIPTION
The component, when received by the third draw is in the form of a case
as shown in Fig. No. 1.
The case is received from the Annealing Department where it was an-
nealed, pickled and washed. When the case is delivered to the Anneal-
ing Department from the bumping operation, the metal has a very
bright, brassy appearance and a smooth ﬁnish. After the case has been
annealed, the metal appears dull and has a rough ﬁnish.
The case is made of brass (70% copper, 30% zinc). The closed end of the
cylinder is the bottom and the open end is the mouth.
The dimensions of the cup are as follows:
Before Third Draw After Third Draw
Outside Diameter .574 — .571 Outside Diameter .519— .517
Inside Diameter .272 — .270 Inside Diameter .228— .226
Bottom Thickness .140 — .136 Bottom Thickness .150— .165
Sidewall Variation .0005— .002 Sidewall Variation .001— .002
Over-all Length l.636ul.629 Over-all Length 2.116—2.118
After the drawing operation, the case is delivered to the Annealing De-
partment where it is annealed, pickled and washed before being delivered
to the fourth draw.
FIG. 2. AFTER THIRD DRAW


After After After After After After
Annealing Washing Third First Annealing Washing
Operation Operation Draw Trim Operation Operation
[16]
CALIBER .30 THIRD DRAW CASE
Inspection
Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the drawing operation, a careful visual inspec-
tion of the cases must be made. The cases should be inspected for scratches
on the inside and outside walls, for crooked heads, crooked tops, and bodies
that are not round. When these defects are found, require an immediate ad-
justment of the machine in order to correct the fault. Whenever defective
cases are found, the lot from which they come must be removed from the
machine and properly identiﬁed so the bad lot will not get mixed up with
the good cases. -
Gages are expensive instruments machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool since heat causes expansion of the
metal and results in a temporary variation in the case size.
The outside diameter of the case
is gaged with a twin ring gage.
Cases must pass through the
larger or “go” ring and must
not pass through the smaller
“no go" ring.


The bottom thickness of the case is
checked on a dial indicator. Vari-
ation in this dimension greatly
affects succeeding draws.


I17]
CALIBER .30 THIRD DRAW CASE Inspection
The sidewall thickness gage used
for checking the sidewall thick-
ness of a case is a dial indicator
with a horizontal punch held
stationary directly underneath
the stem. The case is placed
on the horizontal punch and the
reading of the sidewall variation
taken while the case is revolved
on the axis of the punch.


The above described inspection methods are those most commonly em-
ployed in Caliber .30 third draw case. However, other methods may be
developed to maintain the manufacturing standards.
[18]
CALIBER .30 THIRD DRAW CASE
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than the starting button to determine
whether the clutch is disengaged.
Make frequent inspection to determine whether proper and sufficient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
I19]
CALIBER .30 THIRD DRAW CASE
Adjustments
Punch The punch may become worn causing the inside of the case to be too
small in diameter or may become scratched causing scratches on the inside
of the case. In either case the punch must be replaced.
Replacement

Tools:
Procedure:
if
PUNCH BLOCK ASSEMBLY
1?/8" wrench
1.
Remove the rear guard by lifting it up and pulling it out away from
the machine.
Use a 13/8" wrench to remove the gland nut in the punch holder while
holding the punch with the other hand.
Pull down on the punch removing the assembly from the punch
holder.
Remove the bushing, gland nut and the split collar from the worn or
broken punch and place these parts on the new punch, making sure the
wide shoulder on the split collar is up.
Insert the punch assembly in the punch holder and tighten the gland
nut.
Caution: Be sure that the punch is clean.
Replace the rear guard.
Check the replacement for accuracy by drawing a case.
I 20 l
CALIBER .30 THIRD DRAW CASE
Adjustments

Die Replacement
Tools:
Procedure:
The dies may become worn causing the case to be too large in diameter
or may become scratched causing scratches on the outside of the case. In
either case the die must be removed and replaced with a new die.
til


DIE BLOCK ASSEMBLY
screwdriver
1.
Remove the rear guard by lifting up and pulling out on the bottom.
Lift out the die block lock pin.
Pull out the die block, keeping one hand underneath to prevent
stripper from dropping out.
Turn the die block upside down allowing the dies to fall out into your
hand. Turn the die block right side up.
Slide the die block back in the machine part of the way while getting
new dies.
Replace the dies in the die block making sure that the bottom die is
on the bottom with the tapered end down.
Push the die block back in the machine and replace the die block
lock pin.
Replace the guard.
Check for accuracy by drawing a case.
I 21 l
CALIBER .30 THIRD DRAW CASE
Adjustments

Pin Wheel Bridge
In order to adjust the position of the bridges in relation to the pins on the
pinwheel, each bridge can be adjusted by the vertical bolts connected to
the bridges. Each bolt adjusts one of the bridges and should be adjusted
so that the cases will travel along the bridge to the feed mouth. If the
bridges are not properly adjusted, the cases will fall from the pins before
arriving at the feed mouth, or will jam along the bridge.

INTERIOR VIEW OF PIN WHEEL HOPPER
TOOIS:
Procedure:
Two 1%” wrenches
1. Open the hopper inspection gate by pulling down on the gate.
2. Use two 1%" wrenches. Hold the top nut with one wrench and loosen
the bottom lock nut on the vertical adjusting bolt with the other
wrench.
3. Turn the adjusting nut until the bridge is approximately 3/4" from
the pins on the pin wheel.
4. Tighten the lock nut while holding the adjusting nut,in place and
close the hopper inspection gate.
5. Check the adjustment for accuracy by turning on the power and
observing whether or not the cases fall properly down through the
feed tube.
I22]
CALIBER .30 THIRD DRAW CASE Adjustments

Hopper Feed The feed tube mouth receives the cases after they travel the length of
Tube Mouth the pin wheel bridge. The mouth should be in line with the pins on the
pin wheel so that the cases will drop from the pins into the feed tube
mouth. If the mouth is not adjusted properly, the cases will jam at the
feed mouth. Adjustment is made on the adjusting bolt that connects the
feed tube mouth to the pin wheel bridge.


§. '
1. ‘A .
> ' .‘ ‘ '\:r" ‘
~..*R.. ...o.A ENLARGEMENT OF
HOPPER FEED GUIDE MOUTH Feed FEED MOUTH ADJUSTMENT
Mouth
Adjustment
Tools: 1/4" wrench
Procedure: 1. Open the hopper inspection gate by pulling down on the gate.
2. Use a 1/4" wrench to loosen the set screw on the bottom of the feed
tube bridge.
3. Adjust the feed tube mouth by hand until it is in alignment with the
pins on the pin wheel, and tighten the set screw.
4. Check by turning on the hopper motor and observing the action of
the cases.
5. When accuracy has been attained, close the inspection gate.
[23]
CALIBER .30 THIRD DRAW CASE
Adjustments
__*___—_—__—_—_—__——_—;.———-——
Feed Fingers
Tools:
Procedure:
The feed ﬁngers push the cases along the feed track to the punch and die.
If it is not properly adjusted, the case may fail to drop from the feed
socket into the feed track, or if the feed ﬁnger is set too far back, the cases
will not travel smoothly along the feed track. The position of the feed
ﬁngers is adjusted by adjusting the nuts on top of the push rod. They
should be adjusted so that the case just clears the feed ﬁnger when the
case drops from the feed socket into the feed track.

Feed Finger
Adjustment


ENLARGEMENT OF
FEED FINGER ADJUSTMENT
FEED ASSEMBLY
Two 11/4" wrenches
1.
2.
3.
Lift the guard by hand until the latch engages the bottom of the guard.
Place three or four cases in the feed track against the feed ﬁnger.
Disconnect the feed tubes by turning with your hand until the bayonet
ﬁtting is disengaged, and place a case in the feed tube socket.
Turn the ﬂywheel one complete turn and continue until the ram is at
its lowest position. This places the feed ﬁngers at the extreme back
stroke.
Lower the front guard.
Use two 11/4" wrenches to loosen the lock nut on top of the push rod.
Use a 1%" wrench to turn the adjusting nut on top of the push rod
until the case in the feed tube socket drops into the feed track.
Tighten the lock nut while holding the adjusting nut in place.
Turn the ﬂywheel until the ram is at the top dead center.
Caution: Make sure all guards are in place before starting the machine.
I24}
CALIBER .30 THIRD DRAW CASE Adjustments
Brake Adjust the brake so that it will keep the ram from falling when the
clutch is disengaged. It must be adjusted so that the brake drum is
gripped ﬁrmly when the brake is applied, but must not be so tight that
it drags when the drum is in motion.
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BRAKE ASSEMBLY SKETCH OF BRAKE ASSEMBLY
Tools: 7/8” wrench, V2" wrench
Procedure: 1. Use a 7/8” wrench to loosen the lock nuts on both of the adjusting
screws on the brake shoes.
2. Use a %” wrench to loosen the adjusting screw a fraction of a turn,
bringing the shoe closer to the brake drum.
3. Tighten the lock nuts on the adjusting screws.
4. Operate the machine and observe the action of the brake.
Note: The above procedure should be repeated until the brake drags
slightly while the machine is in motion. Then the adjusting screws
should be tightened just enough to free the shoe from the drum.
I25]
CALIBER .30 THIRD DRAW CASE Adjustments
Brake Release Rod The brake release rod connects the brake lever to the clutch lever. Its
function is to synchronize the action of the brake and the clutch. When
the clutch is disengaged, the brake lever should be released so that the
brake may be applied through the brake spring. Also when the clutch is
engaged, the rod should act to pull the brake lever sufﬁciently to release
the brake shoe from the brake drum. For proper adjustment the adjusting
nut should be about 1%” above the brake lever.
I


ENLARGEMENT OF
BRAKE RELEASE ROD
-i ll IIII, tiililtllllllllﬂllllllllllll.Illlllllllll
BRAKE
Tools: Two 1%,” wrenches
Procedure: 1. Use an IV“-,” wrench to loosen the lock nut on the brake release rod
while holding the adjusting nut with another 1%” wrench.
2. Use an M6" wrench to turn the adjusting nut until it is about 11/4”
above the_brake lever.
3. Tighten the lock nut while holding the adjusting nut in place.
4. To check for accuracy, engage the clutch, turn on the power, and then
disengage the clutch and observe whether or not the brake lever is
released.
[26]
CALIBER .30 THIRD DRAW CASE Adiusfmenfs
Broke Spring The brake spring acts to close the brake shoe against the brake drum.
The spring must have sufﬁcient tension to press the brake shoe ﬁrmly
against the brake drum when the brake rod is released.
.1‘


Spring
BRAKE ASSEMBLY
Tools: 1%" wrench
Procedure: 1. Use a. 1146” wrench to loosen the lock nut on the brake spring rod.
2. Use a 1%” wrench to turn the adjusting nut on the spring rod until
there is a ﬁrm pressure against the brake shoes.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Check the adjustment by operating the clutch lever and observing
whether or not the brake shoe presses ﬁrmly against the drum when
the clutch is disengaged.
[27]
CALIBER .30 THIRD DRAW CASE
Adjustments
Detector Stem The detector stern actuates the knockout bar which in turn actuates the
clutch lever trip.
If the knockout bar is adjusted properly and the
detector system fails to trip the clutch when there is an inverted case or
foreign material in the case on the feed track, the stems must be adjusted.
The stems should be adjusted so they almost touch the bottom of the case
when the ram is in its bottom dead center.


ENLARGEMENT OF ADJUSTMENT
FOR DETECTOR STEM
Adjustment
For Detector
Stem
DETECTOR ASSEMBLY
Tools:
Procedure:
1%” wrench, 1/2" wrench
1.
2.
3.
Raise the front guard until the latch engages the bottom of the guard.
Place test cases under the detector stem, mouth up.
Engage the clutch and turn the ﬂywheel until the ram is at bottom
dead center.
Hold the stem with a %” wrench and loosen the lock nut with an
1%,” wrench.
Adjust the detector stem until it touches the bottom of the case lightly.
Use an I1/in” wrench to tighten the lock nut on the detector stem.
Turn the ﬂywheel with a ﬂywheel rod until the ram is about three-
fourths its upward travel, then disengage the clutch and continue
turning the ﬂywheel until it has reached the top dead center.
Lower the glass guard before resuming production.
I 28 I
CALIBER .30 THIRD DRAW CASE
Adjustments
Knockout Bar

Tools:
Procedure:
The purpose of the detector system is to disengage the clutch if there is
an inverted case or foreign material in the case on the feed track. If it
fails to perform its function, either the knockout bar or the detector stem
is out of adjustment. The knockout bar should be checked ﬁrst by bring-
ing the ram to bottom dead center and checking the clearance between the
knockout bar and the clutch lever trip. A clearance of about .004”
should exist at this point. If the clearance is not correct the knockout bar
must be adjusted.
or
Lock Nuts


ENLARGEMENT OF
KNOCKOUT BAR
DETECTOR ASSEMBLY
Two 7/3" wrenches, feeler gage
1. Raise the front guard until the latch engages the bottom of the guard.
2. Lower the ram with a ﬂywheel rod until it is at the bottom of the
stroke.
3. Use a 7/8” wrench to loosen the lock nuts on top of the bottom part
of the knockout bar.
4. Use a %" wrench to adjust the knockout bar by turning the bottom
adjusting screws until there is a .004” clearance between the knockout
bar and the emergency release pin.
5. Tighten the lock nuts against the knockout bar.
6. Raise the ram by turning the ﬂywheel with the ﬂywheel rod.
7. Release the latch on the bottom of the guard and allow the guard to
drop back into position.
[29]
CALIBER .30 THIRD DRAW CASE
Adjustments
Clutch Lever Spring When the clutch lever is released, it is pulled up by the clutch lever spring.

This action should disengage the clutch and release the brake lever so the
brake shoe can be pressed against the brake drum. If the spring does not
perform its function, the tension must be increased.
I


-I‘ $-‘it
if “*~* r. \__
x. 5*
if 5
"Tf""f*\~
.3 5%
S 2
; ENLARGEMENT
Rf" ; BRAKE SPRING
I ADJUSTMENT
REAR VIEW: CLUTCH LEVER
SPRING CIRCLED
Tools:
Procedure:
Two %” wrenches
1. Use a V8” wrench to loosen the lock nut on the adjusting screw.
2. Use a 7/8" wrench to turn the adjusting nut until the tension on the
spring will draw the kick-out cam ﬁrmly against the clutch housing
when the clutch is disengaged.
Use a %” wrench to hold the adjusting nut while tightening the lock
nut, using another 7/8” wrench.
I30]
CALIBER .30 THIRD DRAW CASE
Adjustments

Friction Ball Spring The friction balls backed up by springs form the stations for the cases in
the feed track. If the springs become worn or dirty, the cases will not
travel smoothly along the feed track. This necessitates the removal of
the feed track guides, the cleaning of the springs and the replacing of the
worn springs.
Replacement
Tools:
Procedure:


FEED TRACK ASSEMBLY
3 ” Allen wrench, %” Allen wrench, V” wrench 8" screwdriver
8 8 r
1.
2.
9°71?‘
10.
11.
Raise the front guard until the latch engages on the bottom of the
guard.
Remove the feed tubes from the bridge by turning the bayonet
ﬁttings by hand until disengaged.
Use a 38" wrench to remove the nuts from each end of the bridge
and remove the bridge from the machine.
Use a 5/16" Allen wrench to remove all of the Allen screws in each side
of the feed track, also the screws in the back stop. Lift the feed
tracks and the back stops from the machine.
Use an 8" screwdriver to remove the screws from the sides of the
feed track. Lift the plate from the feed track.
Remove the ball bearings from the top of the springs.
Lift the springs out, inspect for tension and breakage.
Put a drop of oil on the springs and replace in the feed track. Place
the ball bearings on top of the springs and replace the feed track plate.
Caution: Watch that the ball bearings do not bind while the plate
is being replaced.
Replace the tracks in the machine and tighten the Allen screws.
Replace the back stops and tighten the Allen screws.
Release the catch on the guard and lower it in place.
[31]
CALIBER .30 THIRD DRAW CASE
Troubles and Corrections
Objective
Scored or Scratched
Walls
Crooked Draw
TROUBLES AND CORRECTIONS
The adjuster will meet many troubles and defects in the operation of this
machine. It is impossible to anticipate all the problems that may con-
front an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
Recognition of the following troubles is made by visual and gage inspection
of the component together with constant observation of the machine as
it operates.
Visual inspection will reveal scratches on the inside or outside walls of
the case. Finger nail inspection is especially valuable in detecting
scratches on the outside wall.
The causes are: The corrections are:
1. Foreign matter (dirt, grit, shav- 1. Remove the cooling solution,
ings, etc.) in the cooling solution.
Foreign matter (dirt, dried soap,
etc.) on the cases.
Chipped punch——a piece broken
off the end of the punch.
Skinned punch—punch surface
marred.
Cracked die—fracture in the
cross section of the die.
Scratched die—scratched on the
inside surface of the die.
clean the reservoir, replace with
clean cooling solution.
. Send the cups to the Washing
Department to be rewashed.
. Replace with a new punch.
. Polish the punch if it is not too
badly skinned. If it is beyond
repair, replace with new punch.
. Replace with new die.
. Polish the die if the scratch is
not too deep, or replace with a
new die if necessary.
Gaging discloses uneven sidewall thickness, crooked tops, or uneven
bottoms.
The causes are:
The corrections are:
1. Bent punch. 1. Straighten the punch in an arbor
press. If it cannot be straight-
ened, replace with a new punch.
2. Worn die—drawing surface too . Replace with a new die.
large or irregular.
Foreign matter (dirt, shavings,
burrs, etc.).
. Remove the die and the die
block. Clean with a rag and
replace.
[32]
CALIBER .30 THIRD DRAW CASE
Troubles and Corrections

Crooked Draw 4. Improper anneal——cups either
(Cont.)
Thick Bottom
Thin Bottom
Punch Outs
4. If too hard, return to Annealing
Department to be reannealed; if
too soft, call inspector and check
source of supply.
annealed too hard or too soft.
Gaging discloses insuflicient material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Not enough angle on taper of 1. Replace with new punch.
punch.
2. Radius on end of punch insuﬂi-
cient.
2. Replace with new punch.
Gaging indicates too much material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Too much angle on the taper of 1. Replace with new punch.
the punch.
2. Radius at the end of the punch 2. Replace with new punch.
too great.
Visual inspection discloses that the bottom of the case is punched out or
the side of the case is deformed by the punch.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Improper anneal——the case met- 1. Send to the annealing room.
al is too hard.‘
2. Improper anneal——the case met- . This cannot be corrected. Check
al is too soft. source of supply and call in-
spector.
3. There is no radius on the punch. . Replace with a new punch.
The punch is too large on the
drawing end.
4. The die is upside down. The die . Remove the die and replace it in
is not placed in the die block
the proper position.
properly.
CALIBER .30 THIRD DRAW CASE
Troubles and Corrections

Short Case
Long Case
Shea red Tops
Undersize Diameter
Oversize Diameter
Wrinkled Mouth
Gaging discloses the case is not long enough and the walls are too thick
to meet speciﬁcations.
The causes are: The corrections are:
1. The die is too large—it is over- 1. Replace with a new die.
size in the drawing surface.
2. Punch is too small. 2. Replace with a new punch.
Gaging discloses the case is too long and the walls too thin to meet
speciﬁcations.
The causes are: The corrections are:
1. Lap out the die to the proper
size.
1. The die is too small—’undersize
in the drawing surface.
2. The punch is too large. 2. Replace with a new punch.
Visual inspection discloses that the mouth of the case is torn or uneven.
The causes are: The corrections are:
1. Improper annealing——case metal 1. Send to the Annealing Depart-
too hard. ment to be reannealed.
2. Faulty stripper—stripper bro- 2. Repair, or replace with new
ken. stripper.
3. No stripper. 3. Insert stripper.
Gaging discloses diameter of case undersize.
The cause is: The correction is:
1. The die is too small-—undersize
in the drawing surface.
1. Lap out the die to proper size.
Gaging discloses diameter of case is oversize.
The cause is: The correction is:
1. The die is too large—it is over- 1. Replace with a new die.
size in the drawing surface.
Visual inspection discloses mouth of case wrinkled and uneven.
The causes are: The corrections are:
Polish and remove brass from
punch.
1. Rough punch—surface of punch 1.
has excess coating of brass.
Repair or replace with new
stripper.
2. Faulty stripper—stripper bro- 2.
ken.
Lap die if possible, or replace
with new die.
3. Rough or ringed die—rough spot 3.
or brass coating on drawing
surface of die.
4. No stripper. 4. Insert stripper.
I34]
CALIBER .30 THIRD DRAW CASE
Troubles and Corrections

Uneven Flow of
Cases from Hopper
Case Tracks
Damaged
Hopper Jam
Slow Press
Visual inspection discloses that cases are not flowing through the feed
tube and feed tracks.
The causes are: The corrections are:
1. Remove cases from hopper and
check source of supply.
1. Defective or long cases—cases
from previous draw to long or
defective.
2. Cases jammed in feed tube. 2. Clear feed tube.
Clean and check source of sup-
ply.
Repair feed ﬁnger or replace
with new feed ﬁnger.
3. Foreign matter (dirt, shavings, 3.
etc.).
4. Feed ﬁnger burred. 4.
5. Broken feed ﬁnger operating rod 5. Replace with new springs.
springs.
6. Arm in pin wheel hopper loose. 6. Tighten arm.
Visual inspection discloses cases not properly traveling along case tracks.
The causes are: The corrections are:
1. Improper adjustment. 1. Proper adjustment.
2. Broken springs. 2. Replace with new springs.
Visual inspection discloses cases are not feeding through hopper to feed
tube properly.
The causes are: The corrections are:
1. Overloaded——too many cases in 1. Remove excess cases.
hopper.
2. Cases stuck to pins in pin wheel 2.
hopper.
3. Belt slips—1oose belt, oily belt. 3.
Clear hopper and check pins for
burrs.
Tighten belt; if oily, clean.
A lowered production rate may indicate that the stroke of the press is
slowed down.
The causes are: The corrections are:
1. Dry bearings. 1. Check the lubrication. Call
Maintenance Department.
2. Galled gibs. 2. Check the lubrication. Call
Maintenance Department.
3. Loose belt. 3. Adjust the motor on the slides.
CALIBER .30 THIRD DRAW CASE Troubles and Corrections
\
Clutch Clicks Visual inspection discloses that the clutch does not operate properly.
The cause is: The correction is:
1. Bent or broken pins, rods or 1. Call Maintenance Department.
springs. The clutch dog will not
release properly.
Motor Stops Visual inspection discloses the motor is not running and the press is
stopped.
The cause is: The correction is:
1. Overload or burnt out armature, 1. If the machine is overloaded,
bearings, etc. clear the cause of the overload;
press the reset button to start
the motor. If there is any other
cause for the motor to stop, shut
off the power; call the Main-
tenance Department.
[36]
CALIBER .30 THIRD DRAW CASE
Tool Servicing
Objective
Servicing New Dies
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the
drawing of the bullet jackets and cartridge cases. Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters‘ will be concerned primarily with the removal of brass and
small scratches that appear on working surfaces of dies and punches, and
they must be careful, when using an abrasive on any tool, not to alter
materially its dimensions.
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1.
Dies as received from the tool room are normally undersize to allow
for expansion pressure and for lapping to a desired size when necessary.
. The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
. As a precaution, before a test run is made, the die bore should be
inspected for roughness and polished if necessary. If the bore is rough
causing undue friction, more metal than is necessary may be pulled
from the bottom of the jacket or case at the start of the draw.
The product from the test run should be carefully gaged and inspected.
Then, and then only, if an undersize or out-of-true die is indicated,
should the die be lapped.
If trial in the machine shows that the die is undersize, place it in a
three jaw chuck on a speed lathe to lap it.

OVER-ALL VIEW OF SPEED ‘LATHE
I37]
CALIBER .30 THIRD DRAW CASE
Tool Servicing

6.

Check the die to see that it is straight and secure in the chuck.

FIG. 1
CORRECT METHOD OF PLACING
DIE IN CHUCK
Lapping Procedure 1.
10.
Carboloy Dies
FIG. 2
INCORRECT METHOD OF PLACING
DIE IN CHUCK
When lapping is necessary, proceed as follows: Use a lap stick made
of brass, lead, ﬁber or wood about the same diameter as the die hole.
Dip the lap stick in a solution of #120 emery dust and olive oil or
coal oil.
Hold the lap stick as nearly as possible in line with the angle of the
taper. When lapping the land, hold the stick at a right angle to the
mouth of the die to keep the land true. A land which is not true
causes irregular wall thickness and crooked tops on jackets and cases.
While holding the lap stick against the die, give the stick a rapid in
and out movement. This cuts down the ridges left by the grinder
wheel in the metal surface and makes it smoother. Repeat this
operation according to the amount of metal that must be taken out
of the die.
Wipe the die clean with a cloth.
Next, polish the die with the finest grade of emery cloth available,
not coarser than #220.
Finish the polishing operation with crocus cloth.
Wipe out the inside of the die again with a cloth.
Remove the die from the chuck and check the size of the die with a
plug gage.
Be sure the die is free of all emery dust before replacing it in the
machine for production.
To lap a carboloy die, follow the same procedure, with diamond dust
and olive oil instead of emery dust.
[38]
CALIBER .30 THIRD DRAW CASE
Tool Servicing

Servicing Scratched
‘ Dies
Servicing 0 New
Punch
Lapping
1. Before removing a die from a machine to look for scratches, remove
the stripper to determine whether the stripper, rather than the die, is
scratched.
2. Check the die or stripper visually to determine how badly it is
scratched. If the die or stripper has a very deep scratch, it should be
sent to the Tool Service Department.
3. If it is found that the scratch is in the die, check the die with a die
“wear limit” plug gage to determine how much metal can be worked
out of it without making the die too large.
4. To polish the die, place it in a three jaw chuck on a speed lathe.
5. Polish it with ﬁne emery cloth, then with crocus cloth.
6. If the scratch can’t be removed by polishing, the die must be lapped.
See lapping procedure, or send to the Tool Service Department if
necessary.
7. Check the die size with the “wear limit” plug gage before putting it
into production.
Before an abrasive of any kind is applied to a new punch its dimensions
should be carefully checked with micrometer or proﬁle gage, and its
working surface should be examined for ﬁnishing or handling marks and
lack of polish. A highly polished punch aids in stripping and allows metal
to flow freely thereby reducing the tendency of brass to pile up on the
working surface.
An Adjuster will not be required to lap more than .0005” from a new
punch. If more than this must be removed to bring the punch to size, it
should be returned to the Tool Service Department for correction. Lap-
ping is done with a piece of abrasive cloth wrapped around and moved
back and forth along the axis of the punch as it revolves in a speed chuck.
If the abrasive were held stationary, deep rings would be cut into the
surface, thereby ruining the ﬁnish.
The punch is shown in Fig. 1 correctly chucked, and in Fig. 2 incorrectly
held (See page 37). Avoid excessive overhang of the punch as this is a
safety hazard; make sure that the jaws are correctly set and tightened
securely. Do not allow the jaws to grasp the working surface of the punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with cross-hatched effect.
CALIBER .30 THIRD DRAW CASE
Tool Servicing

Polishing
The lapping operation must be followed by polishing. Polishing is done
in the same manner as lapping except that a ﬁner abrasive is used, as for
example, crocus cloth. A ﬁnal operation called draw polishing is done with
the chuck stopped. To draw polish a punch move the abrasive cloth
lengthwise over the entire working surface avoiding rotary motion of the
punch or the abrasive. Continue this ﬁnal operation until all lapping
marks are removed and the desired high polish or mirror like ﬁnish is
obtained.


Servicing a Used
Punch
FIG. 3
CORRECT METHOD OF PLACING
PUNCH IN CHUCK
FIG. 4
INCORRECT METHOD OF PLACING
PUNCH IN CHUCK
As a punch is used its working surface wears accumulating scratches and
a coating of brass. Excessive wear is determined by measuring with
micrometer or checking with proﬁle gage. Obviously, an undersize punch
must be replaced with one of approved dimensions. Scratches, if not too
severe, may be removed by the lapping and polishing operations described
above. A light coating of brass may be removed by the polishing operation
alone. The question of how soon a new punch will need lapping or
polishing can be answered only from experience since many variable factors
enter into the problem.
[40]
CALIBER .30 THIRD DRAW CASE
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces Friction
Lubrication
Anti-friction
Bearings
MACHINE LLIBRICATION
The efficiency of all machines depends, to a great extent, upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss. I
A major cause of inefficiency is friction. Friction as far as we are concerned
here, is the force that resists the sliding of one surface over another. It
makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufﬁciently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the‘resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
(1) Petroleum oils and greases. Petroleum oil or crude oil is a mineral
oil that is pumped from the earth.
By various degrees of reﬁning, oils of different properties are obtained for
the thousands of different types of lubrication needed in industry.
Lubricating grease is a compound of petroleum oil and soap.
(2) Vegetable oils and animals oils are mixed with petroleum oils for
many applications. -
(3) Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction. We thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[41]
CALIBER .30 THIRD DRAW CASE
Machine Lubrication
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
/
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.'q9§.°‘tI>9°.l\'-i
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed
of the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage, and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable, where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen, good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.'qP7.°‘!‘=“S'*°.l\°
Frequency of lubrication.
I4-9-I
CALIBER .30 THIRD DRAW CASE
Machine Lubrication

Methods of Getting
Lubricant to Bearing
Surface
Hints on Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
2. Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°9?‘P‘PP°
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
. Screw down cups.
. Compression cups.
1
2
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5
. Grease packing.
A systematic control of all lubrication is important. Lubrication must
be done periodically and lubrication cups must be kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubri-
cation.”
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two pIaces——in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times except when
the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way into a
grease barrel can be easily forced into a bearing and cause the machine
to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think that it
should be changed, take it up with your supervisor.
I43]
CALIBER .30 THIRD DRAW CASE Machine Lubrication

LUBRICATION CHART


N0. of Fittings, Frequency of
Lubricant Machine Part Grease Cups, Lubrication
Etc. Hours
Crankshaft Bearings 2 8
Pitman Bearing 1 8
LIGHT GREASE Gibs 4 8
(Blue Gun) Clutch Assembly 1 8
Hopper 1 24
Connecting Screw Knuckle 1 8
Flywheel and Clutch 1 8
Feed Finger Assembly 4 8
Feed Finger 6 8
MEDIUM OIL Detector Punch Assembly 5 8
(Red Oiler) Clutch Lever 7 24
Brake Assembly 6 24
Brake Shaft 2 24
HEAVY OIL Wrist Pin Reservoir 1 24
(Yellow Oiler) Worm Gear Drive for Hopper 1 1 wk.

[44]
CALIBER .30 THIRD DRAW CASE
Index
Adjustment, Brake, 25
Brake Release Rod, 26
Brake Spring, 27
Clutch Lever Spring, 30
Detector Stem, 28
Die Replacement, 21
Feed Fingers, 24
Friction Ball Spring Replacement,
31
Hopper Feed Tube Mouth, 23
Knockout Bar, 29
Pin Wheel Bridge, 22
Punch Replacement, 20
Annealing Department, 16
Anti-Friction Bearings, 41
"Anvil, 12
Ball Spring Tension, 8
Bayonet Connection, 7
Bolster Plate, 8, 11
Bottom Thickness, 16
Brake, 6, 26
Action, 2
Adjustment, 25
Assembly, 25
Drum, 2, 25, 27
Lever, 26
Release Rod Adjustment, 26
Rod, 27
Shoe, 2, 25, 27
Spring, Adjustment, 27
Spring Rod, 27
Carboloy Die, 38
Case, 16
Tracks, 7
Tracks, Damaged, 35
Clutch, 6, 9, 26
Action, 2
Clicks, 36
Lever, 2, 10, 26, 30
Lever Latch Pin, 3, 6
Lever Spring Adjustment, 30
Lever Trip, 28
Coil Spring Feed Tube, 15
Springs, 10
Component, 16
Connecting Rod, 10
Controls, 3
Cooling Pump, 9
Solution, 3
Solution Feed Pipes, 9
Solution Pump, 1
Crankshaft, 2, 3
Flywheel, 9
Speed, 1
Crocus Cloth, 38
Crooked Draw, 32
Heads, 17
Tops, 17, 32
INDEX
Cup, 16
Detector Stem, 6, 28
Stem Adjustment, 28
Stems, 3
System, 3, 6, 28, 29
Dial Indicator, 17
Diameter, 20
Diamond Dust, 38
Die, 3, 11, 13, 15, 24
Block Assembly, 11
Block Base Plate, 11
Block Holder, 11
‘Plug Gage, 37
Replacement Adjustment, 21
Disposal, 14
Emery Dust, 38
Feed Finger, 14, 15, 24
Fingers, 3, 8
Fingers Adjustment, 24
Motor, 1
Mouth, 22
Pipe, 15
Track, 6, 14, 15, 24
Track Guides, 31
Tracks, 3, 7, 8
Tube, 5, 14
Tube Bridge, 23
Tubes, 3, 4, 7
Floor Space, 1
Flywheel, 2, 24
Foreign Objects, 3
Friction, 41
Ball Spring Replacement Adjust-
ment, 31
Balls, 31
Gages, 17
Gland Nut, 12
Grease, 42
Guide Ring, 11, 13
Hopper Assembly, 4
Feed Tube Mouth Adjustment, 23
Inspection Gate, 22, 23
Jam, 35
Motor, 3
Inside Diameter, 16
Knockoff Bar, 3, 6
Knockout Bar, 28
Knockout Bar Adjustment, 29
Lap Stick, 38
Lapping, 37, 38, 39
Long Case, 34
Lubricating Film, 41
Lubrication, 4, 14, 41
Chart, 44
Hints on, 43
Methods, 42
Machine Motor, 1
Main Drive Motor, 3
Manufacturer, 1
Metallurgy Department, 33
Micrometer, 40
Motor, 3, 4
Control Switch, 3
Stops, 36
Olive Oil, 38
Outside Diameter, 16
Over-all Height, 1
Length, 16
Overhead Hopper, 14, 15
Overload Switch, 3
Oversize Diameter, 34
Pin Wheel Bridge, 5
Wheel Bridge Adjustment, 22
Wheel Hopper, 3, 4, 5, 14, 15
Wheel Hopper Box, 14, 15
Wheel Shaft, 4
Pinion Gear, 4
Plug Gage, 17, 38
Plunger Rod, 8
Polishing, 40
Power, 2
Production, 1
Proﬁle Gage, 40
Pump, 3
Motor, 3
Punch, 3, 12, 13, 14, 15, 24
Holder, 12
Holder Assembly, 12
Holder Block, 3, 12
Outs, 33
Replacement Adjustment, 20
Rake-Off Spring, 5
Ram, 3, 6, 10, 14, 15
Reservoir, 3
Rocker Arm Assembly, 8
Rolling Key Clutch, 2
Scored Walls, 32
Scratched Walls, 32
Scratches, 17, 20
Selecting a Lubricant, 42
Servicing New Dies, 37
Servicing New Punch, 39
Scratched Dies, 39
Used Punch, 40
Shear Tops, 34
Short Case, 34
Sidewall Thickness Gage, 18
Variation, 16
Sleeve, 12
Slow Press, 35
Spacer, 13
Ring, 11
Split Collar, 12
Stripper, 11, 13, 14, 15
Holder, 13
Ring, 11
[45]
CALIBER .30 THIRD DRAW CASE
Index
Stroke, 1
Thick Bottoms, 33
Thin Bottoms, 33
Three-jaw Chuck, 37
Toggle Switches, 3
Tools, 1
Transmission, 2
Twin Ring Gage, 17
Type of Feed, 1
Undersize Diameter, 34
Uneven Bottoms, 32
Flow of Cases, 35
Uneven Sidewall Thickness, 32
V Belt, 3, 4, 15
Belts, 2
Visual Inspection, 17, 32
Weight, 1
Wrinkled Mouth, 34
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Fourth Draw Case
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
~* l
PREFACE
An original series of training manuals, pertaining to the adjustments of
'Caliber .30 and Caliber .50 cartridge manufacturing machines, was de-
veloped from notes and sketches made by Western Cartridge Company
personnel while in training at Frankford Arsenal early in 1941, and later
completed by them while serving as Chief Instructors in the Training
Department of Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for
the machines and machine parts used in the manufacture of small arms
ammunition. Photographic illustrations have been freely substituted for
drawings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible but they
are as of this date and are subject to changes.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more
than $10,000.”
(June 5, 1917, C 30, Title 1, Sec. 1; 40 Stat. 217. Act of March
28, 1940; Public No. 443, 76th Congress, 3rd Session.)
II
MANUAL CORRECTlONS—CALlBER .30 FOURTH DRAW CASE
LOCATION
Page 11,- 1 6 & 7
Page 14- 1 8
Page 80—Proc 8
Page 16- 1 5
ERROR
Guide Ring
1st Draw
2nd Draw
1/8 " Wrench
“Annealed”
CORRECTION
Top Die
3rd Draw
4th Draw
% " Wrench
Omit
TABLE OF CONTENTS
PAGE
Catalogue Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tool Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
III

DRAW PRESS—CALIBER .30 FOURTH DRAW CASE
IV
CALIBER .30 FOURTH DRAW CAsE Catalogue Data

CATALOGUE DATA
Manufacturer E. W. Bliss Co., Brooklyn, New York
Machine Vertical Straight Side Single Crank Press E. W.
Description Bliss N o. 304 6 V Belt drive motor to crankshaft.
Machine Motor 7 % h.p.; 3 Phase; 60 cycle; 220/440 V.; 23.5/11.8
amps.; 865 R.P.M.
Type of Feed Automatic Pin Wheel Hopper 6 R.P.M.
Feed Motor Master Gearhead 1/8 h.p.; 1 Phase; 60 cycle;
115/120 V.; 3.4/1.7 amp.; 1725 R.P.M.; Co. Shaft
48 R.P.M.
Production ‘ 180 components per minute
Crankshaft Speed 90 R.P.M.
Stroke 9"
Cooling Solution Centrifugal (Gusher) Model 1-P3; 1/8 h.p.; Single
Pump Phase; 60 cycles; 110 V.; 1.1 amps.
Tools: Piece No.:
Punch D-4
Top Die .4605 x 12°
Bottom Die .460 x 12°
Stripper .464A
Stripper Holder 1.492 x 60°
Stripper Spring .464A
Split Collar AE-8
Split Collar Spring 21/3" x .10” x .016
Bushing Sleeve AE-4
Floor Space 4 ft. x 7 % ft.
Over-all Height 10 ft. x 101/, ft.
Weight 8000 lbs.
CALIBER .30 FOURTH DRAW CASE
Machine Description

Hopper Box
Hopper Motor
Pin Wheel Hopper
Feed Tubes
Switch
Power and
Transmission

2 I.-I-I- I
. 5
MACHINE DESCRIPTION
Motor
Flywheel


Guard
I!‘
1 I Crankshaft
Connecting Rod


3 \
t
1.. "
I ‘ Safety Guard
I '


-. ‘ '1'
IE ~
‘II;
t‘
i r,
FRONT VIEW
The E. W. Bliss single draw press, No. 304, illustrated above, is powered by
a 7% h.p. motor, through six V belts, to the flywheel mounted on a
horizontal crankshaft.
Incorporated in the ﬂywheel hub is a rolling key clutch for control of
power to the crankshaft through linkage to an individual clutch lever.
A conventional brake drum is located on the end of the crankshaft op-
posite the ﬂywheel. A lined brake shoe, secured and located by a bracket
attached to the machine frame, provides the friction necessary to hold the
crankshaft in position when the clutch is disengaged.
I2]
CALIBER .30 FOURTH DRAW CASE
Machine Description

Power and
Transmission (Cont. )
Pin Wheel Hopper
Feed Tracks
Ram
Detector Stems
Cooling Solution
Controls
The clutch and brake action are synchronized through the clutch lever.
When the clutch is engaged, the brake is released, and when the clutch is
disengaged, the brake is applied.
In normal operation, if the clutch is disengaged for any reason, the
crankshaft will always stop at the maximum upward position of the crank.
For inspection or adjustment purposes, the crankshaft is stopped and held
in any desired position while the machine is rotated by hand.
The pin wheel hopper receives cases from an overhead source and through
feed tubes deposits the cases, “mouth-up,” in the feed tracks on the bed
of the machine.
The motive ‘power for the pin wheel hopper is supplied by a % h.p.
reduction gear head motor, on an adjustable mounting bracket at the left
side of the hopper, through a V belt to the pin wheel.
The feed tracks, with the assistance of the feed fingers, transfer the cases
from the feed tubes to the punch and die stations.
The ram is a heavy cast-iron block. Its mass assists the power stroke of
the punch and absorbs the shock of impact and subsequent vibration.
The lower surface is machined for the attachment of a punch holder block.
The ram, the sides of which are ﬁtted into V grooves to guide it in its
vertical motion, is connected to the crankshaft throw by a non-adjustable
connecting rod.
Two coil springs are attached between the back side of the ram and a
spring bracket mounted on the machine frame above the crankshaft. The
springs act as a counterbalance and assist in dissipating the vibration set
up by the punches’ contact with the cases during the drawing process.
The detector system, which is mounted on the front of the ram, is a
mechanism which detects inverted cases, cases on their sides, and foreign
objects within cases as they travel through the feed tracks.
‘Above each feed track is located a detector stem. If a detector stem
encounters an improperly positioned case or a foreign object in a case, the
stem will be forced upward, and will move the knockoff bar to the right.
The knockoff bar will strike and move the clutch lever latch pin to the
right, tripping the clutch lever; thus the clutch is disengaged, the brake
is applied, and the machine is stopped.
To prolong die and punch life, each case is bathed by a cooling solution
which acts both as a cooling and a lubricating agent.
The base of the machine forms a reservoir for this cooling solution which
is pumped through a pipe system to the die. The pump is driven by a
1/8 h.p. vertical, direct drive motor.
The main motor control switch is of the push button “start and stop”
type. An overload switch, with a “reset” push button is also provided
for protection of the main drive motor.
I3]
CALIBER .30 FOURTH DRAW CASE
M'achine Description

Controls (Cont.)
Lubrication
Rear of Press
Two toggle switches, contained in the same case, are provided for control
of the hopper and pump motors. The right hand switch is for the pump
motor, and the left hand switch controls the hopper motor.
Lubrication of all moving parts is accomplished by Alemite-Zerk ﬁttings,
oil cups, oil holes, or distribution of lubricant by oiler, swab, etc., over
desired point. (See Lubrication Chart, page 43)
The rear view of the caliber .30 Fourth Draw Press shows the motors and
adjustable brackets. The press is started and stopped by a clutch in the
crankshaft ﬂywheel.
Below the frame is shown the 1/8 h.p. motor that drives the cooling solution
pump, which circulates the cooling solution from the reservoir in the
machine bed through the pipe system to the punches and dies. The
cooling solution serves as both a coolant and lubricant.
Adjustable
Bracket

Cooling
— Solution
Feed Pipes
REAR VIEW
I4]
CALIBER .30 FOURTH DRAW CASE
Machine Description
Pin Wheel Hopper
The pin wheel hopper and box are located at the top and to the left of the
machine.
The pin wheel hopper box is a cast-iron reservoir with the bottom sloping
toward an opening which leads into the pin wheel hopper. The pin
wheel hopper, attached to the front of the hopper box, is mounted on a
projecting cast-iron, bronze-lined bearing, into which is ﬁtted the pin
wheel shaft and hub.
The pin wheel hopper consists of an inner and an outer dish-shaped rim
and a mid-section of pin rings and spacer rings, bolted to form a hopper
assembly. The outer rim has three spokes attached to a hub shaft on
which the entire hopper revolves. The hopper is driven by a V type
belt from a gear reduction V8 h.p. motor. The belt ﬁts in a V groove
cut around the back side of the pin wheel. .
Hopper

FRONT VIEW OF PIN WHEEL HOPPER WITH DOOR OPEN
[5]
CALIBER .30 FOURTH DRAW CASE Machine Description
Pin Wheel Hopper The pin rings have a series of steel pins, spaced approximately 1" apart
(Cont) on their inner circumference, and set at an angle with the radii. _,The
spacer rings are wider than the pin rings and are chamfered on their inner
edges. This chamfer forms a channel between each of the spacers, to
guide the components onto the pins.
As the pin wheel hopper‘ rotates clockwise, some of the pins pick up cases,
and convey them upward. Contacting each row of pins as they rotate
upward is a spring steel strip, called the rake-off spring, which rakes off
all cases that are not properly seated on the pins. As the cases continue
their upward travel they contact a pin wheel bridge which holds them
on the pins as they reach the top of the circle. There is a pin wheel
bridge for each row of pins. When the cases reach the end of the pin
wheel bridge they slide off, “mouth-up,” into the mouth of the feed tube.
The door for the front of the pin wheel hopper is dish-shaped to match
the pin wheel rim, and is hinged at the left of the hopper box. The door
is held shut by a rotary latch.
Pin Wheel Steel Pin Wheel Bridge
Bridge Pins Adjustment

PIN WHEEL HOPPER
I6]
CALIBER .30 FOURTH DRAW CASE Machine Description
Feed Tubes and The lower end of the feed tube mouth is connected to the upper end of the
Bridge feed tube by means of a bushing. A bayonet type of bushing is used to
connect the lower end of the tube to the feed tube bridge.
The feed tube bridge is bolted to the bolster plate and above the feed
tracks. The feed tube bridge holds the feed tubes in position over the
feed tracks.
The cases slide, head down, from the feed tube mouth down the feed
tubes, to a position on the feed ﬁngers in the feed tracks.
Bayonet
Feed Tubes Connection

FEED TUBES AND BRIDGE
I7]
CALIBER .30 FOURTH DRAW CASE
Machine Description

Feed Tracks
Rocker
Arm
Shaft
The machine has a series of two-piece feed tracks that hold the cases in a
“mouth-up” position. Each track is bolted to the bolster plate of the ma-
chine. On the inner face of each track is a series of ball-spring stops
spaced to hold the cases in an upright position. On the rear of each track
is a brass back-stop to prevent the cases from being forced past the dies.
As the ram ascends an arm fastened to the ram lifts a feed ﬁnger operating
rod which actuates a rocker arm assembly, which furnishes motive power
for the feed ﬁngers.
The case, which has just emerged from the feed tube, is forced against the
others in the feed tracks by the feed ﬁngers. This causes the case in the
rear of the tracks to be forced past the ball-spring stops, to a position
over the dies, where the punch descends and forces the case through the
dies.
Back Stops


/ Feed
Fingers
FEED TRACKS AND CONNECTING PARTS
I3]
CALIBER .30 FOURTH DRAW CASE Machine Description
Crankshaft and The ﬂywheel transmits power to the ram, through the crankshaft and
Ram connecting rod.
There are two heavy coil springs which cushion the impact of the ram on
its downward stroke and help in a small way to lift the ram on its upward
stroke.
The clutch lever is used to start and stop the press. In the running
position it is hooked onto the latch pin catch. For ordinary stopping,
the latch pin kicks the lever off its hook. The rod on the clutch lever
connects the lever to the clutch.

Shock Absorber
Springs \

FRONT VIEW OF RAM REAR VIEW
AND CONNECTING PARTS
Clutch
Lever
Latch Pin
9 .
9
.’~ '
3*
k \ ‘.
I "
,I
5
3
I‘ l
\

CLUTCH LEVER AND ONE TYPE
OF SAFETY LOCK
[9]
CALIBER .30 FOURTH DRAW CASE Machine Description

Detector System The detector system is a mechanism which detects cases not in proper
position, and foreign objects within feed tracks. The detector system
which is bolted to the front of the ram, consists of a detector stem for
each feed track. If a detector stem encounters a foreign object in a case
or locates an improperly positioned case, the detector stem will be forced
up, and by cam action on its upper end will move the knockoff bar to
the right. The knockoff bar will strike the clutch lever latch pin tripping
the clutch lever which disengages the clutch and applies the brake,
thereby stopping the action of the ram. The clutch lever returns to an
“off” position by spring action.

DETECTOR-KNOCKOFF ASSEMBLY


. -ij/ Latch Pin

Push Rod
Feed __
Track
Rocker Arm
Shaft
CLOSE UP OF FEED TRACK
‘[10]
CALIBER .30 FOURTH DRAW CASE TOOI Holder Description

TOOL HOLDER DESCRIPTION
Punch Block Anvil: The anvil is inserted in the top side of the punch holder
Assembly / block in contact with the head of the punch and the punch
holder. It protects the face of the ram from the thrust of the
W punch.
-- Punch Holder Block: The punch holder block has two dowel
pins for alignment and is bolted to the under side of the ram
l by four Allen screws. It holds the punch holder assemblies.
Punch Holder: The punch holder is placed into the punch
holder block from the top side by “Press ﬁt,” ﬂanged end up.
The lower end is threaded to receive a hexagon gland nut. It
holds the punch assembly in the punch holder block.
Split Collar: The split collar is composed of two halves which
M/ are held in place by a coiled spring. It acts as a ﬂange on the
I 0 head end of the punch against which the sleeve is held by the
gland nut.


/ Punch: The punch, with the gland nut, spacer sleeve and
split collar in place, is inserted into the bottom sides of the
punch holder, head end up. This gland nut is then screwed into
the punch block holder.
Sleeve: The sleeve is placed on the punch from the bottom end
/ before the gland nut. It acts as a spacer in the assembling of
0 the punch.

Gland Nut: The gland nut, which has threads on its outer
surface, is screwed into the inner threads of the punch holder,
PYJ"E\2'Hol;_gzE forcing the spacer against the split collar. The gland nut thus
ASSEMBLY holds the punch assembly in the punch holder.
Button Anvil
*5 I./
\


\ \
»
Key
V
R\\\\\\\\\\\_\\ \
n\\\\‘%/
/A


-I
V


.'\'
Punch Holder
Split Collar
Bushing
Gland Nut
Punch
.‘s\\\\\ \\


CROSS SECTIONAL DRAWING OF PUNCH BLOCK ASSEMBLY
[ 11 I
CALIBER .30 FOURTH DRAW CASE Tool Holder Description

Die Block Assembly Top Draw Die: The top draw die is placed in the die hole of the die block
from the top side to rest on the bottom die-. It forms the outside diameter
of the case as the case is forced through it by the punch.
" Bottom Draw Die: The bottom draw die is inserted ﬁrst from the top
[J
/ side of the die holder into the die assembly hole of the die block. It sizes
the case to the speciﬁed diameter.
D / Die Block: The die block holds the die assembly. It is held in the chan-
nel of its bolster plate by a lock pin. The bolster plate is adjustable to
allow centering of the die assembly contained in the die block under the
punch. The vertical lip on the rear end of the die block assists the adjuster
in inserting, locating and removing the die block. There is one die assem-
bly for each punch.


Lock Pin: The lock pin is inserted through a small hole in the rear end of
the die block. It holds the die block in place on the bolster plate.
Stripper Holder: The stripper holder is inserted in the die assembly hole
from the bottom side and rests on the bolster plate.
Stripper: The stripper consists of three segments held together by a
coiled spring. It is inserted in the stripper holder with the large side of the
tapered hole up. It strips the case from the punch after it has been forced
through the die assembly.


Die Block Base Plate: The die block base plate serves as an anvil for
VIEW OF THE DIE . . . .
BLOCK ASSEMBLY the die block. The bottom projection guides the cases onto the conveyor.


Top Die


\‘-pt‘ “
O
CROSS SECTIONAL DRAWING OF DIE BLOCK ASSEMBLY


I12]
CALIBER .30 FOURTH DRAW CASE Tool Description

TOOL DESCRIPTION
Tool Name: Punch—Fourth Draw
Piece No.: D-4
Location: Held vertically in ram
Normal Life: 147,000 pieces.
Punch is made of tool steel, hardened, ground and
polished. Shank is slightly softer than working end.
Tool Name: Top Die—Fourth Draw
Piece N o. : .4605x12°
Location: Die Block
Normal Life: 14,000 pieces
TOP Die Die is made of tool steel, hardened, ground and polished.


Tool Name: Bottom Die—Fourth Draw
Piece No.: .460 x12°
Location: Die block
Normal Life: 14,000 pieces.
Die is made of tool steel, hardened, ground and pol-
ished.
Tool Name: Stripper—-Fourth Draw
Piece No.: .464A
Location: Die block—under die
Normal Life: 41,000 pieces.
Stripper is hardened tool steel, ground and polished.
Tool Name: Stripper holder—Fourth Draw
Piece No.: 1.492x60°
Location: Between die and stripper
Normal Life: 1,000,000 pieces.
Stripper holder is hardened tool steel, ground on all
surfaces.

Stripper Holder
I13]
CALIBER .30 FOURTH DRAW CASE
Process Sequence
Overhead Hopper
Pin Wheel Hopper
Box
Pin Wheel Hopper
Feed Tube
Feed Finger and
Feed Track
Ram and Punch
The Draw
Stripper
and Disposal
Lubrication
PROCESS SEQUENCE
The cases are fed by gravity from a truck or conveyor into the overhead
hopper and drop through a feed pipe, into the pin wheel hopper box.
Cases ﬂow from the pin wheel hopper box through an opening past the
agitator into the bottom part of the pin wheel hopper.
As the pin wheel hopper rotates, cases are agitated and picked up by pins
on the inside circumference of the pin wheel and carried up past the rake-
off springs which knock off misaligned cases and push partly set cases all
the way on pins. As the cases are carried to the top of the pin wheel they
are held on the pins by the bridge. At the end of the bridge they drop off
one at a time into the open end of the feed tube m~outh up.
Cases fall by gravity down through the coil spring feed tube into a bushing
mounted on the feed tube bridge and rest momentarily on the feed ﬁnger.
On the downward stroke of the ram the feed ﬁnger moves back permitting
the case to fall into the feed track. On the upward stroke of the ram the
feed ﬁnger moves forward pushing the cases along the feed track past the
spring buttons. The ball spring stop keeps the cases in an upright posi-
tion and prevents them from falling over. Cases pass by the counter
under and past the detector stems which detect foreign matter and in-
verted cases.
They pass to the rear of the feed tracks where they drop into the guide
ring directly over the dies and under the punch.
The ram descends with the punch and forces the case through the guide
ring into and through the die and stripper.
The forcing of the case through the die reduces the wall thickness and
diameter and increases the length of the case. This is known as the draw.
Before the draw, the component is known as the ﬁrst draw case and, after
the draw, as the second draw case.
As the punch withdraws from the dies, the cases are stripped off by a three-
segmented stripper located under the die, then falls onto a slide down a
chute through a rotary washer to a mechanical conveyor.
During the drawing operation the cases are lubricated and tools cooled by
a cooling solution which ﬂows over the cases through an opening under the
work plate.
[14]
CALIBER .30 FOURTH DRAW CASE Process Sequence

FLOW CHART

Overhead Hopper
Cases are fed by gravity from truck or conveyor
into overhead hopper through feed pipe.
I
Feed Pipe
Conveys cases by gravity down into pin wheel
hopper box.


I
Pin Wheel Hopper Box
Cases ﬂow through opening in pin wheel hopper
box past agitator into bottom of pin wheel hopper.
I
Pin Wheel Hopper
Rotates and cases are picked up by pins and car-


ried up past rake-off springs to top of pin wheel Hopper is Powered by a V8 h-P-
where they are held by the bridge. At the end of _ 1‘ edllction motor through a V-
the bridge they drop off, one at a time, into open type belt-


end of coil spring feed tube, mouth up.


I
Coil Spring Feed Tube
Conveys cases by gravity, mouth up, into the
bushing mounted in the feed tube bridge, where
they rest momentarily on the feed hammer.
I
Feed Finger
Moves backward, allowing the case to drop into
feed track. It then moves forward pushing the
case along the feed track.


Feed ﬁnger is powered from the
——- rocker arm shaft through the push
rod through the ram.


Feed Track
Guides the cases, single ﬁle, past and under the
detector stem to rear of track, where cases drop
into the dies and under the punch.
I
Dies and Punch
As the ram descends, the punch forces the case


Ram is powered from the Pitman
connecting rod through the crank-
through the dies and stripper increasing the length, h ft 1 t h d ﬂ h
and decreasing the diameter and the sidewall _ :,_:y1;eck1)le1(iCS if 7%yvi,1 Seligtoﬁ
thickness of the case. mounted on top of press,


Stripper
After the punch forces the case through the dies, it
withdraws and the case is stripped off by a three-
segmented stripper under the dies and falls onto a
slide and drops down a chute through a rotary
washer to a mechanical conveyor.

[15]
CALIBER .30 FOURTH DRAW CASE Product Description

PRODUCT DESCRIPTION
\
Product The component, when received by the Fourth draw, is in the form of a
Description case as shown in Fig. 1.
The component is received from the Annealing Department, where it was
annealed, pickled and washed. When the component is delivered to-the
Annealing Department from the third draw press, the metal has a very
bright, brassy appearance and a smooth ﬁnish. After the cup has been
annealed, the metal appears dull and has a rough ﬁnish.
The component is made of brass (70% copper, 30% zinc). The closed
end of the cylinder is the bottom and the open end is the mouth.
The dimensions of the cup are as follows:
Before Fourth Draw After Fourth Draw
Outside diameter .519— .517 Outside diameter .464— .463
Inside diameter .480— .482 Inside diameter .441— .443
Bottom thickness .150— .165 Bottom thickness .170~ .190
Sidewall variation .001— .002 Sidewall variation .001— .002
Over-all length 1.734~1.736 Over-all length 2.822-2.862
After the drawing operation, the case is delivered to the Annealing De-
partment, where it is annealed, pickled and washed before being delivered
to the second trim machine.
FIG. 1. BEFORE FOURTH DRAW FIG. 2. AFTER FOURTH DRAW


Mouth
I" Sidewall
" Q I‘ Bottom
.~ ‘b
After After Alter After After After Atter
Third First Annealing Washing Fourth Washing ' Second
Draw Trim Process Operation Draw Operation Trim
[16]
CALIBER .30 FOURTH DRAW CASE
Inspection
Visual
Gage Core
Gages
INSPECTION
At frequent intervals, after the drawing operation, a careful visual inspec-
tion of the cases must be made. The cases should be inspected for scratches
on the inside and outside walls, for crooked heads, crooked tops, and bodies
that are not round. When these defects are found, require an immediate ad-
justment of the machine in order to correct the fault. Whenever defective
cases are found, the lot from which they come must be removed from the
machine and properly identiﬁed so the bad lot will not get mixed up with
the good cases.
Gages are expensive instruments machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool since heat causes expansion of the
metal and results in a temporary variation in the case size.
The outside diameter of the case
is gaged with a twin ring gage.
Cases must pass through the
larger or “go” ring and must
not pass through the smaller
“no go” ring.


The bottom thickness of the case is
checked on a dial indicator. Vari-
ation in this dimension greatly
affects succeeding draws.


The above described inspection methods are those most commonly em-
ployed in Caliber .30 fourth draw case. However, other methods may
be developed to maintain the manufacturing standards.
I17]
CALIBER .30 FOURTH DRAW CASE
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than the starting button to determine
whether the clutch is disengaged.
Make frequent inspection to determine whether proper and sufficient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
I18]
CALIBER .30 FOURTH DRAW CASE
Adiusfments
Punch The punch may become worn causing the inside of the case to be too
small in diameter or may become scratched causing scratches on the
inside of the case. In either case the punch must be replaced.
Replacement
T00|s:
Procedure:


n’
PUNCH ASSEMBLY
1 %” Wrench
1.
Remove the rear guard by lifting it up and pulling it out away from
the machine.
Use a 1%” wrench to remove the gland nut in the punch holder while
holding the punch with the other hand.
Pull down on the punch removing the assembly from the punch holder.
Remove the bushing, gland nut and the split collar from the worn or
broken punch and place these parts on the new punch, making sure
the wide shoulder on the split collar is up.
Insert the punch assembly in the punch holder and tighten the gland
nut.
Caution: Be sure that the punch is clean.
Replace the rear guard.
Check the replacement for accuracy by drawing a case.
[19]
CALIBER .30 FOURTH DRAW CASE
Adjustments

Die Replacement
Tools:
Procedure:
The dies may become worn causing the case to be too large in diameter or
may become scratched causing scratches on the outside of the case. In
either case the die must be removed and replaced with a new die.
[ll
:-
DIE BLOCK ASSEMBLY
Screwdriver
1.
2.
3.
Remove the rear guard by lifting up and pulling out on the bottom.
Lift out the die block lock pin.
Pull out the die block, keeping one hand underneath to prevent
stripper from dropping out.
Turn the die block upside down allowing the dies to fall out into your
hand. Turn the die block right side up.
Slide the die block back in the machine part way while getting new dies.
Replace the dies in the die block making sure that the bottom die is
on the bottom with the tapered end down.
Push the die block back in the machine and replace the die block lock
pin.
Replace the guard.
Check for accuracy by drawing a case.
[20]
CALIBER .30 FOURTH DRAW CASE Adjustments

Pin Wheel Bridge In order to adjust the position of the bridges in relation to the pins on
the pin wheel, each bridge can be adjusted by the vertical bolts connected
to the bridges. Each bolt adjusts one of the bridges and should be adjusted
so that the cases will travel along the bridge to the feed mouth. If the
bridges are not properly adjusted, the cases will fall from the pins before
arriving at the feed mouth, or will jam along the bridge.


ENLARGEMENT OF
BRIDGE ADJUSTMENT


Bﬁdge
Adjustment
INTERIOR OF HOPPER
Tools; Two 1%” wrenches
Procedure: 1. Open the hopper inspection gate by pulling down on the gate.
2. Use two 11/6;” wrenches to hold the top nut with one wrench and loosen
the bottom lock nut on the vertical adjusting bolt with the other
wrench. ‘
3. Turn the adjusting nut until the bridge is approximately %" from
the pins on the pin wheel.
4. Tighten the lock nut while holding the adjusting nut in place and
close the hopper inspection gate.
5. Check the adjustment for accuracy by turning on the power and
observing whether or not the cases fall properly down through the
feed tube.
[21]
CALIBER .30 FOURTH DRAW CASE Adjustments

Hopper Feed The feed tube mouth receives the cases after they travel the length of the
Tube Mouth pin wheel bridge. The mouth should be in line with the pins on the pin
wheel so that the cases will drop from the pins into the feed tube mouth.
If the mouth is not properly adjusted, the cases will jam at the feed
mouth. Adjustment is made on the adjusting bolt that connects the feed
tube mouth to the pin wheel bridge.
Feed Tube Mouth Adjustment


ENLARGEMENT OF FEED TUBE
MOUTH SHOWING
ADJUSTMENT


PIN WHEEL HOPPER SHOWING FEED TUBE MOUTH
Tools: 1/4” wrench
Procedure: 1. Open the hopper inspection gate by pulling down on the gate.
2. Use a %” wrench to loosen the set screw on the bottom of the feed
tube bridge.
3. Adjust the feed tube mouth by hand until it is in alignment with the
pins on the pin wheel, and tighten the set screw.
4. Check by turning on the hopper motor and observing the action of the
cases.
5. When accuracy has been attained, close the inspection gate.
I221’
CALIBER .30 FOURTH DRAW CASE
Adjustments
\

Feed Fingers
The feed ﬁngers push the cases along the feed track to the punch and die.
If it is not properly adjusted, the case may fail to drop from the feed
socket into the feed track, or if the feed ﬁnger is set too far back, the
cases will not travel smoothly along the feed track. The position of the
feed ﬁngers is adjusted by adjusting the nuts on top of the push rod.
They should be adjusted so that the case just clears the feed ﬁnger when
the case drops from the feed socket into the feed track.

F d F‘
‘T Afjiustihfﬁi
ENLARGEMENT OF FEED
FINGER ADJUSTMENT
FEED FINGER ADJUSTMENT IN
RELATION TO THE FEED TRACKS
Tools:
Procedure:
Two 11/4" wrenches
1.
2.
3.
4.
109° 739°?‘
Lift the guard by hand until the latch engages the bottom of the guard.
Place three or four cases in the feed track against the feed ﬁnger.
Disconnect the feed tubes by turning with your hand until the bayonet
ﬁtting is disengaged, and then place a case in the feed tube socket.
Turn the ﬂywheel one complete turn and continue until the ram is
at its lowest position. This places the feed ﬁngers at the extreme
back stroke.
Lower the front guard.
Use two 11/4” wrenches to loosen the lock nut on top of the push rod.
Use a 11/4" wrench to turn the adjusting nut on top of the push rod
until the case in the feed tube socket drops into the feed track.
Tighten the lock nut while holding the adjusting nut in place.
. Turn the ﬂywheel until the ram is at the top dead center. Caution:
make sure all guards are in place before starting the machine.


I 23 I
CALIBER .30 FOURTH DRAW CASE
Adjustments

Brake
BRAKE ASSEMBLY
Tools:
Procedure:
Adjust the brake in order that it might keep the ram from falling when
the clutch is disengaged. It must be adjusted so that the brake drum is
gripped ﬁrmly when the brake is applied, but must not be so tight that
it drags when the drum is in motion. ‘
\
SKETCH OF BRAKE ASSEMBLY
%" wrench, %" wrench
1.
Use a 78" wrench to loosen the lock nuts on both of the adjusting
screws on the brake shoes.
Use a %” wrench to loosen the adjusting screw a fraction of a turn,
bringing the shoe closer to the brake drum.
. Tighten the lock nuts on the adjusting screws.
Operate the machine and observe the action of the brake.
Note: The above procedure should be repeated until the brake drags
slightly when the machine is in motion. Then the adjusting
screws should be tightened just enough to free the shoe from
the drum.
I24]
CALIBER .30 FOURTH DRAW CASE Adjustments
Brake Release Rod The brake release rod connects the brake lever to the clutch lever. Its
function is to synchronize the action of the brake and the clutch. When
the clutch is disengaged, the brake lever should be released so that the
brake may be applied through the brake spring. When the clutch is
engaged, the rod should act to pull the brake lever sufﬁciently to release
the brake shoe from the brake drum. For proper adjustment the adjusting
nut should be about 11/4" above the brake lever.
-
0
n
“
“
“I
>0
*-
.-
“
*
M
-”
.“
8-“
r“
-
-“


BRAKE RELEASE ROD
ASSEMBLY
-. ; Illj .mI~IImmIII~Ii I


Brake Release
/' Rod
' . ‘R10!
VIEW SHOWING BRAKE RELEASE ROD
%
‘.
Tools: Two 1%” wrenches
Procedure: 1. Use an 1%” wrench to loosen the lock nut on the brake release rod
while holding the adjusting nut with another %;” wrench.
2. Use an 1%" wrench to turn the adjusting nut until it is about 114'’
above the brake lever.
3. Tighten the lock nut while holding the adjusting nut in place.
4. To check for accuracy, engage the clutch, turn on the power, then
disengage the clutch and observe whether or not the brake lever is
released.
I25]
CALIBER .30 FOURTH DRAW cASE Adjustments

Brake Spring The brake spring acts to close the brake shoe against the brake drum. The
spring must have sufficient tension to press the brake shoe ﬁrmly against
the brake drum when the brake rod is released.


1
."
. IIItItI,IIIIIIIIIII'II I IIIIII IIIIIIIIIIII


BRAKE SPRING
BRAKE ASSEMBLY
Tools: 1%” wrench
Procedure: 1. Use a 11/16" wrench to loosen the lock nut on the brake spring rod.
2. Use a 1%" wrench to turn the adjusting nut on the spring rod until
there is a ﬁrm pressure against the brake shoes.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Check the adjustment by operating the clutch lever and observing
whether or not the brake shoe presses ﬁrmly against the drum when
the clutch is disengaged.
I26]
CALIBER .30 FOURTH DRAW CASE
Adjustments
Detector Stem
F d *
Traecllrs/T
mm.-- -
DETECTOR STEM AND ADJACENT PARTS
Tools:
Procedure: 1.
2.
3.

The detector stem actuates the knockout bar which in turn actuates the
clutch lever trip. If the knockout bar is adjusted properly and the detector
system fails to trip the clutch when there is an inverted case or foreign
material in the case on the feed track, the stems must be adjusted. They
should be adjusted so that they almost touch the bottom of the case when
the ram is in its bottom dead center.


ENLARGEMENT OF
DETECTOR STEM
I '1 Iv-
t
‘I
‘Md’ wrench, %" wrench
Raise the front guard until the latch engages the bottom of the guard.
Place test cases under the detector stem, mouth up.
Engage the clutch and turn the ﬂywheel until the ram is at bottom
dead center.
Hold the stem with a 1/2” wrench and loosen the lock nut with an
1%;" wrench.
Adjust the detector stem until it touches the bottom of the case lightly.
Use an 1%" wrench to tighten the lock nut on the detector stem.
Turn the ﬂywheel with a ﬂywheel rod until the ram is about three-
fourths its upward travel, then disengage the clutch and continue
turning the ﬂywheel until it has reached the top dead center.
Lower the glass guard before resuming production.
[27 I
CALIBER .30 FOURTH DRAW CASE
Adjustments

Knockout Bar
Tools:
Procedure:
The purpose of the detector system is to disengage the clutch if there is an
inverted case or foreign material in the case on the feed track. If it fails
to perform its function, either the knockout bar or the detector stem is
out of adjustment. The knockout bar should be ﬁrst checked by bringing
the ram to bottom dead center and checking the clearance between‘ the
knockout bar and the clutch lever trip. A clearance of about .004"
should exist at this point. If the clearance is not correct, the knockout
bar must be adjusted.


KNOCKOUT BAR
Knockout
Bar
DETECTOR SYSTEM (KNOCKOUT BAR)
Two 7/8" wrenches, feeler gage
1.
2.
3.
Raise the front guard until the latch engages the bottom of the guard.
Lower the ram with a ﬂywheel rod until it is at the bottom of the stroke.
Use a VB" wrench to loosen the lock nuts on top of the bottom part of
the knockout bar.
Use a V8" wrench to adjust the knockout bar by turning the bottom
adjusting screws until there is a .004” clearance between the knockout
bar and the emergency release pin.
Tighten the lock nuts against the knockout bar.
Raise the ram by turning the ﬂywheel with the ﬂywheel rod.
Release the latch on the bottom of the guard and allow the guard
to drop back into position.
[28]
CALIBER .30 FOURTH DRAW CASE
Adjustments
Clutch Lever Spring


REAR VIEW SHOWING CLUTCH LEVER SPRING
TOOIS:
Procedure:
When the clutch lever is released, it is pulled up by the clutch lever spring.
This action should disengage the clutch and release the brake lever so the
brake shoe can be pressed against the brake drum. If the spring does not
perform its function, the tension must be increased.


ENLARGEMENT OF
CLUTCH LEVER SPRING
Two 7 8" wrenches
1. Use a 78" wrench to loosen the lock nut on the adjusting screw.
2. Use a "/8” wrench to turn the adjusting nut until the tension on the
spring will draw the kickout cam ﬁrmly against the clutch housmg
when the clutch is disengaged.
3. Use a 3/8" wrench to hold the adjusting nut while tightening the lock
nut with another 7/8" wrench.
I29]
CALIBER .30 FOURTH DRAW CASE
Adjustments
Friction Ball Spring
Replacement
Tools:
Procedure:
The friction balls backed up by springs form the stations for the cases in
the feed track. If the springs become worn or dirty, the cases will not
travel smoothly along the feed track. This necessitates removal of feed
track guides, cleaning of the springs, and the replacing of worn springs.


FEED TRACK DISASSEMBLED
%" Allen Wrench, §1/6” Allen Wrench, %3'' Wrench, 8" Screwdriver
1.
2.
10.
11.
Raise front guard until latch engages on the bottom of the guard.
Remove the feed tubes from the bridge by turning the bayonet
ﬁttings by hand until disengaged.
Use a 3/8” wrench to remove the nuts from each end of the bridge
and remove the bridge from the machine.
Use a %” Allen wrench to remove all of the Allen screws in each side
of the feed track, also the screws in the back stop. Lift the feed
tracks and the back stops from the machine.
Use an 8’I screwdriver to remove the screws from the sides of the feed
track. Lift the plate from the feed track.
Remove the ball bearings from the top of the springs.
Lift the springs out, and inspect for tension and breakage.
Put a drop of oil on the springs and replace in the feed track. Place
the ball hearings on top of the springs and replace the feed track plate.
Caution: Watch that the ball bearings do not bind while the plate is
being replaced.
Replace the tracks in the machine and tighten the Allen screws.
Replace the back stops and tighten the Allen screws.
Release the catch on the guard and lower it in place.
I 30 I
CALIBER .30 FOURTH DRAW CASE Troubles and Corrections

TROLIBLES AND CORRECTIONS
Obiecﬁve The adjuster will meet many troubles and defects in the operation of this
machine. It is impossible to anticipate all the problems that may con-
front an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
Recognition of the following troubles is made by visual and gage inspection
of the component together with constant observation of the machine as
it operates.
Visual inspection will reveal scratches on the inside or outside walls of
the case. Finger nail inspection is especially valuable in detecting
Scored or Scratched
Walls
Crooked Draw
scratches on the outside wall.
The causes are:
The corrections are:
1. Foreign matter (dirt, grit, shav- 1. Remove the cooling solution,
ings, etc.) in the cooling solution. clean the reservoir, replace with
clean cooling solution.
2. Foreign matter (dirt, dried soap, 2. Send the cups to the Washing
etc.) on the cases. Department to be rewashed.
3. Chipped punch—a piece broken 8. Replace with a new punch.
off the end of the punch.
4. Skinned punch—punch surface 4. Polish the punch if it is not too
marred. badly skinned. If it is beyond
repair, replace with new punch.
5. Cracked die—-fracture in the 5. Replace with new die.
cross section of the die.
6. Scratched die——scratched on the 6. Polish the die if the scratch is
inside surface of the die.
not too deep, or replace with a
new die if necessary.
Gaging discloses uneven sidewall thickness, crooked tops, or uneven
bottoms.
The causes are:
The corrections are:
1. Bent punch. 1. Straighten the punch in an arbor
press. If it cannot be straight-
ened, replace with a new punch.
2. Worn die——drawing surface too 2. Replace with a new die.
large or irregular.
3. Foreign matter (dirt, shavings, 3. Remove the die and the die
burrs, etc.).
lock. Clean with a rag and
replace.
l31l
CALIBER .30 FOURTH DRAW CASE
Troubles and Corrections

Crooked Draw
(Cont.)
Thick Bottom
Thin Bottom
Punch Outs
4. If too hard, return to Annealing
Department to be reannealed; if
too soft, call inspector and check
source of supply.
4. Improper anneal—cups either
annealed too hard or too soft.
Gaging discloses insufﬁcient material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Not enough angle on taper of 1. Replace with new punch.
punch.
2. Radius on end of punch insuffi- 2. Replace with new punch.
cient.
Gaging indicates too much material drawn out of the bottom of the case.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
The causes are: The corrections are:
1. Too much angle on the taper of 1. Replace with new punch.
the punch.
2. Radius at the end of the punch 2. Replace with new punch.
too great.
Visual inspection discloses that the bottom of the case is punched out or
the side of the case is deformed by the punch.
Caution: Check tool identiﬁcation and dimensions. If tools are within
speciﬁcations, shut machine down until anneal has been checked by
Metallurgy Department. (Tools must never be altered by the adjuster.)
I
The causes are: The corrections are:
1. Improper anneal——the case met- 1. Send to the annealing room.
al is too hard.
2. This cannot be corrected. Check
source of supply and call in-
spector.
2. Improper anneal—the case met-
al is too soft.
3. There is no radius on the punch. 3. Replace with a new punch.
The punch is too large on the
drawing end.
4. The die is upside down. The die 4.
is not placed in the die block
properly.
Remove the die and replace it in
the proper position.
I32l
CALIBER .30 FOURTH DRAW CASE Troubles and Corrections

Short Case Gaging discloses the case is not long enough and the walls are too thick
to meet speciﬁcations.
The causes are: The corrections are:
1. The die is too large—it is over- 1. Replace with a new die.
size in the drawing surface.
2. Punch is too small. 2. Replace with a new punch.
Long Case Gaging discloses the case is too long and the walls too thin to meet
speciﬁcations.
The causes are: The corrections are:
1. The die is too small—undersize 1. Lap out the die to the proper
in the drawing surface. size.
2. The punch is too large. 2. Replace with a new punch.
Sheared Tops Visual inspection discloses that the mouth of the case is torn or uneven.
The causes are: The corrections are:
1. Improper annealing—case metal 1. Send to the Annealing Depart-
too hard. ment to be reannealed.
2. Faulty stripper—stripper bro- 2. Repair, or replace with new
ken. stripper.
3. No stripper. 3. Insert stripper.
Underslze Didmeler Gaging discloses diameter of case undersize.
The cause is: The correction is:
1. The die is too small-—undersize 1. Lap out the die to proper size.
in the drawing surface.
Oversize Diclmelel‘ Gaging discloses diameter of case is oversize.
The cause is: The correction is:
1. The die is too large—it is over- 1. Replace with a new die.
size in the drawing surface.
wrinkled MOUII1 Visual inspection discloses mouth of case wrinkled and uneven.
The causes are: The corrections are:
1. Rough punch——surface of punch 1. Polish and remove brass from
has excess coating of brass. punch.
2. Faulty stripper——stripper bro- 2. Repair or replace with new
ken. stripper.
3. Rough or ringed die——rough spot 3. Lap die if possible, or replace
or brass coating on drawing with new die.
surface of die.
4. No stripper. 4. Insert stripper.
[33]
CALIBER .30 FOURTH DRAW CASE
Troubles and Corrections
Uneven Flow of
Cases from Hopper
Case Tracks
Damaged
Hopper Jam
Slow Press
Visual inspection discloses that cases are not ﬂowing through the feed
tube and feed tracks.
The causes are: The corrections are:
1. Defective or long cases—-—cases 1. Remove cases from hopper and
from previous draw to long or check source of supply.
defective.
2. Cases jammed in feed tube. 2. Clear feed tube.
Clean and check source of sup-
ply-
Repair feed ﬁnger or replace
with new feed ﬁnger.
3. Foreign matter (dirt, shavings, 3.
etc.).
4. Feed ﬁnger burred. 4.
5. Broken feed ﬁnger operating rod 5. Replace with new springs.
springs.
6. Arm in pin wheel hopper loose. 6. Tighten arm.
Visual inspection discloses cases not properly traveling along case tracks.
The causes are: The corrections are:
1. Improper adjustment. 1. Proper adjustment.
2. Broken springs. 2. Replace with new springs.
Visual inspection discloses cases are not feeding through hopper to feed
tube properly.
The causes are: The corrections are:
1. Overloaded——too many cases in 1. Remove excess cases.
hopper.
Clear hopper and check pins for
burrs.
2. Cases stuck to pins in pin wheel 2.
hopper.
3. Belt slips—loose belt, oily belt. 3. Tighten belt; if oily, clean.
A lowered production rate may indicate that the stroke of the press is
slowed down.
The causes are: The corrections are:
1. Dry bearings. 1. Check the lubrication. Call
_ Maintenance Department.
2. Galled gibs. 2. Check the lubrication. Call
Maintenance Department.
3. Loose belt. 3. Adjust the motor on the slides.
[34]
CALIBER .30 FOURTH DRAW CASE Troubles and Corrections

Clutch Clicks Visual inspection discloses that the clutch does not operate properly.
The cause is: The correction is:
1. Bent or broken pins, rods or 1. Call Maintenance Department.
springs. The clutch dog will not
release properly.
Motor Stops Visual inspection discloses the motor is not running and the press is
stopped.
The cause is: The correction is:
1. Overload or burnt out armature, 1. If the machine is overloaded,
bearings, etc. clear the cause of the overload;
press the reset button to start
the motor. If there is any other
cause for the motor to stop, shut
off the power; call the Main-
tenance Department.
CALIBER .30 FOURTH DRAW CASE
Tool Servicing
Objective
Servicing New Dies

TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the
drawing of the bullet jackets and cartridge cases. Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters will be concerned primarily with the removal of brass and
small scratches that appear on working surfaces of dies and punches, and
they must be careful, when using an abrasive on any tool, not to alter
materially its dimensions.
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1. Dies as received from the tool room are normally undersize to allow
for expansion pressure and for lapping to a desired size when necessary.
2. The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
3. As a precaution, before a test run is made, the die bore should be
inspected for roughness and polished if necessary. If the bore is rough
causing undue friction, more metal than is necessary may be pulled
from the bottom of the jacket or case at the start of the draw.
4. The product from the test run should be carefully gaged and inspected.
Then, and then only, if an undersize or out-of-true die is indicated,
should the die be lapped.
5. If trial in the machine shows that the die is undersize, place it in a
three jaw chuck on a speed lathe to lap it.


OVER-ALL VIEW OF SPEED LATHE
C
[36]
CALIBER .30 FOURTH DRAW CASE
Tool Servicing
6.
Check the die to see that it is straight and secure in the chuck.


Lapping Procedure
Carboloy Dies
FIG. 1
CORRECT METHOD OF PLACING
DIE IN CHUCK
1.
10.
FIG. 2
INCORRECT METHOD OF PLACING
DIE IN CHUCK
When lapping is necessary, proceed as follows: Use a lap stick made
of brass, lead, ﬁber or wood about the same diameter as the die hole.
Dip the lap stick in a solution of #120 emery dust and olive oil or
coal oil.
Hold the lap stick as nearly as possible in line with the angle of the
taper. When lapping the land, hold the stick at a right angle to the
mouth of the die to keep the land true. A land which is not true
causes irregular wall thickness and crooked tops on jackets and cases.
While holding the lap stick against the die, give the stick a rapid in
and out movement. This cuts down the ridges left by the grinder
wheel in the metal surface and makes it smoother. Repeat this
operation according to the amount of metal that must be taken out
of the die.
Wipe the die clean with a cloth.
Next, polish the die with the ﬁnest grade of emery cloth available,
not coarser than #220.
Finish-the polishing operation with crocus cloth.
Wipe out the inside of the die again with a cloth.
Remove the die from the chuck and check the size of the die with a
plug gage.
Be sure the die is free of all emery dust before replacing it in the
machine for production.
To lap a carboloy die, follow the same procedure, with diamond dust
and olive oil instead of emery dust.
l37l
CALIBER .30 FOURTH DRAW CASE
Tool Servicing
Servicing Scratched
Dies
Servicing a New
Punch
Lapping
1. Before removing a die from a machine to look for scratches, remove
the stripper to determine whether the stripper, rather than the die, is
scratched.
2. Check the die or stripper visually to determine how badly it is
scratched. If the die or stripper has a very deep scratch, it should be
sent to the Tool Service Department.
3. If it is found that the scratch is in the die, check the die with a die
“wear limit” plug gage to determine how much metal can be worked
out of it without making the die too large.
4. To polish the die, place it in a three jaw chuck on a speed lathe.
5. Polish it with ﬁne emery cloth, then with crocus cloth.
6. If the scratch can’t be removed by polishing, the die must be lapped.
See lapping procedure, or send to the Tool Service Department if
necessary.
7. Check the die size with the “wear limit” plug gage before putting it
into production.
Before an abrasive of any kind is applied to a new punch its dimensions
should be carefully checked with micrometer or proﬁle gage, and its
working surface should be examined for ﬁnishing or handling marks and
lack of polish. A highly polished punch aids in stripping and allows metal
to ﬂow freely thereby reducing the tendency of brass to pile up on the
working surface.
An Adjuster will not be required to lap more than .0005” from a new
punch. If more than this must be removed to bring the punch to size, it
should be returned to the Tool Service Department for correction. Lap-
ping is done with a piece of abrasive cloth wrapped around and moved
back and forth along the axis of the punch as it revolves in a speed chuck.
If the abrasive were held stationary, deep rings would be cut into the
surface, thereby ruining the ﬁnish.
The punch is shown in Fig. 1 correctly chucked, and in Fig. 2 incorrectly
held (See page 37). Avoid excessive overhang of the punch as this is a
safety hazard; make sure that the jaws are correctly set and tightened
securely. Do not allow the jaws to grasp the working surface of the punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with cross-hatched effect.
[38]
CALIBER .30 FOURTH DRAW CASE
Tool Servicing
Polishing


CORRECT METHOD OF PLACING
PUNCH IN CHUCK
Servicing a Used
Punch
The lapping operation must be followed by polishing. Polishing is done
in the same manner as lapping except that a ﬁner abrasive is used, as for
example, crocus cloth. A ﬁnal operation called draw polishing is done with
the chuck stopped. To draw polish a punch move the abrasive cloth
lengthwise over the entire working surface avoiding rotary motion of the
punch or the abrasive. Continue this ﬁnal operation until all lapping
marks are removed and the desired high polish or mirror like ﬁnish is
obtained.
FIG. 3
FIG. 4
INCORRECT METHOD OF PLACING
PUNCH IN CHUCK
As a punch is used its working surface Wears accumulating scratches and
a coating of brass. Excessive wear is determined by measuring with
micrometer or checking with proﬁle gage. Obviously, an undersize punch
must be replaced with one of approved dimensions. Scratches, if not too
severe, may be removed by the lapping and polishing operations described
above. A light coating of brass may be removed by the polishing operation
alone. The question of how soon a new punch will need lapping or
polishing can be answered only from experience since many variable factors
enter‘ into the problem.


[39]
CALIBER .30 FOURTH DRAW CASE
Machine Lubrication
Friction
Introducing
Lubricating
Film Reduces Friction
Lubrication
Anti-friction
Bearings
MACHINE LUBRICATION
The efficiency of all machines depends, to a great extent, upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction as far as we are concerned
here, is the force that resists the sliding of one surface over another. It
makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated suﬂiciently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
(1) Petroleum oils and greases. Petroleum oil or crude oil is a mineral
oil that is pumped from the earth.
By various degrees of reﬁning, oils of different properties are obtained for
the thousands of different types of lubrication needed in industry.
Lubricating grease is a compound of petroleum oil and soap.
(2) Vegetable oils and animals oils are mixed with petroleum oils for
many applications.
(3) Graphite——tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction. We thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[40]
CALIBER .30 FOURTH DRAW CASE
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Constant or intermittent operation.
2
3
4
5. Cleanliness of surroundings.
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures ligh~ter bodied oils should be used as the speed
of the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage, and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable, where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen, good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
I’q.°“~‘$"t'>‘.°°.l\"
Frequency of lubrication.
[41]
CALIBER .30 FOURTH DRAW CASE
Machine Lubrication
Methods of Getting
Lubricant to Bearing
Surface
Hints on Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
2. Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°:q.®P‘:I>$*°
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
. Screw down cups.
. Compression cups.
1
2
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5
. Grease packing.
A systematic control of all lubrication is important. Lubrication must
be done periodically and lubrication cups must be kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubri-
cation.”
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble. R
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places—-in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times except when
the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way into a
grease barrel can be easily forced into a bearing and cause the machine
to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think that it
should be changed, take it up with your supervisor.
I42]
CALIBER .30 FOURTH DRAW CASE Machine Lubrication
LUBRICATION CHART


No. of Fittings, Frequency of
Lubricant Machine Part Grease Cups, Lubrication
Etc. Hours
Crankshaft Bearings 2 8
Pitman Bearing 1 8
LIGHT GREASE Gibs 4 8
(Blue Gun) Clutch Assembly 1 8
Hopper 1 24
Connecting Screw Knuckle 1 8
Flywheel and Clutch 1 8
Feed Finger Assembly 4 8
Feed Finger 6 8
MEDIUM OIL Detector Punch Assembly 5 8
(Red Oiler) Clutch Lever 7 24
\ Brake Assembly 6 24
Brake Shaft 2 24
HEAVY OIL Wrist Pin Reservoir 1 24
(Yellow Oiler) Worm Gear Drive for Hopper 1 1 wk.

[43]
CALIBER .30 FOURTH DRAW CASE
Index
Adjustment, Brake, 24
Brake Release Rod, 25
Brake Spring, 26
Clutch Lever Spring, 29
Detector Stem, 27
Die Replacement, 20
Feed Fingers, 23
Friction Ball'Spring, 30
Hopper Feed Tube Mouth, 22
Knockout Bar, 28
Pin Wheel Bridge, 21
Punch Replacement, 19
Anneal, 16, 32
Annealing Department, 16, 32
Anti-friction Bearings, 41
Anvil, 11
Back-Stop, 8
Ball Bearings, 30
Ball-Spring Stop, 8
Bolster Plate, 7, 8
Bottom Die, 12, 13
Thickness, 16
Brake Action, 3
Adjustment, 24
Drum, 2, 24, 25, 26, 29
Lever, 25
Release Rod Adjustment, 25
Shoe, 2, 24, 25, 26, 29
Spring Adjustment, 26
Bushing, 14
Carboloy Die, 37
Case, 7, 8, 10
Tracks Damaged, 34
Cases, 3, 6, 14, 17, 30
Chuck, 39
Clutch, 2, 3, 4, 9, 24
Clicks, 35
Lever, 2, 3, 9, 10, 25
Lever Latch Pin, 10
Lever Spring Adjustment, 29
Lever Trip, 27, 28
Coating of Brass, 39
Coil Spring Feed Tube, 15
Components, 6, 16
Controls, 3
Conveyor, 14
Cooling Solution, 3
Solution Pump, 1, 4
Crankshaft, 2, 3, 9
Flywheel, 4
Speed, 1
Crocus Cloth, 37, 38
Crooked Draw, 31
Cup, 16
Defects, 17
Detector Stem, 10, 28
Stem Adjustment, 27
Stems, 3
INDEX
Detector System, 10
Die, 8, 15, 20, 31, 36, 37
Block, 12, 20
Block Assembly, 12
Block Base Plate, 12
Block Lock Pin, 20
Replacement Adjustment, 20
Dies, 4
Dimensions, 16
Disposal, 14
Draw, 14
Polishing, 39
Emery Cloth, 37 , 38
Feed Finger Operating Rod, 8
Fingers, 14, 15
Fingers Adjustment, 23
Motor, 1
Pipe, 15
Socket, 23
Track, 8
Track Guides, 30
Tracks, 3, 7, 10, 14, 15, 23
Tube Bridge, 7
Tubes, 3, 6, 7, 14, 21, 23
Floor Space, 1
Flywheel, 2, 9
Friction, 40
Ball Spring Adjustment, 30
Gage, 38
Care, 17
Plug, 36
Proﬁle, 39
Twin Ring, 17
Gaging, 33
Gland Nut, 11, 19
Graphite, 41
Grease, 42
Hints on Lubrication, 43
Hopper Box, 5, 6
Feed Tube Mouth Adjustment, 22
Jam, 34
Inside Diameter, 16
Knockoff Bar, 3, 10
Knockout Bar, 27
Bar Adjustment, 28
Lap Stick, 37
Lapping, 37, 38
Latch Pin, 9
Pin Catch, 9
Lock Pin, 12
Long Case, 33
Lubricating Film, 40
Lubrication, 4, 14
Chart, 43
Methods, 42
Machine Motor, 1
Manufacturer, 1
Metallurgy Department, 32
Micrometer, 38, 39 \
Motor, 2, 3, 4, 5, 15
Stops, 35
New Punch, Servicing, 38
Outside Diameter, 16
Over-all Height, 1
Length, 16
Overhead Hopper, 14, 15
Overload Switch, 3
Oversize Diameter, 33
Pin Rings, 6
Wheel Bridge, 6, 22
Wheel Bridge Adjustment, 21
Wheel Hopper, 3, 5, 6, 14, 15
Wheel Hopper Box, 14, 15
Wheel Shaft, 5
Plug Gage, 36
Polishing, 39
Power, 2, 3
Production, 1
Proﬁle Gage; 38, 39
Punch, 8, 11, 13, 14, 15, 19, 31, 39
Block Assembly, 11
Holder, 11, 19
Holder Block, 3, 11
Outs, 32
Replacement Adjustment, 19
Punches, 4
Rake-off Spring, 6
Ram, 3, 8, 9, 10, 14, 24, 28
Rocker Arm Assembly, 8
Arm Shaft, 15
Rotary Latch, 6
Scored or Scratched Walls, 31
Scratched Dies, Servicing, 38
Scratches, 17, 19, 20, 39
Selecting a Lubricant, 41
Servicing New Dies, 36
New Punch, 38
Scratched Dies, 38
Used Punch, 39
Sheared Tops, 33
Short Case, 33
Sidewall Variation, 16
Sleeve, 11
Slow Press, 34
Split Collar, 11, 19
Stations, 30
Stripper, 12, 13, 14, 15, 38
Holder, 12, 13
Stroke, 1
Thick Bottom, 32
Thin Bottom, 32
Three Jaw Chuck, 36
Toggle Switches, 4
Tools, 1
Top Die, 12, 13
Transmission, 2, 3
I44]
CALIBER .30 FOURTH DRAW CASE Index

Twin Ring Gage, 17 Uneven Flow of Cases from Hopper, V-type Belt, 2, 3, 5, 15
Type of Feed, 1 34 Weight, 1
Undersize Diameter, 33 Visual Inspection, 17, 31, 33, 34 Wrinkled Mouth, 33
[.45]
(TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
First and Second
Case Trim
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAL
CORRECTIONS—CALIBER .30 FIRST AND SECOND CASE TRIM
LOCATION
Page 4- fl 4
Page 18—Spec
Page 19—Spec
ERROR
Clutch mounted on left end of machine
Bottom Thickness before and after 1st Trim
.155—.162
Bottom thickness after and before 2nd Trim
.181-.194
CORRECTION
Clutch mounted on right end of machine
Bottom thickness before and after 1st Trim
.150-.165
Bottom thickness after and before 2nd Trim
.17 0—.190
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product Description. . . . . . . . . . . . . .‘ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
III

CALIBER .30 FIRST AND SECOND TRIM MACHINE
IV
CALIBER .30 FIRST AND SECOND CASE TRIM
Catalogue Data

Manufacturer
Machine
Description “
Type of Feed
Line Shaft Motor
Production
R.P.M. of Spindle
Tools
Height
Weight
Floor Space
CATALOGUE DATA
Peters Engineering Company, Philadelphia, Penn-
sylvania.
Horizontal single spindle, rotary cutter trim
machine. Belt-driven from line shaft.
Pin wheel hopper mounted on work bench. Belt-
driven from line shaft. 7 R.P.M.
5 h.p.; 3 phase; 60 cycle; 220/440 volt; 865 R.P.M.
120 per minute.
1640 at spindle, line shaft 312 R.P.M.; belt-driven
from motor; cutter 625 R.P.M.
First Trim Piece No. Second Trim Piece No.
Nose nut K-1 Nose nut K-2
Burr cutter K-1 Burr cutter R-2
Stripper ring K-1 Stripper ring K-2
Sleeve K-1 Sleeve K-2
Spring %_x .450x .024 Spring %x .450x .024
Spindle K-1 Spindle K-2
Rotary cutter R-2 Rotary cutter R-2
7 ft. 4 in.
2,000 Lbs.
6’ x 4'3”
CALIBER .30 FIRST AND SECOND CASE TRIM
Machine Description
MACHINE DESCRIPTION
The Peters Trim Machine trims the cases to a uniform length. This
operation is necessary after both the third and fourth draw in order that
the length of the case can be standardized for succeeding operations.
The Caliber .30 ﬁrst case trim machine and the Caliber .30 second case
trim machine are identical with the exception of tools and tool holders
which vary in size.


Line Shaft ____
Rotary Cutter j »~'
Assembly
CALIBER .30 FIRST AND SECOND CASE TRIM MACHINE
Carrier
Power and The Peters horizontal spindle, rotary cutter, trim machine, illustrated
Transmission above, is mounted on the forward edge of a ﬂat topped bench. The
machine is connected to, and driven by, two ﬂat type leather belts running
to a line shaft, which is mounted to the back edge of the bench. The line
shaft is driven bya 5 h.p. electric motor, mounted on the ﬂoor at theleft end
of the bench. A ﬂat type leather belt connects the motor to the line shaft.
The line shaft may extend to drive as many as nine to eleven machines.
The leather belt which drives the spindle is a constantly running belt, the
spindle being driven direct from the line shaft.
Power is transmitted
through the leather belt to the main driveshaft by means of a manually
operated friction type clutch.
I 2 I
CALIBER .30 FIRST AND SECOND CASE TRIM
Mdchine Description

Main Driveshaft
Pin Wheel Hopper
Feed Check and
Leather Disc
Spindle
Rotary Cutter
Case Carrier
The main driveshaft is held in a horizontal position below the machine
bed by three bearings. The right and left bearings are of the babbitt
type, while the one in the center is a cast-iron ﬁtted bearing.
The main driveshaft consists of three cams, two of which are of the eccen-
tric type operating the rotary cutter and the case carrier through linkage.
The third one is a cylindrical type cam which through a cam follower
actuates the injecting shaft and the stripper bar in a right to left motion.
The cylindrical cam is a constant type cam which imparts continuous
motion to the injecting shaft and stripper bar.
The pin wheel hopper receives cases from an overhead source through a
feed chute to the hopper box. It consists of an inner and an outer rim and
a mid-section of pin rings and spacer rings bolted together in a hopper
assembly. The outer rim has three spokes attached to a hub shaft on
which the entire hopper revolves; this shaft extends through the hopper
box. The pins pick up the cases, carrying them to the top of the hopper
where they enter the feed bridge. As the cases travel across the feed
bridge, carried by the pins, they slide from the pins into the feed tube
mouth. From the mouth they are gravity fed to the feed bushing. The
hopper is driven by a ﬂat leather belt connected to the line shaft.
The feed tube delivers the cases from the hopper to a feed bushing. The
feed bushing incorporates a case check arm which is actuated by the
carrier to allow one case in the feed bushing at a time. As the carrier
descends to a horizontal position, the feed check arm is released, allowing
another case to pass into the feed bushing. As the case enters the feed
bushing, it rides against the carrier radius until the carrier rises to receive
it. When the carrier rises, it contacts the feed check arm, which descends
into the feed tube, holding the succeeding case securely as the carrier
receives the case contained in the feed bushing.
A rotating leather disc, driven by a V-type belt from the hopper pulley,
contacts and assists the case from the feed bushing into the carrier.
The spindle is constantly driven by a leather belt from the hne shaft. The
spindle shaft is held in the spindle head assembly by two ball bearings.
The spindle assembly consists of a spring, sleeve, burr cutter and stripper
ring, all of which is held on the spindle shaft by a nose nut. The end of the
spindle opposite the nose nut is tapered to allow a drive fit into the spindle
shaft socket. '
The rotary cutter blade is held on an arbor shaft mounted to the front
edge of the machine frame, facing the spindle. The cutter is connected to,
and driven by, a leather belt from a pulley on the hopper shaft. The
rotary cutter is actuated to and from the spindle by an eccentric cam
through linkage. The arbor shaft is held in position by two arbor screws
which are threaded through the rotary cutter brackets.
The case carrier is actuated, through linkage, from the eccentric cam on
the main driveshaft. The carrier is a bronze casting which receives the
cases individually from the feed bushing and transfers them to a hori-
zontal position in line with the spindle, where the injecting stem pushes
[3]
CALIBER .30 FIRST AND SECOND CASE TRIM
Machine Description
Case Carrier
(Cont)
Injecting Stern and
Stripper Bar
Main Shaft
Clutch
them from the carrier onto the spindle. The carrier rises, actuated by the
cam, to receive another case while the stripper bar removes the trimmed
case from the spindle.
The injecting stem, actuated by the cylindrical cam, moves forward to
push the cases from the carrier onto the rotating spindle. After the trim-
ming operation, the stripper bar, actuated by the cylindrical cam, pushes
the case from the spindle. As the case leaves the spindle, a jet of air
separates the scrap ring from the case; the scrap ring drops into the scrap
chute and the case falls into the case chute leading to the conveyor belt
and elevator.
The main shaft clutch is mounted on the main shaft at the left end of the
machine. Connected to the end of the main shaft, outside the clutch, is a
hand wheel. To make any adjustments, the clutch should be in an en-
gaged position and the machine should be operated by turning the hand
wheel.
[4]
CALIBER .30 FIRST AND SECOND CASE TRIM Machine Description

Set Cam Cam- Allen Bearing Cam-
Screw Follower Shaft 7 Cam Set Screw Housing Shaft
W‘


Bearing Housing Cam Cam Linkage Turnbuckle
Follower Arm
ECCENTRIC CAM WHICH ECCENTRIC CAM WHICH
OPERATES THE ROTARY CUTTER OPERATES THE CASE CARRIER
Camshaft Bearing Housing
Cylindrical Cam
Track Machine Leg


CYLINDRICAL CAM WHICH
OPERATES THE INJECTING STEM
Main Driveshaft The main driveshaft incorporates the two eccentric cams, which operate
the rotary cutter and case carrier. These two cams are mounted on the
main driveshaft at a position near the left end of the machine. The
cylindrical cam operating the injecting stem and stripper bar is mounted
at a position near the right end of the main driveshaft. The injecting stem
and stripper bar are actuated in a right to left motion by a cam follower
which rides in the track of the cylindrical cam. The cam follower is
mounted on the threaded section of the injecting stem which allows an
adjustment to be made governing the injecting stem and stripper bar
stroke. The rotary cutter and case carrier are operated through linkage to
the eccentric cams. The cam followers are held in contact with the
eccentric cams by coil springs, which are attached to the cam follower arm
and the machine frame. The main driveshaft is held in a horizontal posi-
tion, running lengthwise of the machine, below the machine frame. It
rotates in three bearings; the two outer bearings are held in place by four
cap screws while the center bearing is held in place by two cap screws.
[5]
CALIBER .30 FIRST AND SECOND CASE TRIM Machine Description
Pin Wheel Steel Feed Tube Adjusting and Feed Tube Spur Worm Gear Fricton
Hopper Bridge Pins Mouth Lock Nuts Mouth Gear Housing Clutch


I V ..
Bridge Bridge Spokes Feed Agitator Leather Clutch
Bracket Adjustment Bolt Tube Shaft Belt Lever
CLOSE-UP OF INTERIOR REAR VIEW OF PIN WHEEL
OF PIN WHEEL HOPPER HOPPER AND HOPPER BOX
jg: Round Leather
Belts
Clutch Lever I
. I FRONT RIGHT END VIEW OF HOPPER
Pin Wheel Hopper The pin wheel hopper revolves in a clockwise direction driven by a ﬂat
leather belt from the line shaft. It is driven by a shaft extending through
the center of the hopper with a bevel gear attached to the outer end. The
spur gear meshes with a worm gear mounted to a crankshaft at the back
of the hopper. The cross-shaft extends out to the left side of the hopper
and is provided with a manually operated friction type clutch, which
allows the hopper to be stopped while the line shaft continues to turn. A
pulley is mounted on the left end of the cross-shaft outside the clutch for
attachment of the leather belt. A manually operated agitator shaft
extends through the bottom of the hopper box; in the event a jam occurs,
the cases should be agitated by manually operating the agitator shaft.
Attached to the right side of the hopper is a stub shaft which mounts two
V-type pulleys, which through two round leather belts, drives the leather
disc and the rotary cutter. The stub is equipped with a jaw type clutch
which allows the rotary cutter and leather disc to be stopped independ-
ently of the line shaft. The two driver pulleys are belt-driven from the
line shaft.
[6]
CALIBER .30 FIRST AND SECOND CASE TRIM
Machine Description

Injecting Stern and
Stripper Bar

INJECTING STEM AND STRIPPER BAR
The injecting stem and stripper bar, actuated by the cylindrical cam,
through the cam follower, extend the length of the machine. The injecting
stem is composed of an injecting stem holder and injecting stem. The
injecting stem travels from right to left and is held in a raised position
above the machine bed by two brackets, which are ﬁtted with bronze bush-
ings. The stripper bar rides on the machine bed and is guided through
slots cut in the brackets holding the injecting stem. The brackets are
bolted to the machine frame. The stripper bar actuates the stripper ring
to push the case from the spindle after the trimming operation. The strip-
per bar is equipped with two stops, attached below the spindle, which con-
tact the stripper arm to actuate the stripper ring from left to right.
[7]
CALIBER .30 FIRST AND SECOND CASE TRIM Machine Description

CLOSE UP OF ROTARY CUTTER ASSEMBLY
Spindle Assembly The spindle assembly is supported by a bracket bolted to the machine
frame. The spindle shaft rotates in two sets of ball bearings which are
incorporated in the supporting brackets. The drive pulley is mounted on
the spindle shaft between the two brackets for connection of the spindle
shaft through a ﬂat leather belt to the line shaft. The stripper bar is further
guided in its right to left motion through two openings in the supporting
brackets. The spindle shaft is equipped at the right end with a tapered
socket into which the spindle is ﬁtted. The spindle shaft turns constantly,
driven by the line shaft through the leather belt.
[8]
CALIBER .30 FIRST AND SECOND CASE TRIM Tool Holder Description
TOOL HOLDER DESCRIPTION
Spindle Assembly Nose Nut: The nose nut is internally threaded for attachment
- to the threaded end of the spindle. Its surface tapers slightly
toward the outside end. The nose nut abutts against the burr
cutter and is held in this position by a countersunk set screw.


Burr Cutter: The burr cutter is assembled on the spindle from
the threaded end and is held against the shoulder by “press fit.”
The case is ﬁtted over the burr cutter, which acts as a founda-
ii tion for the case as it is trimmed by the rotary cutter. The burr
cutter eliminates burrs left on the case by the rotary cutter.
Stripper Ring: The stripper ring is circular with its drilled
center counterbored for insertion over the sleeve ﬂange. A
‘I groove is contained around the circumference of its outside
surface into which the stripper bracket is ﬁtted.
Sleeve: The sleeve is a hollow cylinder drilled lengthwise to
provide a sliding ﬁt on the spindle. A shoulder on one end is
counterbored to ﬁt over a portion of the spring.
Spring: The spring is assembled on the spindle from the
threaded end. It forces the sleeve against the shoulder of the
burr cutter and also permits the sleeve to move away from the
burr cutter during the cutting operation.
Spindle: The spindle is constructed of tool steel as shown in
the cross-sectional drawing below. All of the parts above
described are assembled on it. The tapered end of the spindle
shank is held in the spindle shaft socket by “drive ﬁt.”


Stripper Ring
\ ‘ S '
Nose Nut pnng
//Y \\\Y ' § 7/‘
II""~"'I'i'/~"—_Ih—I
7’/I//At”/I/I. k\\\ 'IIIIIIIIIIIII’/ . I
\ I
Spanner Hole Cur“, Spindle Shank
. \
CROSS-SECTIONAL DRAWING or SPINDLE ASSEMBLY
l 9 l
CALIBER .30 FIRST AND SECOND CASE TRIM Tool Holder Description
Rotary Cutter Hexagonal Lock Nut: The hexagonal lock nut locks
Assembly the rotary cutter against the arbor shoulder. It is placed
on the arbor from the threaded end after the cutting
disc and washer have been assembled in place.
Washer: The washer, backed up by the lock nut, exerts
a uniform pressure against the center of the rotary cut-
ter. Its purpose is to prevent scoring and breaking the
rotary cutter.
I 0
~ 3 _l\
. I-
.
Rotary Cutter: The rotary cutter is assembled from
the threaded end of the arbor and held against the
.--w
‘» shoulder of the arbor spacer by the hexagonal lock nut.
‘ The outside edge has a 45 to 50 degree beveled edge.
The rotary cutter trims the case to the desired length.


. W Shoulder Spacer: The shoulder spacer is an integral
part of the arbor. It acts as a spacer between the
rotary cutter and the pulley, and also acts as a shoulder
against which the rotary cutter and pulley are held.
Pulley: The pulley is held in place on the arbor by a
hexagonal nut. A ﬂat leather belt connecting the pulley
with a pulley on the hopper shaft_ drives the arbor.
Arbor: The arbor is made of tool steel and is illustrated
in the cross-sectional drawing appearing at the bottom
of this page. The center of the arbor is drilled to act as
an oil reservoir for lubricating the female centers located
at each end. (See diagram at bottom of page.) An oil
set screw is set in the shaft for admission of oil to the
drilled center. The arbor is held in the rocker arm
casting by two male centering adjustment screws.
Hexagonal Lock Nut: The hexagonal lock nut is in-
ternally threaded and holds the pulley against the
shoulder spacer.


///////////o
‘
‘


V
‘ Oil Reservoir Oil Set Screw
Female Center Female Center

Hexagonal Lock Nut
Washer


,§\\\ 7 »~ \ ~ , \\\\.\\\\t\\\\\\\\\\\\\\\\\\\\\\\
'\\\\g ‘ / Arbor
‘N
/6 Pulley
CROSS-SECTIONAL DRAWING OF ROTARY CUTTER ASSEMBLY


Rotary Cutter
R
’I//!7/////I//
I 10 l
CALIBER .30 FIRST AND SECOND CASE TRIM TOOI Description
TOOL DESCRIPTION
First Case Trim
Tool Name: Spindle
Piece No.: K-1
Location: In back of rotary cutter
Normal Life: Indeﬁnite
Spindle is made of tool steel, ground and polished.


SPINDLE
Tool Name: Sleeve
Piece N 0.: K-1
Location: On spindle
Normal Life: Indeﬁnite
Sleeve is made of tool steel, ground and polished.


SLEEVE
Tool Name: Nose Nut
Piece No.: K-1
Location: On end of spindle
Normal Life: 500,000 pieces


A The nose nut is made of tool steel, hardened, ground and
NOSE NUT polished.
M
6 Tool Name: Burr Cutter
Piece No.: K-1
Location: On spindle
Normal Life: 105,000 pieces
Burr cutter is made of tool steel, hardened, ground and
polished.
BURR CUTTER
Tool Name: Rotary Cutter
Piece No.: R-2
Location: On arbor in front of spindle
Normal Life: 91,786 pieces
Rotary cutter is made of tool steel, hardened, ground
and polished.


ROTARY CUTTER
I11]
CALIBER .30 FIRST AND SECOND CASE TRIM Tool Description
Tool Name: Spring
Piece No.: V; x _.450 x .024
Location: On spindle
Normal Life: 200,000 pieces
The spring is manufactured from spring steel, ground
and hardened.
Tool Name: Stripper Ring
Piece No.: K-1
Location: On spindle
Normal Life: 116,667 pieces
Stripper ring is made of tool steel, ground and polished.

STRIPPER RING I
[12]
CALIBER .30 FIRST AND SECOND CASE TRIM
Tool Description
TOOL DESCRIPTION
Second Case Trim
.4
SPINDLE
E ¢H\a.-wvﬁ-vi
\»
SLEEVE
.¢-ﬂy ‘\.
NOSE NUT
BURR CUTTER


ROTARY CUTTER
Tool Name: Spindle
Piece No.: K-2
Location: In back of rotary cutter
Normal Life: Indeﬁnite
Spindle is made of tool steel, ground and polished.
Tool Name: Sleeve
Piece No.: K-2
Location: On spindle in back of rotary cutter
Normal Life: Indeﬁnite
Sleeve is made of tool steel, ground and polished.
Tool Name: Nose Nut
Piece No.: K-2
Location: On end of spindle
Normal Life: 200,000 pieces
The Nose Nut is made of tool steel, hardened, ground
and polished.
Tool Name: Burr Cutter
Piece No.: R-2
Location: On spindle
Normal Life: 105,000 pieces
Burr cutter is made of tool steel, hardened, ground and
polished.
Tool Name: Rotary Cutter
Piece No.: R-2
Location: In front of the spindle
Normal Life: 91,786 pieces
Rotary cutter is made of tool steel, hardened, ground
and polished.
[13]
CALIBER .30 FIRST AND SECOND CASE TRIM Tool Description

Tool Name: Spring
\ \ Piece No.: % x .450 x .024
l\ ' I Location: On stripper
\/I Normal Life: 200,000 pieces
The spring is manufactured from spring steel, ground
SPRING and hardened.
Tool Name: Stripper ring
Piece No.: K-2
Location: On spindle
Normal Life: 116,667 pieces
Stripper ring is made of tool steel, ground and polished.


STRIPPER RING
I14I
CALIBER .30 FIRST AND SECOND CASE TRIM
Process Sequence

Overhead Hopper
Pin Wheel Hopper
Box
Pin Wheel Hopper
Feed Tube
Carrier and Feed
Check
Injecting Stem and
Spindle
Rotary Cutter
Stripper and
Disposal
PROCESS SEQUENCE
The cases are gravity fed from an overhead source into the overhead
hopper and flow through the feed pipe down into the pin wheel hopper box.
The cases flow through an opening in the pin wheel hopper box, past an
agitator, into the bottom of the pin wheel hopper.
As the pin wheel hopper rotates, the cases are agitated and picked up by a
series of pins mounted on the inner circumference of the pin wheel. The
pins carry the cases upward past the rake-off spring, which removes
misaligned cases and presses the partly set cases all the way onto the pins.
As the cases are carried across the top of the pin wheel, they are held on the
pins by the bridge. At the end of the bridge they drop off, one at a time,
into the open end of the feed tube, mouth up.
The cases fall by gravity down through the coil spring feed tube, into the
feed bushing, and stop against the carrier.
As the carrier moves up to receive the case, the trip strikes the feed check
arm, which actuates the feed check mechanism, and stops the ﬂow of cases
but allows one case at a time to enter the carrier. The case is assisted into
the carrier by a revolving leather friction disc. As the carrier moves down,
it conveys the case to a horizontal position, in line with the revolving
spindle and injecting stem. The downward movement of the carrier also
releases the feed check mechanism and permits the succeeding case to
move down and stop against the carrier.
As the injecting stem moves from right to left, it pushes the case onto the
spindle in position for the rotary cutter. The stripper also moves to the
left, striking the shoulder of the spindle sleeve and opening the gap in the
spindle cutter. This gap is necessary to allow the rotary cutter to shear
against the cutting edge of the burr cutter.
The injecting stem holds the case ﬁrmly by spring pressure, while the
rotary cutter moves in, trimming the case to the proper length. As the
rotary cutter moves in, the carrier moves up to receive the next case and
the above operation is repeated.
The injecting stem and stripper bar move away from the spindle, relieving
the pressure on the spindle sleeve, and allowing the gap on the spindle to
close. The case and scrap ring are removed from the spinme by the
stripper ring located in the stripper block.
The case falls through a chute onto a conveyor under the machine. The
scrap ring is blown into another chute by an air jet and falls into a separate
truck under the machine.
[15]
CALIBER .30 FIRST AND SECOND CASE TRIM
Process Sequence
FLOW CHART

Overhead Hopper
Cases are gravity fed from truck or conveyor into
overhead hopper through feed pipe.


Feed Pipe
Conveys cases from overhead hopper into pin wheel
hopper box.


Pin Wheel Hopper Box
Cases flow through opening in pin wheel hopper box,
past agitator, into bottom of pin wheel hopper.


Pin Wheel Hopper
Rotates and cases are picked up by pins and carried
past rake-off spring to the top of the pin wheel,
where they are supported by the bridge. At the
end of the bridge they fall off, one at a time, mouth
up, into open end of coil spring feed tube.


Powered through worm gear
from pulley, ﬂat belt from
line shaft.


Coil Spring Feed Tube
Conveys cases from the pin wheel hopper past feed
check into the bushing, where they rest against the
radius bar of the carrier.


Feed check is actuated by
spring to arm, through spring
to trip on carrier.


Carrier
As the carrier moves up to receive a case, the trip
strikes the feed check mechanism, allowing one case
at a time to enter carrier which then moves down to
a horizontal position, in alignment with spindle and
push rod.


Downward motion by spring
action. Upward by a shaft,
through stroke arm, adjust-
ment arm, rocker arm, cam
follower, camshaft, clutch
pulley, ﬂat leather belt, line
shaft from motor.


Injecting Stem
Moves from right to left, pushing the case onto the
spindle.


Actuated by cylindrical cam
from shaft, clutch pulley, flat
leather belt, from line shaft.


I [16]
CALIBER .30 FIRST AND SECOND CASE TRIM Process Sequence

FLOW CHART (Cont.)
I


Spindle
Revolves, holding the case in position for the cutting P Owered by pulley’ and ﬂat
leather belt, from line shaft.


tool.
Rotary Cutter
Moves forward, trimming the case to its proper
length. On the forward motion, the carrier moves
up allowing another case to enter, and repeats the
Powered by pulley, round
leather belt, from clutch pul-
ley, round leather belt from


. . . line shaft.
trimming operation.
Injecting Stem Stripping
and Disposal
As the injecting stem and stripper move back from Stripper ring is actuated by
the spindle, the case is stripped off by a stripper a cylindrical Cam from Shaft,
ring located in the stripper block. clutch pulley’ ﬂat belt, line
Scrap is forced into a chute by air pressure. The Shaft-
trimmed case drops into a chute to a conveyor
under the machine.


[17]
' CALIBER .30 FIRST AND SECOND CASE TRIM Product Description

PRODUCT DESCRIPTION
First Case Trim
The component when received by the ﬁrst trim machine is in the form of a
case as shown in Fig. 1.
The case is made of brass (70% copper, 30% zinc). The closed end of
the case is known as the bottom and the open end as the mouth.
The cases are received by the ﬁrst trim machine from the Washing Depart-
ment where they are washed and dried. The cases are delivered to
the Washing Department from the third draw press.
The dimensions of the case are as follows:
Before ﬁrst trim operation After ﬁrst trim operation
Outside diameter .517—.519 Outside diameter .517— .519
Bottom thickness .155—.162 Bottom thickness .155— .162
Over-all length variable Over-all length 1.728—1.7 55
Inside length 1.573—1.593
After the trimming operation, the cases are sent to the Sorting Department
to be sorted, and then to the Annealing Department where they are
annealed, pickled and washed before being delivered to the fourth draw.
(See Fig. 2)

FIG. 1 FIG. 2
BEFORE FIRST TRIM AFTER FIRST TRIM
[18]
CALIBER .30 FIRST AND sccono CASE TRIM Product Description

PRODUCT DESCRIPTION
Second Case Trim
The component when received by the second trim machine is in the form
of a case as shown in Fig. 1.
The case is made of brass (70% copper, 30% zinc). The closed end of the
case is known as the bottom and the open end as the mouth.
The cases are received by the second trimming machine from the Washing
Department where they are washed and dried. The cases are delivered to
the Washing Department from the fourth draw press.
The dimensions of the case are as follows:
Before second trim operation After second trim operation
Outside diameter .4630—.4642 Outside diameter .4630—.4642
Bottom thickness .181 —.194 Bottom thickness .181 —.194
Sidewall variation .010 —.011 Sidewall variation .010 —.011
Over-all length Over-all length 2.551—2.584
Inside length 2.370—2.390
After the trimming operation, the cases are sent to the pocketing machine.
(See Fig. 2)

FIG. 1 FIG. 2
BEFORE SECOND TRIM AFTER SECOND TRIM
I19]
CALIBER .30 FIRST AND SECOND CASE TRIM
Inspection

Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the trimming operation, a careful visual
inspection of the cases must be made. The cases should be inspected for
dents on the head and the body, also for inside and outside burrs on the
mouth, and for long and short cases. These defects indicate an immediate
adjustment of the machine is necessary to correct the fault. Whenever de-
fective cases are found, the lot from which they come must be removed
from the machine and properly identiﬁed, so they will not be mixed with
good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use, or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool, since heat causes expansion of the
metal and results in a temporary variation in the case size.
PLUG GAGE
The length of the case is checked
with a plug gage which indi-
cates the standard inside case
length. This gage also checks
the case for inside burr.


The above described inspection methods are those most commonly
employed in the trimming operation on a Caliber .30 Case Trim Machine.
However, other methods may be developed to maintain the manufacturing
standards.
[20]
CALIBER .30 FIRST AND SECOND CASE TRIM
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be clean and free from all
foreign objects at all times.
No adjustments are to be made on this machine while it is in motion or
until the handwheel has stopped.
Adjustments on or near the rotary cutter require extreme care to prevent
injury to the adjuster’s hands.
In order to insure proper adjustment of the machine and alignment of its
tools, always turn the machine over by hand before engaging clutch.
Safety guards must be in their proper place on the machine except when
repairs or inspections are being made.
Inspect the machine periodically during the day’s run to determine
whether or not all connections and adjustments are secure.
I21]
CALIBER .30 FIRST AND SECOND CASE TRIM
Adjustments
Injecting Stem
TOOI:
Procedure:
The injecting stem, actuated by a cam, pushes the case onto the spindle.
It should be adjusted so that there is about V16" clearance between the
stem and the spindle. The stem is adjusted by turning a split lock nut
on the injecting. stem holder. Another split lock nut on the injecting stem
holder closer to the stem point, adjusts the spring tension on the stem.

INJECTING STEM ASSEMBLY
Screwdriver.
1. Use a screwdriver to loosen the screws on the guard over the stem and
remove the guard.
2. Turn the handwheel until the stem is as close as possible to the spin-
dle.
3. Use a screwdriver to loosen the lock screws on the split nut on the
stem holder farthest from the stem.
4. Turn the split nut until there is about $65" clearance between the stem
and the spindle.
5. Tighten the two screws on the split nut.
6. Loosen the lock screws on the split nut against the spring on the stem
holder.
7. Turn the split nut until there is a distance of about 1" between it and
the cam follower.
8. Tighten the lock screws on the split nut.
9. Replace the guard and tighten the screws.
I22]
CALIBER .30 FIRST AND SECOND cAsE TRIM Adjustments

Clutch The clutch is adjusted by turning the two screws on the clutch ﬁngers. It
should be adjusted so that the clutch will engage sufficiently to operate the
machine, but will slip in case of a jam.
Tools: Screwdriver, 1%” wrench
Procedure: 1. Use an 11/16" wrench to loosen the lock nuts on the adjusting screws
located on the clutch ﬁngers.
2. Use a screwdriver to tighten the two adjusting screws a like amount to
increase the pressure on the clutch. Loosen the screws to decrease
the pressure.
3. Hold the screws in place and tighten the lock nuts.
4. Check the adjustment by holding the clutch disc and turning the ﬂy-
wheel to determine how much force is necessary to make the clutch slip.
Nut Screwgs Flat Leather Belt


‘ I
Clutch Lever Flywheel Handwheel Screw at Left End
CLOSE-UP OF CLUTCH VIEW OF LEFT END OF
ASSEMBLY MACHINE
Leather Disc The leather disc assists the case into the carrier. The leather disc shaft is
mounted on an eccentric cam. To adjust the disc, loosen the Allen set
screw against the cam mounting; then turn the cam, lowering or raising
the disc. Raising the disc increases its pressure against the case and
increases the speed at which the case is assisted into the carrier; conversely,
lowering the disc will decrease the pressure against the case and will
decrease the speed with which the case is assisted into the carrier.
[23]
CALIBER .30 FIRST AND SECOND CASE TRIM Adjustments

Rotary Cutter The rotary cutter is mounted on a rocker arm. Adjustment can be made
(Depth) on the rocker arm to change the depth of the cutter. It is adjusted so that
the cutter cuts through the case, but does not ride on the burr cutter.
Allen Screw
Set Leather Rocker Allen Rotary Lock at Right
Screw Disc Arm Set Screw V Pulley Cutter Nut End


Screw at Left End Adjusting Screw Rocker Arm
VIEW OF LEFT END OF CLOSE-UP OF ROTARY CUTTER
MACHINE ASSEMBLY
Tools: Two 15/16" wrenches.
Procedure: 1. Use a 1:’/15” wrench to loosen the nut on the outside of the adjusting
screw located on the rocker arm. Tighten the nut on the inside to
adjust the cutter for a deeper cut.
2. Use a 1%” wrench to loosen the inside nut in the adjusting screw and
tighten the nut on the outside of the adjusting screw to adjust the
cutter away from the spindle.
3. Turn the ﬂywheel until the cutter is as close as possible to the spindle.
The cutter should enter the gap but should not touch the spindle at
the bottom of the gap.
[24]
CALIBER .30 FIRST AND SECOND CASE TRIM
Adiustments
Rotary Cutter
(Alignment)
VIEW OF LEFT END
The rotary cutter can be adjusted to the right or left by changing the posi-
tion of the arbor shaft. The cutter should be adjusted as close to the edge
of the burr cutter as possible without actually rubbing against the edge.
Screw
Allen at
Set Rotary Lack Right
Screw Cutter V Pulley Nut End


CLOSE-UP OF ROTARY CUTTER
OF MACHINE ASSEMBLY
Tools: 15/16" wrench, V16” Allen wrench, off-set screwdriver.
Procedure:
1.
Use a 5/15” Allen wrench to loosen the lock screw on the left side of the
arbor.
. Use a 1%” wrench to loosen the lock nut on the right side of the arbor.
To move the cutter to the left, use an off-set screwdriver to loosen the
screw on the left end of the shaft, and tighten the screw on the right
end. Both screws should be turned a like amount.
To move the cutter to the right, loosen the screw at the right end of
the shaft and tighten the screw at the left end of the shaft. Both
screws should be turned a like amount.
Tighten the lock screw on the arbor.
Turn the ﬂywheel until the cutter is at its nearest position toward the
spindle, and turn the cutter shaft to observe whether or not the cut-
ter rubs on the burr cutter.
I25]
CALIBER .30 FIRST AND SECOND CASE TRIM ' Adjustments

Burr Gap The stripper ring adjustment determines the width of the gap that is left
for the trimming operation. The stripper, actuated by a cam connected
to the main shaft, pushes the spindle sleeve back, providing the necessary
gap between the spindle and the burr cutter. The gap should be about
X6" wide.


- '-~ _ Lock Nut
I _ Adjusting Screw
SPINDLE ASSEMBLY REAR VIEW
Tools: 1%” wrench, 7/16” wrench.
Procedure: 1. Turn the handwheel until the stripper ring is in its farthest position
to the left.
2. Loosen the lock nut on the adjusting screw which holds the stripper
plate in position. '
3. Use a 7/16” wrench to turn the adjusting screw until the desired gap is
attained between the spindle sleeve and the burr cutter.
4. Hold the adjusting screw in place and tighten the lock nut.
5. Operate the machine and observe the trimming operation.
I 26 I
CALIBER .30 FIRST AND secono CASE TRIM Adiustments
Carrier The carrier is actuated by a cam on the main driveshaft. The carrier
receives the cases from the feed bushing and carries them in a horizontal
position to be pushed onto the spindle by the injecting stem. If the carrier
is not in line with the spindle when it is in the lowest position, it can be
adjusted by adjusting the turnbuckle connected to the carrier arm.
,~.s
‘lli
" ‘~Feed


Carrier
Feed Tube Carrier Injecting Stem
Leather
Disc
Lock Nut
- Lock Nut
-— Turnbuclcle
— Lock Nut


FRONT VIEW SHOWING THE REAR VIEW SHOWING THE TURN-
CARRIER BUCKLE AND FEED CARRIER
Tool: 1%" wrench.
Procedure: 1. Use a 1%" wrench to loosen the two lock nuts on the turnbuckle.
2. Turn the turnbuckle, raising or lowering the carrier, whichever is
necessary, to line the carrier with the spindle.
3. Hold the turnbuckle in position and tighten the two lock nuts.
4. Operate the machine to observe the action of the carrier.
[27]
CALIBER .30 FIRST AND SECOND CASE TRIM
Adjustments

Carrier
3A" Nut
Currier Arm
TOOI:
Procedure:

The carrier is adjusted in line with the feed bushing by adjusting the posi-
tion of the bolt that connects the turnbuckle to the carrier adjusting arm.

Turnbuckle
TURNBUCKLE AND CARRIER ADJUSTMENT
%" wrench
1.
2.
Turn the handwheel until the carrier is at its extreme upper position.
Use a %" wrench to loosen the nut on the screw that connects the
turnbuckle to the carrier arm.
Move the screw in the slot in the carrier arm until the carrier is in line
with the feed bushing.
Hold the screw in position and tighten the nut.
Operate the machine by hand to observe the action of the carrier.
CALIBER .30 FIRST AND SECOND CASE TRIM
Adjustments

Timing
Tools:
Procedure:
If the rotary cutter cam has slipped on the shaft, and the action of the
cutter is out of time with the action of the injecting stem, the action of
the rotary cutter must be synchronized with the action of the stem by
adjusting the rotating cutter cam.
ECCENTRIC CAM WHICH OPERATES THE ROTARY CUTTER
Screwdriver, 1/4" wrench.
1.
2.
.\".°“-*9“
Loosen the screws on the guard over the injecting stern and remove
the guard.
Turn the handwheel until the injecting stem is at the extreme left
position.
Use a 1/4" wrench to loosen the set screw on the cam that actuates the
rotary cutter.
Turn the cam so that its high point is against the cam follower. The
cutter should be at its farthest position from the spindle and should
start its movement toward the spindle if the handwheel is turned.
Hold the cam in this position and tighten the set screw.
Replace the guard and tighten the screws.
Turn the handwheel over to observe the action of the cutter In rela-
tion to the action of the injecting stem.
[29]
CALIBER .30 FIRST AND SECOND CASE TRIM
Adjustments
__ﬂ_—__—_Y__—__—————_-—————
Timing
Tools:
Procedure:
If the carrier cam has slipped on the shaft, and the carrier is out of time
with the injecting stem, it is necessary to synchronize the action of the
injecting stem with the action of the carrier.

ECCENTRIC CAM WHICH OPERATES THE CASE CARRIER
Screwdriver, 1/4" Allen wrench.
1.
9°
Loosen the screws which are located on the guard over the injecting
stem and remove the guard.
Turn the handwheel until the injecting stem is at the extreme right.
Use a 14" Allen wrench to loosen the set screw on the carrier cam.
Turn the cam so that its high point touches the cam follower. The
carrier should be at the receiving position and should start its travel
toward a horizontal position if the handwheel is turned.
Hold the cam in this position and tighten the set screw.
Replace the guard and tighten the guard screws.
[30]
CALIBER .30 FIRST AND SECOND CASE TRIM
Adjustments
HopperFeed
Bﬁdge
Tool:
Procedure:
Feed Tube Mouth
Tool:
Procedure:
The cases are carried on the pins on the pin wheel across the hopper bridge.
The bridge is adjusted by adjusting the nut on the vertical bolt connected
to it.
1%" wrench.
1. Hold the adjusting nut and use an 1%" wrench to loosen the lock nut
on the vertical bolt.
2. Use an 1%” wrench to turn the adjusting nut, either raising or lowering
the feed bridge until it is about %” from the pins on the pin wheel.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Close and latch the hopper door.

CLOSE UP OF INTERIOR OF PINWHEEL HOPPER
The cases should fall from the pins into the feed tube mouth and down
through the feed tube. If they fail to do this, the feed mouth must be
adjusted in line with the pins on the pin wheel.
1%" wrench.
1. Release the latch and open the hopper door.
2. Use an 1%” wrench to loosen the bottom lock nut on the rod that con-
nects the feed tube mouth to the hopper bridge.
3. Use an 1%” wrench to adjust the top nut until the feed tube mouth is
in line with the pins on the pin wheel.
4. Hold the adjusting nut in place and tighten the lock nut.
5. Close and latch the hopper door.
[31]
CALIBER .30 FIRST AND SECOND CASE TRIM
Troubles and Corrections

TROLIBLES AND CORRECTIONS
Objective The adjuster will encounter many troubles and defects in the operation
Burr on Mouth
of Case
of this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection
of the component, together with constant observation of the machine
as it operates.
Visual inspection discloses that there is a burr or a ragged fragment of
brass adhering to the mouth of the case.
The causes are: The corrections are:
1. The cutting edge of the rotary 1. Remove the rotary cutter from
cutter has become dull.
. The cutting edge of the burr
cutter has become dull.
. Defective case—case is bent,
short, or has a damaged
mouth.
. The burr cutter is not running
true. The cutter is bent or
cracked around the cutting
edge.
. The rotary cutter is not run-
ning true. The cutter is bent
or cracked around the cutting
edge.
. The clearance between the ro-
tary cutter and the spindle
cutter is either too great or
insufficient.
the arbor and replace with a
sharp cutter. Return dull ro-
tary cutter to the Tool Ser-
vicing Department to be re-
ground.
. Remove the burr cutter from
the spindle and replace with a
sharp cutter. Return the dull
burr cutter to the Tool Ser-
vicing Department to be re-
ground.
. Remove defective case and
check source of supply. Call
the inspector.
. Remove the defective cutter
from the spindle and replace
with a new burr cutter.
. Remove the defective cutter
from the arbor and replace
with a new rotary cutter.
. Adjust the rotary cutter as
close to the burr cutter as
possible without allowing the
rotary cutter to strike against
the burr cutter.
[32]
CALIBER .30 FIRST AND SECOND CASE TRIM
Troubles and Corrections

Burr on Mouth
of Case
(Cont.)
Incomplete Trim
Dents on Body
of Case
7. Foreign matter——dirt, dried
10.
soap, on cases.
. The nose nut has become loose
and causes the spindle to be-
come loose.
. End play in spindle assembly
—spindle is loose.
Bent spindle—case does not
properly set on spindle.
10.
Remove the cases from the
hopper and send to the Wash-
ing Department to be re-
washed.
.Adjust the nose nut ﬂush
against the burr cutter by use
of a spanner wrench.
. Tighten the spindle in the
spindle shaft socket by strik-
ing end of nose nut with a
brass hammer.
Remove the bent spindle and
replace with a new spindle.
Return bent spindle to Tool
Servicing Department.
Visual inspection discloses that the case is not trimmed completely and
leaves a ring still hanging on the mouth of the case.
The causes are:
1.
The rotary cutter is not set
deep enough and only puts a
ring around the mouth of the
case.
Rotary cutter becomes loose
and slips on the arbor.
The arbor belt is slipping,
caused by either being too loose
or too oily.
. The arbor adjusting screws are
too tight and prevent the ro-
tary cutter from turning.
1.
The corrections are:
Adjust the rotary cutter to the
proper cutting depth by ad-
justing the set screw in the
rocker arm.
. Tighten the rotary cutter by
adjusting the nut on the
threaded section of the arbor.
. Clean the belt if it is oily or
apply belt dressing if it is slip-
pery from wear. Adjust idler
pulley if the belt is loose.
. Loosen the arbor adjusting
screws so that the arbor runs
freely.
Visual inspection discloses that the body of the case has become dented
OI‘
the outside surface is marred.
The causes are:
1.
The cases are not being inserted
on the spindle properly because
the carrier is not properly ad-
j usted.
. Weak or broken carrier spring.
1.
The corrections are:
Adjust the carrier by changing
the position of the bolt that
connects the turnbuckle to the
carrier arm.
. Remove defective spring and
replace with a new carrier
spring.
[33]
CALIBER .30 FIRST AND SECOND CASE TRIM
Troubles and Corrections

Improper Feed of
Cases from Hopper
and Feed Tube
to Machine
Loose Spindle
Visual inspection discloses that the cases are not feeding properly through
the hopper or feed tube to the carrier, which results in a loss of production.
The causes are:
1.
The hopper is overloaded with
cases.
The space between the bridge
and the pins is too great or is
insufficient to allow the cases to‘
travel on the bridge to the feed
tube mouth.
. Defective cases in the hopper—-
bent, long, short, or mashed
mouths.
Foreign matter——-dirt, scrap in
hopper.
The feed tube has become loose
or disconnected from the mouth
of the feed tube.
. Foreign matter, scrap, dirt in
the feed tube.
The carrier is improperly ad-
justed. The case does not set
on the spindle in proper time
with the rotary cutter.
. The feed check is improperly
adjusted—it allows more than
one case to enter carrier and
causes a jam, or does not allow
any cases to enter the carrier.
. Burrs on the mouth of the case
cause the case to jam in the
feed bushing.
The corrections are:
1.
Remove the excess supply of
cases from hopper.
. Adjust the bridge so that the
cases will travel freely on the
bridge to the feed tube mouth.
. Remove the defective cases
from the hopper and check
source of supply. Call the in-
spector.
. Remove the cases and clean the
foreign matter out of the hop-
per.
. Tighten the set screws in the
sleeve at the mouth of the feed
tube so the feed tube will be
properly secured.
. Remove the feed tube and clean
it of foreign matter.
. Adjust the carrier by changing
the position of the bolt that
connects the turnbuckle to the
carrier arm.
. Adjust the feed check so that
only one case at a time enters
the carrier, by adjusting the
screw beneath the feed check
arm.
Remove the burred case from
the feed bushing and check the
source of supply. Call the in-
spector.
Visual inspection discloses that spindle has become loose and is not
operating properly.
The cause is:
1.
Scrap catches in the gap be-
tween the burr cutter and the
sleeve and causes the stripper,
on its forward stroke, to force
the spindle loose.
The correction is:
1.
Remove the scrap and tighten
the spindle in the spindle shaft
socket by striking the end of
the nose nut with a brass ham-
mer.
[34]
CALIBER .30 FIRST AND SECOND CASE TRIM
Troubles and Corrections
Chipped Rotary Visual inspection discloses that the rotary cutter has become chipped and
is not properly trimming cases.
Cutter
Machine Jams
Scored or
Scratched Walls
The causes are:
1.
The rotary cutter is too close
to the burr cutter.
. The rocker arm is out of time
and causes delayed action of
the rotary cutter.
. The rotary cutter is too hard
and brittle and chips easily.
The rotary cutter is adjusted
too deep and strikes the spindle
which will chip the outer edge.
The corrections are:
1.
Adjust the rotary cutter as
close as possible to the burr
cutter without striking it. If
the rotary cutter is chipped, re-
move it from the arbor and re-
place it with a new cutter.
Return the defective cutter to
the Tool Servicing Department.
. Loosen the screw holding the
cam connected to the main
shaft. Change the position of
the cam by turning it on the
shaft so that the action of the
cutter is synchronized with the
action of the injecting stem.
. Remove brittle cutter from ar-
bor and replace with a new
rotary cutter. Return defect-
ive cutter to the Tool Servicing
Department.
. Adjust the rotary cutter to the
proper cutting depth by ad-
justing the set screw in the
rocker arm.
Visual inspection discloses that the machine has stopped for one of the
following reasons, which has caused a jam.
The causes are:
1.
Inverted cases——a case is fed
into the machine in a wrong
position.
Scrap catching in the spindle
gap will cause the succeeding
case to jam on the spindle.
The corrections are:
1. Remove the inverted case from
the machine and clear the jam.
2. Remove the scrap from the
spindle gap and check to see if
burr cutter has become chipped.
Visual inspection will reveal scratches on the inside or outside walls of
the case. Scratches on the outside wall can be detected by ﬁnger nail
inspection.
The causes are:
1.
Foreign matter, dirt, scrap in
the carrier or feed bushing.
. Rough spindle—the spindle sur-
face has become marred and
will cause inside scratches.
The corrections are:
1.
Remove the carrier or feed
bushing and clean out the
foreign matter.
. Remove the rough or marred
spindle and replace with a new
spindle.
[35]
CALIBER .30 FIRST AND SECOND CASE TRIM
Troubles and Corrections
Short Case Gaging discloses that the case must be rejected because it is too short to
meet speciﬁcations.
Long Case
The cause is:
1.
The spindle is too short—the
cases are inserted too far on the
spindle.
The correction is:
1.
Remove the short spindle and
replace with a new spindle.
Gaging discloses that the case must be retrimmed or rejected because it is
too long to meet speciﬁcations.
The causes are:
1.
The spindle is too long——the
cases are not inserted far enough
on the spindle.
. Defective cases——the case is
bent at the mouth and will not
go all the way on the spindle.
. Variation in head thickness—
which results in variable dis-
tance. Case is inserted in collet.
. Trimmed scrap is not being
stripped from the spindle unit.
. Not enough spring tension on
the injecting stem to hold the
case ﬁrmly on the spindle.
The corrections are:
1.
Remove the long spindle and
replace with a new spindle.
. Remove the defective case and
check the source of supply.
Call the inspector.
Remove the defective cases and
check the source of supply.
Remove the scrap and check
and correct the cause of its ac-
cumulation.
. Increase the spring tension by
adjustment or replacement of
the spring.
[36]
CALIBER .30 FIRST AND SECOND CASE TRIM TQQI Servicing

TOOL SERVICING
Obiective It is essential to maintain a sharp cutting edge on the trimming machine
cutters in order to obtain clean-cut trims. Therefore, the servicing of
tools on this machine requires sharpening of the rotary and burr cutter.
Servicing these cutters involves a certain operation which can best be
done in the tool shop. Care must be taken not to grind away more than
is necessary to develop a new cutting edge as this will decrease the useful
life of the cutter.
Note: The rotary and burr cutters, when received from the tool crib,
are correctly ground and should not require any servicing.
Rotary Cutter 1. The rotary cutter is a ﬂat disc, 323/31>" in diameter and V8" thick,
with its cutting edge beveled to an angle of 45°.
2. When this cutter becomes dull it will not completely trim the cases.
If the cutting edge becomes nicked or broken, the trimming operation
leaves the mouth of the case rough, with jagged edges.
3. Whenever the cutting edge becomes dull or broken the cutter must
be replaced with a new or reconditioned one.
‘ ~¥ “

FIG. 1
ONE OF THE APPROVED METHODS OF GRINDING A ROTARY CUTTER
I37]
CALIBER .30 FIRST AND SECOND CASE TRIM
Tool Servicing

Reconditioning 1. Reconditioning of cutters is to be accomplished in the tool shop.
Cutter
When a cutter is returned to the tool shop for reconditioning, it is
reground according to the speciﬁcations and directions indicated on
the blue print for that job. This type of cutter can be sharpened
many times before it is reduced by grinding to a minimum diameter
of 3”. Ordinarily the removal of .003” will be sufﬁcient to develop a
new cutting edge. A cutter of this kind can be sharpened in a uni-
versal type grinder or in a lathe with grinding attachments.
The cutter is mounted on the adapter best suited for this particular
type work. The grinding wheel should be a Crystolon, Vitriﬁed Type,
grain 120, grade P., structure 8, which is a soft grinding wheel.
Caution: The maximum grinding feed should not exceed .0003” per
cut because of the liability of distortion, due to the thinness of the
cutter. The surface speed of the grinding wheel should be 2700 F.P.M.
After the grinding operation is done, an ordinary oil hone of ﬁne grit
is held lightly against the ground surface. Excessive pressure of the
oil hone will turn a burr on the cutting edge. The oil hone, if properly
applied will remove the feather edge which, if allowed to remain,
would cause a rough trim and result in further breakage of the cutting
edge.
FIG. 2
VIEW OF ONE OF THE APPROVED METHODS OF GRINDING A ROTARY CUTTER
[38]
CALIBER .30 FIRST AND SECOND CASE TRIM
Tool Servicing

Burr Cutter
1.
2.
3.
The burr cutters of the ﬁrst and second trim machines are hardened
steel collars. The ﬁrst trim outside diameter is .437” x .440” long. The
second trim outside diameter is .432” x .625" long.
When the burr cutter becomes dull, it causes a burr or jagged edge
on the inside of the case mouth.
When a cutter becomes dull, return it to the tool crib for a new or
reconditioned one.

FIG. 3
ONE OF THE APPROVED METHODS OF GRINDING A BURR CUTTER
Reconditioning 1. Reconditioning of cutters is to take place in the tool shop. When a
Cutter
cutter is turned in to the tool shop for reconditioning, it is reground
according to the speciﬁcations and the directions indicated on the
blue print for that shop. ‘
Burr cutters can be reground many times, since the operation changes
only the length Each grinding will shorten the cutter about .002"
and leave a new cutting edge.
Note: New cutters are 1" long but can be ground down in length
until the spanner nut adjustment will no longer hold the cutter
tight. The amount a cutter can be ground down varies with different
spindles; however, all burr cutters can be ground down to about
3/4" in length.
The cutter can be ground on a surface grinder. The grinding wheel
should be a Crystolon, vitriﬁed type, grain 120, grade P., structure 8,
which is a soft grinding wheel. Surface speed of the surface grinder
is ﬁxed at between 2750 F.P.M. and 3000 F.P.M. which is sufficient
speed for this type of work. If the grinding wheel feed exceeds .0003 ",
the metal will be distorted due to its hardness.
I39]
CALIBER .30 FIRST AND SECOND CASE TRIM
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efficiency of every machine depends to -a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
2 3. Operate without excessive power loss.
A major cause of inefﬁciency is friction. Friction, as far as we are con- ~
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumeralble micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—-tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are ‘used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
l40l
CALIBER .30 FIRST AND SECOND CASE TRIM
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.‘q?°.°‘tI>“P°.l\'>
Frequency of lubrication.
I 41 l
CALIBER .30 FIRST AND SECOND CASE TRIM
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
.°°.‘q.°>.°‘:‘>~.°°l\°'-‘
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive 'dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I42]
CALIBER .30 FIRST AND SECOND CASE TRIM Machine Lubrication

LUBRICATION CHART


. . N 0. of Fittings, Frequency of
Lubricant _ Machzne Part Grease Cups, etc. Lubrication Hours
LI((;'I§jlrfe(J;r}I?l]i;A*SE Main shaft bearings 3 8
Clutch assembly . . . . . . . . 2 8
Injecting stem . . . . . . . . 2 8
Stripper bar . . . . . . . . 2 8
Follower . . . . . . . . . . . . 2 8
Carrier shaft . . . . . . . . . . 2 8
Leather disc shaft . . . . . . . 1 8
Thrust bearing . . . . . 1 8
Rocker arm casting 2 8
LIGHT OIL Arbor . . . . _ .. . . . 1 As necessary
(Brown Oiler) Ball and socket joint . 1 8
Cutter cam follower 1 8
Carrier rocker arm . 1 8
Stripper bar bearing . 1 8
Tripper shaft . . . . . 1 8
Hopper shaft . . . . . . . . . . I 24
Rotary cutter and disc shaft clutch
assembly . . . . . . . 1 1 wk.
Spindle bearings . 2 2 wks.
Cams . 3 24
HE()$(:{1SgWO(§iI1Jer) Hopper worm drive gears . . . . . Res. 1 wk.

[43]
CALIBER .30 FIRST AND SECOND CASE TRIM
Index
Adjustment, Burr Gap, 26
Carrier, 27, 28
Clutch, 23
Feed Tube Mouth, 31
Hopper Feed Bridge, 31
Injecting Stem, 22
Leather Disc, 23
Rotary Cutter, 24, 25
Timing, 29, 30
Agitator Shaft, 6
Anti-friction Bearings, 40
Arbor, 10
Bottom Thickness, 18, 19
Burr Cutter, 9, 11, 13, 39
Gap Adjustment, 26
on Mouth of Case, 32
Cam, 3, 5
Carrier, 15, 16
Adjustment, 27, 28
Case Carrier, 3, 5
Chipped Rotary Cutter, 35
Clutch, 2, 6
Adjustment, 23
Cross-shaft, 6
Dents on Body of Case, 33
Disposal, 15, 17
Driveshaft, 2, 3
Main, 5
Feed Bridge, 3
Bushing, 3
Check, 3, 15
Chute, 3
Pipe, 16
Tube, 3, 15, 16
Tube Mouth Adjustment, 31
INDEX
Floor Space, 1
Flow Chart, 16, 17
Friction, 40
Gage Care, 20
Gages, 20
Grease, 41
Height, 1
Hexagonal Lock Nut, 10
Hopper Box, 3
Feed Bridge Adjustment, 31
Improper Feed of Cases, 34
Incomplete Trim, 33
Injecting Stem, 3, 4, 5, 7, 15, 16
Stem Adjustment, 22
Stem Stripping, 17
Inside Length, 19
Leather Disc, 3
Disc Adjustment, 23
Line Shaft, 2
Long Case, 36
Loose Spindle, 34
Lubrication, 40
Chart, 43
Film, 40
Hints on, 42
Methods, 41
Machine Jams, 35
Main Driveshaft, 3
Shaft Clutch, 4
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 42
Motor, Line Shaft, 1
Nose Nut, 9, 11, 13
Outside Diameter, 18, 19
Over-all Length, 18, 19
Overhead Hopper, 15, 16
Pin Wheel Hopper, 3, 6, 15, 16
Wheel Hopper Box, 15, 16
Plug Gage, 20
Power, 2, 17
Production, 1
Pulley, 10
R.P.M. of Spindle, 1
Reconditioning Cutter, 38, 39
Rotary Cutter, 3, 5, 6, 10, 11, 13, 15,
17 , 37
Cutter Adjustment, 24, 25
Cutter Assembly, 10
Scored Walls, 35
Scratched Walls, 35
Selecting a Lubricant, 41
Short Case, 36
Shoulder Spacer, 10
Sidewall Variation, 19
Sleeve, 9, 11, 13
.Spindle, 2, 3, 9, 11, 13, 15, 17
Assembly, 8, 9
Spring, 9, 12, 14
Stripper, 15
Bar, 3, 4, 5, 7, 8
Ring, 9, 12, 14
Timing Adjustment, 29, 30
Tools, 1
Transmission, 2
Type of Feed, 1
Visual Inspection, 20
Washer, 10
Washing Department, 18, 19
Weight, 1
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Pocketing Machine
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAL CORRECTIONS—CALIBER .30 POCKETING MACHINE
LOCATION
Page 12
Page 13—-Fig &
Spec
Page 1 7—Spec
Page 23—Fig
Page 26 —Note
ERROR
Bumping
Outside diameter before pocketing
.7 955-.7 97 0
Bottom thickness before pocketing .297—.312
Outside diameter after pocketing .797 0—.8000
Web thickness after pocketing .07 0—.080
Locknuts
Jacket
CORRECTION
Heading
No punch holder shown
Outside diameter before pocketing
.4630—.4642
Bottom thickness before pocketing .1 8l—.194
Outside diameter after pocketing .4645—.4665
Web thickness after pocketing .042—.050
Adjusting Screws
Case
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Iiolder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .' . . . . . . . . . . . . . . . . . . . . . . 18
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
III

OVER-ALL VIEW OF CALIBER .30 POCKETING MACHINE
IV
CALIBER .30 POCKETING MACHINE
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Feed Motor
Production
Speed of
Crankshaft
Stroke
Tools
Floor Space
Height
Weight
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, N. Y.
E. W. Bliss Horizontal Toggle and Crank press.
5 V belt drive motor to flywheel on crankshaft.
5 h.p.; 3 phase; 60 cycle; 220/440 volt; 870 R.P.M.
Pedestal type pin wheel hopper mounted on ma-
chine. Belt drive from motor 7 R.P.M.
Gear head % h.p.; 60 cycle; 1 phase; 115/230
volt.
105 per minute
105 R.P.M.
Front 8%", back 67/16"
Piece No.:
Die E-6
Injecting Stem E-2
Punch E-7
7 ft. 10 in. x 3 ft. 8% in.
7 ft. 3% in.
8,200 lbs.
CALIBER .30 POCKETING MACHINE
Machine Description

Guard
Coverin
9
Flywheel
Power and
Transmission


MACHINE DESCRIPTION
The Caliber .30 Pocketing Machine punches a tapered pocket in the head
of the case, preparing the case for the heading machine.
EW:‘~LI8SI§IIL ‘ \
" ‘U-YILY
CALIBER .30 POCKETING MACHINE
The E. W. Bliss Horizontal Crank and Toggle Press, illustrated above, is‘
powered by a 5 h.p. motor through ﬁve V-type belts connecting the motor
to the ﬂywheel. '
The Horizontal Crank and Toggle Press is equipped with a punch carried
in one of the rams. The punch, actuated by the ram, punches a primer
pocket in the head of the case.
The motor is mounted directly above the ﬂywheel on an adjustable
bracket, which allows proper adjustment of belt tension. The ﬂywheel is
mounted to the front or pocketing ram crankshaft at the front of the
machine.
The motor is controlled by a push button type switch; the red button
breaks the circuit and the black button closes the circuit. As no clutch
is employed on this type machine, the machine is started by releasing the
manually operated brake and pressing the starter switch.
[2]
CALIBER .30 POCKETING MACHINE
Machine Description

Brake
Pocketing Ram
Knockoff Wire
Stem Ram
Eccentric Cam
and Rocker Arms
Pin Wheel Hopper
Lubrication
The brake is manually controlled through linkage from the brake operating
arm to the brake shoes. The brake operating arm is held in a horizontal
position directly above the die holder. The brake linkage is equipped
with an arm which acts to break the electrical circuit to the motor when
the brake is applied. As the electrical circuit is broken, the shoes are
applied to the front and rear face of the ﬂywheel to stop the machine action.
The front or pocketing ram is supported by and travels on two 45° angle
gib plates. The pocketing ram is connected to and actuated by a con-
necting rod attached to the front crankshaft throw. The face of the ram
is machined to hold the tool holder.
A knockoff wire is attached to an operating arm which is actuated by a
cam roller attached to the pocketing ram. The knockoff wire extends out
from the rear edge of the machine frame to a position directly above the
case as it is discharged from the die. The knockoff wire, actuated by the
pocketing ram on every stroke of the ram, knocks the discharged case into
the bottom of the machine bed where it passes out onto a conveyor belt
leading to the elevator.
The stem ram or back ram is connected to and actuated by a connecting
rod attached to the rear crankshaft. The ram face is machined to hold the
working tools. The ram is supported by and travels on two 45° angle gib
plates which are bolted to_ the machine frame on a horizontal plane.
The power is transferred from the front crankshaft through two rocker
arms and an eccentric cam.
The pin wheel hopper is mounted on a supporting bracket located at the
rear center of the machine. The cases are fed into the hopper box from an
overhead chute, and are agitated in the hopper by a manually oper-
ated lever, which extends through the bottom of the hopper to a position
within easy reach of the operator. These cases are then delivered to the
machine through a feed tube, to the feed sleeve, from the feed sleeve into
the die. As each case is fed into the die, it discharges the preceding case
from the die.
The machine is lubricated by means of Alemite-Zerk ﬁttings attached to
the various working parts.
The gibs and other exposed parts which have a tendency to overheat
quickly should be oiled frequently with an oil can containing the appro-
priate grade and viscosity of lubricant. (See Lubrication Chart, page 44.)
[3]
CALIBER .30 POCKETING MACHINE Machine Description

. . - . . ,


Stem Bumper
Crankshaft F , Crankshaft
Rocker _ _ K I . ' I , I _ Rocker
' ' 1 Arm
Arm I
Eccentric ‘
Cam
ECCENTRIC CAM AND ROCKER ARMS
Eccentric Cam The power is transmitted from the front, or bumper crankshaft, through
and Rocker Arms two rocker arms and an eccentric cam to the back or stem ram crankshaft.
The bumper crankshaft turns 360°, or in a complete revolution. A rocker
arm leads from the crankshaft to a point off center on the eccentric cam.
The eccentric cam is mounted on a stub shaft at the back center of the
machine. A second rocker arm shaft, attached to the off center point on
the cam, leads to the back or bumper stem crankshaft. The motion of the
bumper crankshaft, by use of the rocker arms and eccentric cam, is trans-
formed from a 360° revolution to a 90° are at the bumper stem crankshaft.
[4]
CALIBER .30 POCKETING MACHINE
Machine Description


U
Pin Wheel /
Hopper
Feed Tube
is ‘
Brake Lever / X . ,_
Rams
Injecting Stem
Ram
' _ Spanner Nuts
TOP VIEW SHOWING RAMS
The face of each ram is machined to hold a tool holder. The bumper ram
contains the tool holder which holds the bumping punch. The tool holder
incorporates two spanner nuts, which allow an adjustment to be made on
the bumper tool. The stem ram contains the tool holder which holds the
injecting stem. Two spanner nuts are incorporated in the tool holder
allowing an adjustment to be made on the injecting stem.
l5l
CALIBER .30 POCKETING MACHINE Machine Description

vvlllljljjllil
Brake shoe
1%" Lock Nut
3/g" Adjusting
Screw
3/‘H
BRAKE ASSEMBLY
Brake The brake shoes are attached to a bracket which holds the shoes in posi-
tion against the inner and outer surface of the ﬂywheel. The brake shoe
operating lever which is connected to the brake shoes by a series of con-
necting links, applies the brake shoes against the ﬂywheel to stop the
machine when the brake lever is pulled back. A small trip arm, attached
at a right angle to the vertical brake shaft, breaks the electrical circuit by
contacting an auxiliary switch when the brake is applied. The switch is
attached to the back side of the frame at the right end of the machine.
[(5]
CALIBER .30 POCKETING MACHINE Machine Description
Springs
Pocketing
Punch
Feed Box Feed Tube
Push Finger


_ Cap Screw
Case Slide
Die Block Injecting Stem
DIE BLOCK AND FEED SLIDE ASSEMBLIES
Die Block and The die block is incorporated in the machine frame and is located between
Feed Slide the two rams. A feed box is attached to the top surface of the die block.
The cases are fed from the feed tube into the feed box; from here they are
pushed by a push ﬁnger, which is actuated from the eccentric cam.
Each case is pushed by the succeeding cases from the feed box, around
the case slide, until they drop into the case feed sleeve. The stem ram
moves forward, injecting the case into the die. As the pocketing
punch travels forward striking the closed end of the case, it forms the
primer pocket in the case head. The next case, as it is inserted in the die,
ejects the preceding case from the die into the chute leading to the conveyor.
[7]
CALIBER .30 POCKETING MACHINE
Machine Description
Pin Wheel Hopper
and Hopper Box

The pin wheel hopper box is a one-piece casting with a bottom sloping toward
an adjustable gate which leads into the pin wheel hopper. The pin wheel
hopper is attached to the front of the hopper box. The pin wheel consists
of a pin ring, an inner and an outer dish-shaped rim, bolted together to
form a hopper assembly. The outer dish-shaped rim has three spokes
attached to a hub shaft on which the entire hopper revolves. The hopper
is driven by a V-type belt connected to a V8 h.p. motor. The motor is
supported by an adjustable bracket to maintain proper belt tension. The
pin ring has a series of steel pins, spaced approximately 1" apart on its
inner circumference and set at an angle to the radii. A steel band rake-off
keeps the components that are not properly seated on the pins from enter-
ing the bridge. As the hopper revolves clockwise, the cases slide onto the
steel pins and approach a vertical position, with the mouth end down.
When the components approach the upper arc of the circumference, they
contact and are held on the pins by the bridge. In this position they are
nearly mouth end up. At the end of the pin wheel bridge they are in
a nearly vertical position and slide off the p1ns into an adjustable feed tube
mouth. They are then carried by gravity down the feed tube to the feed
sleeve.
ii I;vI"BLiss IIIIV
IIIUII-‘II If
END VIEW SHOWING PIN WI-IEEI. HOPPER
[3 l
CALIBER .30 POCKETING MACHINE Machine Description

Hopper Box
Steel Pins


Hopper Door
___——— Latch
Dish-sha ed
Hopper oor

CLOSE UP OF PIN WHEEL HOPPER
[9]
CALIBER .30 POCKETING MACHINE
Tool Holder Description

Die Block Assembly
TOOL HOLDER DESCRIPTION
Die: The die is cylindrical in shape, and is approximately 4" long and 3" in
diameter, with a longitudinal hole through the center which tapers from
the mouth to the head of the die.
Bushing: The bushing is a hollow cylinder that ﬁts in the die block and
is used as a spacer between the die block and the die.
Anvil: The anvil is designed as shown in the cross-sectional drawing below.
A hole through its center permits the feeding of the case into the die. The
anvil ﬁts in the die block directly behind the bushing. It absorbs shock
and prevents wear on the die block.


Z\\\\\\\\\\\\Y //
t
CROSS-SECTIONAL DRAWING OF DIE BLOCK ASSEMBLY
\
Anvil
I101
CALIBER .30 POCKETING MACHINE Tool Holder Description
Injecting Stem Rear Spanner Adjusting Nut: The rear spanner
Assembly adjusting nut determines the forward adjustment of the
_, injecting stem holder, and is the same as the front span-
ner nut with the exception that it is thicker. Care
must be exercised in assembling the injecting stem
holder to get the spanner nut placed properly.


Front Spanner Adjusting Nut: The front spanner
adjusting nut determines the backward adjustment of
the injecting stem holder. It contains equally spaced
holes to facilitate adjustment with a spanner wrench.
Anvil: The anvil is a solid circular piece that ﬁts in-
side the end of the injecting stem holder. The stem
seats against the anvil, which helps to absorb the
shock on the stem.
Bushing: The bushing is cylindrical with a hole
through the center through which the shouldered part
of the injecting stem ﬁts.
' ’- Injecting Stem Holder: The injecting stem holder is
a threaded bar that ﬁts in the back ram and is held in
place by two spanner adjusting nuts. The front end is
hollow to accommodate the anvil, bushing, and injecting
stem.
Cap Nut: The cap nut is a hexagonal shouldered nut
which is beveled inside to ﬁt the bevel on the shoulder
of the stem. The nut is placed on the injecting stem to
rest on the injecting stem shoulder. The stem is inserted
in the injecting stem holder and the nut is screwed in
place on the injecting stem holder.
.-‘*1
l ‘“ Injecting Stem: The injecting stem is tapered on the
' - ‘ _ _ l 7 working end and has a beveled shoulder on the other
I .\ .7 PM-' .
end. It ﬁts into a bushing in the injecting stem holder.
Cap Nut Injecting Stern
Tool Holder
Injecting Stem


’¢m


Anvil
Rear Spanner
Nut


Bushing Front Spanner
Nut


CROSS-SECTIONAL DRAWING or INJECTING STEM
I 11 I
CALIBER .30 POCKETING MACHINE Tool Holder Description

Punch Holder Rear Spanner Adjusting Nut: The rear spanner adjusting nut
Assembly located on the bumping punch holder, determines the forward
adjustment of the bumping punch. The spanner nut contains
equally spaced holes around its circumference to facilitate its
adjustment with a spanner wrench.
Front Spanner Adjusting Nut: The front spanner adjusting
nut determines the backward adjustment of the bumping punch
and is identical to the rear spanner nut with the exception that it
is thinner.
Punch Holder: The bumping punch holder is a threaded bar
that ﬁts in the front ram. It is held in place by the two spanner
nuts and a set screw which screws through the front of the ram
into a slot in the bumping punch holder.
Anvil: The anvil is a circular piece that ﬁts on the inside of the
front of the bumping holder and absorbs the shock of the bump-
ing punch.

Bushing: The bushing is cylindrical, with a hole through the
center. It ﬁts in the front of the bumping punch holder against
the anvil and acts as a spacer between the bumping punch holder
and the bumping punch.
Punch: The pocketing punch is shaped as illustrated on this
page. It is held in the punch holder by “drive ﬁt.”
Punch Bushing: The punch bushing is cylindrical with a longi-
tudinal hole through its center. It holds the pocketing punch
which is forced into it by drive ﬁt.
58‘ Sclew Pocket Punch


Punch Bushing


s:-_-=':.
.§"/k\\\\\\\i&'\\\\
5?-
4t\\\\\\\\\\\\)‘_
\\\\\\\\\‘
WIIIIIIIIIIIM I
CROSS-SECTIONAL DRAWING OF POCKETING PUNCH AND HOLDER

[ 12 l
CALIBER .30 POCKETING MACHINE
Tool Description


STEM


PUNCH
TOOL DESCRIPTION
Tool Name:
Piece No. :
Location:
Normal Life:
Stem
E-2
Held horizontally in back crosshead
ram
200,000 pieces
Stem is made of tool steel, hardened, ground and pol-
ished. Point of stem is rounded and tapered.
Tool Name:
Piece No.:
Location:
Normal Life:
Tool Name:
Piece No. :
Location :
Normal Life:
Die
E-6
Die block
250,000 pieces
Die is made of tool steel, hardened, ground and pol-
ished. Mouth end of die is rounded and tapered.
Punch
E-7
Held horizontally in front crosshead
ram
166,000 pieces
Punch is made of tool steel, hardened, ground and
polished. The working end is bell-shaped.
[13]
CALIBER .30 POCKETING MACHINE
Process Sequence

Overhead Hopper
Pin Wheel
Hopper Box
Pin Wheel Hopper
Coﬂ Spﬁng
Feed Tube
Push Block
Feed Sﬁde
Feed Sleeve
Injecting Stem
Pocketing Punch
Bumped Case
Knockoff and
Disposal
PROCESS SEQUENCE
The cases are gravity fed from an overhead source down into the overhead
hopper, and drop through a feed pipe into the pin wheel hopper box.
The cases flow from the pin wheel hopper box through an opening, past
the agitator into the lower part of the pin wheel hopper.
As the pin wheel hopper rotates, the cases are agitated and picked up by
pins on the inner circumference of the pin wheel, and are carried up past
the rake-off springs, which knock off misaligned cases and push partly set
cases all the way onto the pins. As the cases are carried to the top of the
pin wheel, they are held on the pins by the bridge. At the end of the
bridge they drop off, one at a time, head down into the mouth of the coil
spring feed tube.
The cases fall by gravity through the coil spring feed tube into a choke.
The choke prevents deformed cases from entering the curved feed pipe.
These deformed cases are removed by the operator so the ﬂow of cases can
continue through the curved feed pipe part way into the feed box where
they stop against the push block.
The push block moves backward, allowing one case at a time to enter the
feed box; then it moves forward, pushing the case past the feed gate into
the curved feed slide.
The curved feed slide conveys the cases in a horizontal position, down to a
position against the injecting stem.
As the injecting stern moves out of the die block, the case slides into the
feed sleeve which holds the case in alignment with the injecting stem and
die.
The injecting stem, moving in from right to left, enters the case, pushes
it into the die, and holds it there to wait for the pocketing punch.
The pocketing punch moves in from left to right, striking the case, and
forming a pocket in the head.
As the pocketing punch and injecting stem move back from the die, another
case slides into the sleeve and the above operation is repeated. As the
succeeding case is pushed into the die by the injecting stem, the pocketed
case is pushed out.
The pocketed case is pushed out to a point where the knockoff wire strikes
it, knocking it downward quickly through a metal chute into a conveyor
underneath the press.
[14]
CALIBER .30 POCKETING MACHINE
Process Sequence

FLOW CHART

Overhead Hopper
Cases are gravity fed from an overhead source into
the overhead hopper through feed pipe.


Feed Pipe
Conveys cases from the overhead hopper into the
pin wheel hopper box.


Pin Wheel Hopper Box
Cases ﬂow through opening in pin wheel hopper box,
past agitator into bottom of pin wheel hopper.


Pin Wheel Hopper
Rotates and cases are picked up by pins and carried
up past the rake-off spring to the top of the pin
wheel where they are held on the pins by the bridge.
At the end of the bridge, they fall off, one at a time,
through a choke and into the coil spring feed tube.


Hopper is powered by a %;
h.p. reduction gear motor by
a V-type belt. Control is by
a toggle switch.


Coil Spring Feed Tube
Conveys the cases by gravity through a choke and
into curved feed pipe, part way into the feed box,
where they stop against the push block.


Push Block
Moves backward allowing one case at a time to
enter feed box; then it moves forward pushing case
past feed gate, into feed slide.


I
Backward motion by two
coil springs. Forward mo-
tion by cam follower, cam on
eccentric wheel from rocker
arm, from front crankshaft.


[15]
CALIBER .30 POCKETING MACHINE . Process Sequence
FLOW CHART (Cont.)
Feed Slide
Conveys the cases in a horizontal position, one at a
time, into the feed sleeve located in the die block.


Feed Sleeve
Holds the case in alignment with the injecting stem


and die.
Injecting stem is powered by
Injecting Stem ram through connecting rod,
Moves from right to left, pushing the case into the toggle shaft, from rocker arm,
die, and holding it there for the pocketing punch. eccentric wheel from rocker
arm to crankshaft.
Pocketing Punch Pocketing punch is powered
Moves in from left to right, striking the case, and by ram through connecting
forming a pocket in the head. rod from crankshaft.


Pocketing Punch and Injecting Stem
Move back from the die, another case slides into the
sleeve, and the above operation is repeated. As the
succeeding case is pushed into the die by the injecting
stem, it pushes the pocketed case out.


Pocketed Case Knockoff wire is powered by
Is pushed out to a point where knockoff wire strikes cam in cam track on the ram,
the case, knocking it downward through a metal through connecting rod from
chute into a conveyor underneath press. crankshaft.


[16]
CALIBER .30 POCKETING MACHINE Product Description
PRODUCT DESCRIPTION
The component, when received by the pocketing machine, is in the form
of a case as shown in Fig. 1.
The case is made of brass (70% copper, 30% zinc). The closed end of the
case is known as the bottom and the open end is the mouth.
The case is received at the pocketing machine from the second trim
machine where it was trimmed to the proper length. There is no annealing
or washing process between the second trim and pocketing operation.
The dimensions of the case are as follows:
Before pocketing operation After pocketing operation
Outside diameter .7955—.7970 Outside diameter .7970-.8000
Bottom thickness .297 —.312 Web thickness .070 - .080
After the pocketing operation, the case is delivered to the Washing
Department, where it is washed and dried before being delivered to the
Heading Department.

FIG. 1 FIG. 2
BEFORE POCKETING AFTER POCKETING
I17]
CALIBER .30 POCKETING MACHINE
Inspection

Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the pocketing operation, a careful visual
inspection of the cases must be made. The cases should be inspected for
scratches on the inside and outside walls, for deposits of metal on the
bottom, wrinkles on the side and mouth, and dents on the bottom. These
defects indicate an immediate adjustment of the machine is necessary to
correct the fault. Whenever defective cases are found, the lot from which
they come must be removed from the machine and properly identiﬁed so
the bad lot will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use, or carelessness in gaging may spring the gage or put a burr on it which
may effect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their being damaged when not in use. The most
accurate checks are made when the cases are cool, since heat causes expan-
sion of the metal and results in a temporary variation in the case size.
The outside diameter of
the case is gaged with a
twin ring gage. Cases must
pass through the larger or
“go” ring but must not
pass through the smaller
“no go" ring.


The web thickness of the case is
checked on a dial indicator; varia-
tion in this dimension greatly affects
succeeding operations.


The concentricity of the pocket is checked
by a dial indicator; concentricity of the
pocket in relation to the outside diameter
is very important.
[18]
CALIBER .30 POCKETING MACHINE Inspection

<r _
Gages (Cont.) The diameter of the pocket is _ _
gaged by a double plug “go” and “no go” gage. The “go”
end of plug gage must always
enter the pocket. The maximum
“no go” must not enter. I


The above described inspection methods are those most commonly em-
ployed in the pocketing of the Caliber .30 case. However, other methods
may be developed to maintain the manufacturing standards.
[19]
CALIBER .30 POCKETING MACHINE
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect
the machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be encoun-
tered, therefore certain adjustments may be required that have not been
described in this section. A thorough analysis of the trouble will indicate
what corrective measures must be taken other than those included in this
manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
No adjustments are to be made while the machine is in motion, or until
the ﬂywheel has stopped.
To insure proper adjustment of the machine, always“ turn the ﬂywheel
over by hand before applying power.
Inspect the machine periodically to determine whether or not all connec-
tions and adjustments are secure.
Turn off the power before applying the foot brake.
The brake should be applied in such a manner as to cause the ram to stop
on its back stroke.
Do not permit the ﬂywheel to make a complete revolution in reverse, since
this will throw the machine out of time and cause it to jam.
Before making adjustments on the machine, always lock the electric
motor stop button with the locking set screw.
The die holder must be adjusted to permit the pocketing punch to strike
the center of the case head, that is, the pocket must be concentric with
the circumference of the case head. This adjustment must be made only
by an experienced adjuster or under his supervision, and only after the
case has been inspected to determine if it is within the required speciﬁ-
cations.
I20]
CALIBER .30 POCKETING MACHINE
Adjustments
Concentricity The die block should be adjusted so that the case is in direct line with the

punch. If the punch and the case are not perfectly aligned, the head of
the case will not be concentric with the pocket.
Concentricity is attained by moving the die block either vertically,
horizontally, or both. In order to know which way the die block should be
adjusted, it is necessary to place a test case in the machine and operate
the machine until the case is headed. The machine is stopped before the
case is ejected from the die and the case and the die are marked with a
vertical line across the face of the case head and the die so that the position
of the case in the die is known after the case has been removed from the
die. Remove the case from the die and test the head for concentricity
with a dial gage. Mark the high point of the head and place the case in
the die in the same position it was before it was removed.
If the high point is either to the right or left horizontally, the die block
must be adjusted correspondingly as shown by the arrows in the sketches
below.


HIGH
POINT TO THE RIGHT


---—-—————-I


N
I lllllillllllllllllllllllllll
\\\“

Ill
‘


Illll _____'_______q
Q


HIGH POINT TO THE LEFT
If the high point of the head is either on the top or bottom of the case when
it is placed back into the die, vertical adjustment of the die block is neces-
sary as shown by the arrows in the sketches below.


HIGH POINT TO THE TOP


—-—-—-—————-—--4


HIGH POINT TO THE BOTTOM

I 21 I
CALIBER .30 POCKETING MACHINE Adjustments
Concentricity (Cont.) The die block may be out of adjustment both vertically and horizontally.
If this is the case, the die block is adjusted as shown by the arrows in the
sketches below:


"1. H T. H ,
E; i ll i @ it
| Ill jj ' I jl I I
I H IHHH 'il'i'>:lj : l . llllllllIllllll[lllllllll' '>:l I
5;: jl: : j ‘ \\ ll jj I
Ill H I | ll
‘_.___
HIGH POINT TO TOP AND RIGHT HIGH POINT TO TOP AND TO LEFT


HIGH POINT TO BOTTOM AND HIGH POINT TO BOTTOM AND
TO RIGHT TO LEFT
CALIBER .30 POCKETING MACHINE
Adjustments

Die Block
(Horizontal)
Lock Nuts
Three—5/15" Allen
Set Screws
Three—11/3" Lock
N uts
1 " Lock Screws
Lock Nuts
Tools:
Procedure:
The die block is adjusted horizontally by turning the three adjusting
screws on the machine at the side of the die block holder. One of the
adjusting screws is threaded into the die block and is used to move
the block toward the left. The other adjusting screws are threaded
into the machine, are forced against the die block and are adjusted to
move the die block to the right.

DIE BLOCK ASSEMBLY
%” wrench, 118" wrench.
1.
2.
9°?‘
Use a screwdriver to remove the four screws from the guard and remove
the guard.
Use a 1%" wrench to loosen the lock nuts on the adjusting screws in
the machine at the side of the die block, while holding the adjusting
screws in place with a 946 ” Allen wrench.
. To move the die block to the right, use a 1%” wrench to loosen the
center adjusting screw a fraction of a turn; use a 946 " wrench to tighten
the two outside adjusting screws.
To move the die block to the left, loosen the two outside adjusting
screws a fraction of a turn and tighten the center adjusting screw.
Tighten the lock nuts on the adjusting screws against the machine.
Check the adjustment by operating the machine and inspecting the
cases on a dial gage.
Note: The above procedure should be repeated until concentricity of
the head of the case is attained.
Replace the guard; insert and tighten the screws holding the guard
in place.
[23]
CALIBER .30 POCKETING MACHIN Adjustments

Pocketing Punch The pocketing punch forms a pocket in the head of the case. Proper
depth of the pocket and correct web thickness depend upon correct ad-
justment of the pocketing punch. If the web is too thick, the punch must
be adjusted closer to the stem; if the web is too thin, the punch must be
adjusted so there is more clearance between the stem and the punch.
The punch is adjusted by turning the spanner nuts on the pocketing
punch holder. Before any work is done on the pocketing punch holder,
the stem must be checked to see that it is correctly adjusted.
Buck
Spanner _.
Nlll Poclreting
Punch
Poclreting
Punch
Holder
Front
Spanner
Nut
Allen
Set Screw

PUNCH HOLDER ASSEMBLY
Tools: 14” steel rod, screwdriver.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place and remove the guard.
2. Use a %” steel rod to loosen slightly the spanner nut closer to the
punch. Tighten the other spanner nut against the bracket to adjust
the punch closer to the stem.
3. Use a V2" steel rod to loosen slightly the spanner nut farther from the
punch. Tighten the other spanner nut against the bracket to adjust
the punch farther from the stem.
4. The above procedure must be repeated, and the web thickness tested
after each setting, until the desired web thickness is attained.
5. Replace the guard; insert and tighten the screws holding the guard
in place.
[24]
CALIBER .:-no POCKETING MACHINE Adjustments

Die Block The die block is adjusted vertically by adjusting the four adjusting screws
(Vertical) on top of the die block holder. The adjusting screws are hollow, permit-
ting the lock screws to pass through the center and to screw into the
machine bed.
2" Adjusting 1 " Lock ' 1” Lock Die Feed
Screws Screws Die Screws Block Mechanism

VIEW OF DIE BLOCK WITH VIEW OF DIE BLOCK WITH
FEED MECHANISM REMOVED FEED MECHANISM IN PLACE
Tools: 2" wrench, 1 ” wrench, %" wrench.
Procedure: 1. Use a screwdriver to remove the four screws from the guard and
remove the guard.
2. Use a Z{;” wrench to remove the cap screws that hold the carriage to
the machine. Remove the carriage.
3. Use a 1" wrench to loosen the four lock screws on top of the die block.
4. To raise the die block holder, use a 2" wrench to tighten the four
adjusting screws a fraction of a turn.
5. To lower the die block, use a 2” wrench to loosen the four adjusting
screws a fraction of a turn.
Caution: Each of the four adjusting screws must be turned a like
amount to keep the die block level.
[25]
CALIBER .30 POCKETING MACHINE Adjustments
Procedure: (Cont.) 6. Tighten the four lock screws while holding the adjusting screw in place.
Note: The above procedure must be repeated until concentricity of
the jacket is attained.
7. Replace the carriage.
8. Replace the guard; insert and tighten the screws holding the guard in
place.
[26]
CALIBER .30 POCKETING MACHINE Adjustments
Injecting Stem The injecting stem pushes the case out of the die just far enough so that
the head of the case is pocketed by the action of the pocketing punch. If
the case is pushed too far out of the die, a ring will be formed on the case
by the outside edge of the die. If the case is not pushed far enough out of
the die, the pocketing punch will not make the pocket in the head of the
case deep enough. Adjustment is made by adjusting the two spanner
nuts on the injecting stem holder. The stem holder must be adjusted so
that the head of the case projects out of the die about £46".
Spanner
Nuts
Injecting
Stem

INJECTING STEM AND HOLDER
Tools: 1//’ steel rod, screwdriver.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place, and remove the guard.
2. Place a test case in the magazine and turn the ﬂywheel by hand until
the head of the case protrudes from the die.
3. If the head of the case does not protrude at least 14;” from the die, use
a %" steel rod to loosen slightly the spanner nut closer to the stem.
Tighten the other spanner nut against the brake.
4. If the head of the case protrudes more than lﬁ”, use a V2” steel rod
to loosen slightly the spanner nut farther from the stem. Tighten the
other spanner nut against the bracket. (In either of the above cases
the adjustment must be repeated until the head of the case protrudes
l/N5" from the die).
[27]
CALIBER .30 POCKETING MACHINE
Adjustments
Procedure: (Cont.)
5.
Remove the test case from the die and turn the ﬂywheel by hand
until the ram is at its normal position. '
Replace the guard; insert and tighten the screws which hold the guard
in place.
Operate the machine and test the web thickness of the cases with a
flush pin gage.
[28]
CALIBER .30 POCKETING MACHINE Adjustments

\
Feed Finger The feed ﬁnger receives the case from the feed tube and places it in line
with the die. In order to adjust the feed ﬁnger so that it is in alignment
with the feed tube and the die, it is necessary to turn the rod that connects
the feed ﬁnger to the push rod.
Feed
Finger

FEED MECHANISM
Tools: M" wrench, 3/42" Allen wrench, screwdriver.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place, and remove the guard.
2. Use a screwdriver to remove the feed tube to observe whether or not
the feed ﬁnger is in line with the feed socket.
3. Turn the rod that connects the feed ﬁnger to the push rod one com-
plete revolution, clockwise if the feed ﬁnger is too far forward, or
counterclockwise if the feed ﬁnger is too far back to be in line with
the feed socket.
4. Replace the feed tube and tighten the Allen screw.
5. Replace the guard; insert and tighten the screws holding the guard
in place.
[291
CALIBER .30 POCKETING MACHINE Adjustments
Hopper Feed As the cases are carried upward by the pin wheel, the case heads contact
Bridge (Horizontal) the hopper bridge which holds the cases on the pins until they reach the
feed tube mouth and fall down through the feed tube. The bridge should
be close enough to the seating spring that the cases do not fall from the
pins before they begin their travel on the bridge. The bridge can be moved
to the desired position by loosening the set screw which holds the bridge
to the hopper.
Bﬂdge


Horizontal ‘-"
Adjustment .'
Located in
the Shaft
Feed Tube
INTERIOR OF PIN WHEEL HOPPER
Tool: 11/4 " wrench.
Procedure: 1. Release the latch and open the hopper door.
2. Use a 1/4" wrench to loosen the set screw on the left end of the hopper
bridge.
3. Move the bridge close to the seating spring and in line with the bottom
of the pins on the pin wheel.
4. Hold the bridge in position and tighten the set screw.
5. Close and latch the hopper door.
6. Check the adjustment by operating the hopper and opening the hopper
inspection gate to see whether or not the cases remain on the pins un-
til they begin their travel on the bridge.
[30]
CALIBER .30 POCKETING MACHINE Adjustments

Hopper Feed The feed bridge can be adjusted vertically by adjusting the nuts on the
Bridge (Vertical) vertical bolt connected to the bridge.


Bridge _
Adjustment ‘
CLOSEUP OF INTERIOR OF PIN WHEEL HOPPER
Feed Tube Mouth The cases should fall from the pins into the feed tube mouth and down
through the feed tube. If they fail to do this, the feed mouth must be
aligned with the pins on the pin wheel.
Tool: P45" wrench.
Procedure: 1. Release the latch and open the hopper door.
2. Use an life" wrench to loosen the bottom lock nut on the rod that
connects the feed tube mouth to the hopper bridge.
3. Use an 11/46” wrench to adjust the top nut until the feed tube mouth is
in line with the pins on the pin wheel.
4. Hold the adjusting nut in place and tighten the lock nut.
5. Close and latch the hopper door.
I31]
CALIBER .30 POCKETING MACHINE Adjustments

Pin Wheel Hopper When the pin wheel hopper motor belt becomes too loose through being
Motor Belt stretched, it is necessary to tighten the belt to assure proper operation of
the pin wheel. ,
Hopper
/ Motor

HOPPER MOTOR BELT ADJUSTMENT
Tools: %" wrench, %” wrench.
Procedure: 1. Use a V8” wrench to loosen the lock nut on the motor adjusting set
screw.
2. Use a V3” wrench to turn the adjusting set screw, moving the motor
away from the hopper pulley, thus tightening the belt.
3. Tighten the lock nut.
[32]
CALIBER .30 POCKETING MACHINE Adjustments

Flywheel Motor When the motor belt becomes too loose, through being stretched, it is
Belt necessary to tighten the belt by raising the motor, to insure proper opera-
tion of the machine.
Machine
Motor
Top Nut
Nut
Lower
Nut
FLYWHEEL MOTOR BELT ADJUSTMENT
Tool: 2" wrench.
Procedure: 1. Use a 2" wrench to loosen the three top nuts on the motor supporting
studs.
2. Use a 2" wrench to turn the three lower nuts to raise the motor, moving
it away from the ﬂywheel, thus tightening the belts.
3. Tighten the three top nuts.
[33]
CALIBER .30 POCKETING MACHINE Adjustments

Flywheel Brake Two brake shoes press against the side of the ﬂywheel when the brake is
applied. If the ﬂywheel does not stop almost immediately upon applica-
tion of the brake, the brake shoes should be adjusted so that they press
more ﬁrmly against the ﬂywheel. Both shoes should be adjusted a like
amount.
Brake shoe
1%" Lock Nut
3/4" Adjusting
Screw
1%" Lock Nuts
3/4" Adjusting
Screws

BRAKE ASSEMBLY
Tools: 11/4" wrench, 9/4" wrench.
Procedure: 1. Use a 1%” end wrench to loosen the lock nuts on the brake shoes. ,
(The brake shoes are located at the bottom of the ﬂywheel.)
2. Use a % ” wrench to tighten each of the adjusting screws about one-half
turn.
3. Hold the adjusting screws in place and tighten the lock nuts.
4. Check the adjustment by operating the machine and applying the
brake.
I34]
CALIBER .30 POCKETING MACHINE
Troubles and Corrections

Objective
Scratched or
Scored Walls
Case Pulling Out
of Die
Pocket Out of
Concentricity
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may con-
front an adjuster, but the production troubles that most commonly occur,
their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as it
operates.
Visual inspection will reveal scratches on the inside or outside walls of the
case. Scratches on the outside wall can be detected by ﬁnger nail inspec-
tion.
The causes are: The corrections are:
1. Rough die—die has excess brass 1. Lap and polish die if possible
coating on inside surface.
or replace with a new die.
2. Chipped die—edge on inner 2. Replace with a new die.
surface of die has become
chipped.
3. Scratched die—scratch on the 3. Polish the die if the scratch is
inside surface of the die. not too deep, or replace with a
new die if necessary.
4. Foreign matter — (dirt, dried 4. Send the cases to the Washing
soap, etc.) on the cases.
Department to be rewashed.
Visual inspection discloses that the case does not ﬁt into the die properly
and is pulled out of the die by the pocketing punch.
The causes are: The corrections are:
1. Brass accumulation on the pock-
eting punch.
1. Polish the punch and remove
excess brass.
2. Die is worn or oversize. 2. Replace with a new die.
3. Remove case and check source
of supply.
3. Component within gage but too
small for the die.
Gaging discloses that the pocket is not concentric with the outside of the
case.
The corrections are:
1. Adjust the die block properly.
The causes are:
1. The die block is out of align-
ment.
2. Cases are crooked and defec-
tive.
2. Check the source of supply;
call the inspector.
[35]
CALIBER .30 POCKETING MACHINE
Troubles and Corrections

Pocket Out of
Concentricity (Cont.)
Inside Pocket
Mo rred
Wrinkles in Case
Dented Mouth
The causes are:
3.
4.
5.
Bent injecting stem.
Die bushing is undersize.
Loose gibs.
. Cases have variable sidewall
thicknesses.
The corrections are:
. Replace with a new stem.
. Replace with a new bushing.
. All gib adjustments are made
by Maintenance Department
only.
. Check the source of supply.
Visual inspection discloses dents, scratches, or metal accumulation on the
head of the case.
The causes are:
1.
Worn pocketing punch—punch
is undersize.
Chipped pocketing punch—a
piece is broken off the end of
the punch.
. Pocketing punch is broken.
Skinned pocketing punch—
punch is surface marred or has
excessive coating of brass.
The corrections are:
1.
Replace with a new pocketing
punch.
Replace with a new pocketing
punch.
Replace with a new pocketing
punch.
Polish the punch if it is not
too badly skinned. If it is be-
yond repair, replace with a new
punch.
Visual inspection discloses wrinkles on the outside near the mouth of
the case.
The causes are:
1.
Undersize die—the mouth of
the die is too small.
. Excessive oil or lubricant on
CEISQS.
Insufficient lubricant.
The corrections are:
1.
Lap and polish the die to the
proper speciﬁcation.
Remove the cases and send to
Washing Department to be re-
washed or reduce the ﬂow of
lubricant.
. Increase the ﬂow to required
amount.
Visual inspection discloses that the mouth of the case is dented.
The cause is:
1.
Knockoff wire is out of time.
The correction is:
1.
Adjust wire properly.
l 36 l
CALIBER .30 POCKETING MACHINE
Troubles and Corrections
Metal Deposit
Under Head
Metal Deposit on
Inside of Case
Oversize Diameter
Cases Cut Off
Case Mashed
Against Die
Cases Fed
Improperly
in Machine
Visual inspection discloses that there is a deposit of metal under the head.
The causes are: The corrections are:
1. Cracked die——there is a crack
on the inside surface of the die.
1. Replace with a new die.
2. Chipped die——edge on the inner
surface of die has become
chipped.
2. Replace with a new die.
Visual inspection discloses that there is a deposit of metal inside of the
case.
The causes are: The corrections are:
1. Injecting stem is chipped. 1. Replace with a new injecting
stem.
2. Injecting stem is cracked. 2. Replace with a new injecting
stem.
Gaging discloses that the body of the case is too large.
The cause is: The correction is:
1. The die is too large. 1. Replace with a new die.
Visual inspection discloses that the case has become cut in half, bent or
severed by the injecting stem.
The causes are: The corrections are:
1. Case feeding into feed box is
too long.
1. Remove the long case and
check the source of supply.
2. Remove the case and check the
source of supply.
2. Case is injected into die im-
properly.
3. Partially ﬁlled feed box. 3. Adjust to get flow of cases into
feed box.
Visual inspection discloses that a case has become mashed against the die.
The causes are: The corrections are:
1. The knockoff wire is out of
adjustment.
1. Adjust knockoff wire properly.
2. Knockoff wire is broken. 2. Replace with a new knockoff
WIPE.
Visual inspection discloses that the cases are not feeding properly through
the feed block and cradle.
The causes are: The corrections are:
1. Remove cases and check the
source of supply.
1. The cases are too long or too
short.
2. Foreign matter——(dirt, scrap,
etc.) in feed block or cradle.
3. Bent case in feed block.
2. Remove feed block or cradle
and clean.
3. Remove bent case and check
the source of supply.
[37]
CALIBER .30 POCKETING MACHINE
Troubles and Corrections
Uneven Flow of Visual inspection discloses that hopper is not feeding cases to machine
properly.
The causes are:
Cases from Hopper
Machine Stops on
Dead Center
1.
Defective or long cases—cases
from fourth draw too long or
defective.
. Case jammed in feed tube.
Foreign matter — (dirt, shav-
ings, etc.) in the hopper.
. Overloaded hopper—too many
cases in hopper.
Bridge is out of adjustment.
. Belt slips—loose belt, oily belt.
The corrections are:
1.
Remove the cases from hopper
and check the source of supply.
. Remove the case and clear
feed tube.
Clean the hopper and check
source of supply.
Remove excess cases.
. Adjust the bridge properly.
. Tighten the belt if it is loose;
clean the belt if oily.
Visual inspection discloses that the machine has stopped on dead center.
The cause is:
1. The injecting stem and the
pocketing punch are locked
against the case in the die.
The correction is:
1. Adjust the machine properly.
[38]
CALIBER .30 POCKETING MACHINE
Tool Servicing

Objective
Servicing of
New Dies
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the
bumping, pocketing, and heading of the cases. Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters will be concerned primarily with the removal of brass and small
scratches that appear on working surfaces of dies and punches; they must
be careful, however, when using an abrasive on any tool, not to alter its
dimensions materially.
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1. Dies as received from the tool room are normally undersize to allow
for expansion pressure, and for lapping to a desired size when necessary.
2. The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
3. As a precaution, before a test run is made, the die bore should be
inspected for roughness and polished if necessary.
4. The product from the test run should be carefully gaged and in-
spected. Then, and then only, if an undersize or out of true die is
indicated, should the die be lapped.

FIG. 1
OVER-ALL VIEW OF SPEED LATHE
I39]
CALIBER .30 POCKETING MACHINE Tool Servicing

Lapping Procedure 1. When lapping is necessary, proceed as follows: Use a lap stick made of
ﬁber or wood about the same diameter as the die hole.
2. Tear off strips of 220 emery cloth about 1" wide and wrap the emery
cloth around the end of the lap stick until it makes a snug ﬁt in the
head of the die.

FIG. 2 FIG. 3
CORRECT WAY TO PLACE DIE IN INCORRECT WAY TO PLACE DIE IN
CHUCK CHUCK
3. Chuck the die in the speed lathe, head out. Care must be taken to get
the die in the lathe properly. See Fig. 2.
4. Insert the lap stick in the head of the die.
5. Run the lathe on low speed, hold the lap stick in your hand and move
it in and out to prevent cutting grooves in the die.
6. Extreme care must be taken to guard against cutting too much metal
out of the die, thus making it too large.
7. Remove the die from the lathe, wipe out with a cloth and gage with
a plug gage.
Servicing When a die becomes scratched on the inside, the above procedure will be
Scratched Dies used for eliminating the scratch providing the scratch is not too deep. In
case of exceptionally deep scratches the die must be returned to the tool
room.
Servicing the When the injecting stem has an accumulation of brass on it, remove the
Injecting Stem stem and polish it with 220 emery cloth, by hand, until the brass is com-
pletely removed. Then polish the stem with crocus cloth.
Servicing the When the pocketing punch has an accumulation of brass on it, it is neces-
Pocketing Punch sary to remove the punch from the machine and polish it with 220 emery
cloth until the brass is completely removed. Then polish the pocketing
punch with crocus cloth.
I40]
CALIBER .30 POCKETING MACHINE
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[41]
CALIBER .30 POCKETING MACHINE
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
:'q.®.°‘t‘>.°°.l\°
Frequency of lubrication.
I 42 I
CALIBER .30 POCKETING MACHINE
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
. Bottle oiler.
. Ring oiler.
. Plain oil cups.
2
3
4
5. Drop feed cups.
6. Wick feed cups.
7. Mechanical, force feed, central lubricating system.
8. Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I43]
CALIBER .30 POCKETING MAcI-IINE Machine Lubrication
LUBRICATION CHART


. . N 0. of Fittings, Frequency of
I/ubmcam Machine Part Grease Cups, etc. Lubrication H ours
Rocker arms . . . . . . . . . . 4 8
Eccentric wheel . . . . . . . . . 1 8
LIGHT GREASE Crankshaft assembly . . . . . . 4 8
(Blue Gun) Connecting rods . . . . . . . . . 6 8
Ram assembly . . . . . . . . . 4 8
Hopper shaft . . . . . . . . . . 1 1 wk.
Brake assembly . . . . . . . . . 1 24
Brake assembly . . . . . . . . . 1 24
Knockoff cam . . . . . . . . . . 1 8
MEDIUM OIL Cam on eccentric . . . . . . . . 1 8
(Red Oiler) Knockoff wire assembly . . . . . 2 8
Push block . . . . . . . . . . . 2 8
Push block conveyor . . . . . . . 4 8
Conveyor cam roller . . . . . . . 1 8

I44]
CALIBER .30 POCKETING MACHINE
Index
Adjustment, Concentricity, 21
Die Block, Horizontal, 23
Die Block, Vertical, 25
Feed Finger, 29
Feed Tube Mouth, 31
Flywheel Brake, 34
Flywheel Motor Belt, 33
Hopper Feed Bridge, Horizontal, 30
Hopper Feed Bridge, Vertical, 31
Injecting Stem, 27
Pin Wheel, Hopper Motor Belt, 32
Pocketing Punch, 24
Anti-friction Bearings, 41
Anvil, 10, 11, 12
Bottom Thickness, 17
Brake, 2, 3, 6
Shoe, 3, 6
Bumped Case, 14
Bushing, 10, 11, 12
Cam Roller, 3
Cap Nut, 11
Case Mashed Against Die, 37
Pulling Out of Die, 35
Cases Cut Off, 37
Fed Improperly in Machine, 37
Concentricity, 18
Adjustment, 21
Crankshaft, 3, 4
Dented Mouth, 36
Dial Indicator, 18
Die, 7, 10, 13
Block, 7, 21, 22
Block Assembly, 10
Block,. Horizontal, Adjustment, 23
Block Vertical, Adjustment, 25
Disposal, 14
Double Plug Gage, 19
Eccentric Cam, 3, 4
Elevator, 3
Feed Box, 7
Finger Adjustment, 29
Motor, 1
Pipe, 15
Sleeve, 8, 14, 16
Slide, 7, 14, 16
INDEX
Feed Tube, 7, 8, 14, 15, 29
Tube Mouth Adjustment, 31
Floor Space, 1
Flow Chart, 15, 16
Flywheel, 2, 6
Brake, Adjustment, 34
Motor Belt Adjustment, 33
Friction, 41
Front Spanner Adjusting Nut, 11, 12
Gage Care, 18
Grease, 42
Height, 1
Hopper Assembly, 8
Box, 8
Feed Bridge, Horizontal, Adjust-
ment, 30
Feed Bridge, Vertical, Adjust-
ment, 31
Injecting Stem, 5, 11, 14, 16
Stem Adjustment, 27
Stem Assembly, 11
Stem Holder, 11
Inside Pocket Marred, 36
Knockoff, 14
Wire, 3, 16
Lapping Procedure, 40
Lathe, 40
Lubricating Film, 41
Lubrication, 3, 41
Chart, 44
Hints on, 43
Methods, 42
Machine Motor, 1
Stops on Dead Center, 38
Manufacturer, 1
Metal Deposit on Inside of Case, 37
Deposit Under Head, 37
Methods of Getting Lubricant to
Bearing Surface, 43
Motor, 2
Outside Diameter, 17
Overhead Hopper, 14, 15
Oversize Diameter, 37
Pin Wheel Hopper, 3, 8, 14, 15
Wheel Hopper Box, 14, 15
Pin Wheel Hopper Motor Belt
Adjustment, 32
Pocket Out of Concentricity, 35, 36
Pocketed Case, 16
Pocketing Punch, 14, 16
Punch Adjustment, 24
Ram, 3
Power, 2
Primer Pocket, 2
Production, 1
Punch, 2, 12, 13
Bushing, 12
Holder, 12
Holder Assembly, 12
Push Block, 14, 15
Ram, 2, 3, 5
Rear Spanner Adjusting Nut, 11, 12
Rocker Arm, 3, 4
Arm Shaft, 4
Scored Walls, 35
Scratched Walls, 35
Selecting Lubricant for Given
Bearing, 42
Servicing Injecting Stem, 40
New Dies, 39
Pocketing Punch, 40
Scratched Dies, 40
Speed of Crankshaft, 1
Stem, 13
Ram, 3
Stroke, 1
Switch, 2
Tools, 1
Transmission, 2
Twin Ring Gage, 18
Type of Feed, 1
Uneven Flow of Cases from
Hopper, 38
Visual Inspection, 18
Washing Department, 17
Web Thickness, 17, 18
Weight, 1
Wrinkles in Case, 36
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Heading Machine


BY
Training Department

Western Cartridge Company _
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 194-1
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAL CORRECTlONS—CALIBER .30 HEADING MACHINE
LOCATION
Page 3- ‘I 6
Page 5 —Fig
Page 9—Fig
Page 12
Pages 26 and 29-
Fig
Page 1 7—Spec
Page 1 9—F'ig
Page 18—Fz'g
ERROR
Jackets
Picture Of Bump
Pocketing Punch
Bumping
Bump Machine
Outside diameter before Heading .7 97 0—.8000
Web thickness before Heading .07 0—.080
Outside diameter after Heading .7 97 0—.8010
Web thickness after Heading .093—.113
Flush Pin Gage
Punch Holder is shown
CORRECTION
Cases
Picture of Head
Heading Punch
Heading
Heading Machine
Outside diameter before Heading .4645-.4665
Web thickness before Heading .042—.050
Outside diameter after Heading .4645—.4670
Web thickness after Heading .060—.068
Dial Indicator
Punch should be shown
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . 20
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
III

'HEADlNG MACHINE
.30
VIEW OF CALIBER
I~V
CALIBER .30 HEADING MACHINE Catalogue Data

CATALOGUE DATA
Manufacturer E. W. Bliss Co., Brooklyn, N. Y.
Machine E. W. Bliss Horizontal Toggle and Crank Press
Description 5 V belt drive motor to ﬂywheel on crankshaft.
Machine Motor 5 h.p.; 60 cycle; 3 phase; 220/440 volt; 870 R.P.M.
Type of Feed Pedestal type pin wheel hopper mounted on ma-
chine. Belt drive from motor; 7 R.P.M.
Feed Motor Gear head; % h.p.; 60 cycle; 1 phase; 115/230
volt; 1725 R.P.M.
Production 105 per minute.
Crankshaft Speed 105 R.P.M.
Stroke Front crank 8%” ; back crank 6746".
Tools: Piece No.
Injecting Stem E- 2
Die E-12
Heading Punch E-23
Height 7 ft. 3% in.
Weight 8,200 lbs.
Floor Space 4 ft. x 8 ft.
Ill
CAUBER .30 HEADING MACHINE
Machine Description

Guard
Covering
Flywheel
Flywheel
Power and
Transmission
MACHINE DESCRIPTION
'_- E.'Iv.nI;IssI'.O '
'"°"\lYl IX '
6
‘M.
CALIBER .30 HEADING MACHINE
The E. W. Bliss Horizontal Crank and Toggle Press, illustrated above,
is powered by a 5 h.p. motor through ﬁve V-type belts connecting
the motor to the flywheel.
The Horizontal Crank and Toggle Press is equipped with a heading
punch which is incorporated in the front ram. As the heading punch,
actuated by the ram, strikes the closed end of the case, it forms the head,
sizes the primer pocket, and stamps the identiﬁcation on the head of
the case.
The motor is mounted directly above the ﬂywheel on an adjustable
bracket which allows proper adjustment of the belt tension. The fly-
wheel is mounted to the front or heading ram crankshaft at the front
of the machine.
The motor is controlled by a push button type switch; the red button
breaks the circuit and the black button closes the circuit. As no clutch
is employed on this type machine, the machine is started by releasing
the manually operated brake and pressing the starter switch.
[2]
CALIBER .30 HEADING MACHINE
Machine Description
Brake
Heading Ram
Knockoff Wire
Stem Ram
Eccentric Cam
and Rocker Arms
Pin Wheel
Hopper
Lubrication
The brake is manually controlled through linkage from the brake oper-
ating arm to the brake shoe. The brake operating arm is held in a
horizontal position directly above the die holder. The brake linkage is
equipped with an arm which acts to break the electrical circuit to the
motor when the brake is applied. As the electrical circuit is broken, the
shoes are applied to the front and rear face of the ﬂywheel to stop the
machine action.
The front or heading ram is supported by and travels on two 45° angle gib
plates. The heading ram is connected to and actuated by a connecting
rod attached to the front crankshaft throw. The face of the ram is
machined to hold the tool holder.
A knockoff wire is attached to an operating arm which is actuated by a
cam roller attached to the heading ram. The knockoff wire extends out
from the rear edge of the machine frame to a position directly above the
case as it is discharged from the die. The knockoff wire, actuated by
the heading ram on every stroke of the ram, knocks the discharged case
into the bottom of the machine bed where it passes out onto a conveyor
belt leading to the elevator.
The stem ram or back ram is connected to and actuated by a connecting
rod attached to the rear crankshaft. The ram face is machined to hold
the working tools. The ram is supported by and travels on two 45°
angle gib plates which are bolted to the machine frame in a horizontal
position.
The power is transferred from a crankshaft through two rocker arms and
an eccentric cam.
The pin wheel hopper is mounted on a supporting bracket located at the
rear center of the machine. The cases are fed into the hopper box from
an overhead chute, and are agitated in the hopper by a manually operated
lever which extends through the bottom of the hopper to a position
within easy reach of the operator. The cases are fed to the machine
through a feed tube, to the feed sleeve, from the feed sleeve into the
die. Each jacket is discharged from the die by the following jacket
being inserted. As each case is fed into the die, it discharges the pre-
ceding case from the die.
The machine is lubricated by means of Alemite-Zerk ﬁttings attached
to the various working parts.
The gibs and other exposed parts which have a tendency to overheat
quickly should be oiled frequently with an oil can containing an appro-
priate grade and viscosity of lubricant. (See Lubrication Chart, page 45)
I3]
CALIBER .30 HEADING MACHINE Machine Description


Bumper
Stem
' Crankshaft
Crankshaft
Rocker , ,
Arm
Eccentric _
Cam
ECCENTRIC CAM AND ROCKER ARMS
Eccentric Cam and Power is transmitted from the front, or heading crankshaft, through two
Rocker Arm rocker arms and an eccentric cam to the back or stem ram crankshaft.
The heading crankshaft turns 360°, or a complete revolution. The rocker
arm leads from the crankshaft to a point off center on the- eccentric cam.
The eccentric cam is mounted on a stub shaft at the back center of the
machine. A second rocker arm shaft, attached to the off center point
on the cam, leads to the back or heading stem crankshaft. The motion
of the heading crankshaft, by use of the rocker arms and eccentric cam,
is transformed from a 360° revolution to a 90° are at the heading stem
crankshaft.
I4]
CALIBER .30 HEADING MACHINE Machine Description


Spanner
Nuts _ Knockoff
‘ Wire
’ Springs
Set
Screw _
Bumper
Tool ’ V
Holder Feed
/ Tube
Allen
__ Set Screw
Cup
Screw
RAMS, TOOL HOLDERS AND CRADLE
Roms The face of each ram is machined to hold a tool holder. The heading
ram contains the tool holder which holds the heading punch. The tool
holder incorporates two spanner nuts, which allow an adjustment to be
made on the heading tool. The stem ram contains the tool holder which
holds the injecting stem. Two spanner nuts are incorporated in the tool
holder which allows an adjustment to be made on the injecting stem.
[5l
CALIBER .30 HEADING MACHINE Machine Description


Brake shoe
1%" Lock Nut
3/4" Adjusting
Screw
11/," Lock Nus_h
th
3/4" Adjusting
Screws
BRAKE ASSEMBLY
Brake The brake shoes are attached to a bracket, which holds the shoes in posi-
tion against the inner and outer surface of the ﬂywheel. The brake
shoe operating lever, which is connected to the brake shoes by a series
of connecting links, applies the brake shoes against the ﬂywheel to stop
the machine when the brake lever is pulled back. A small trip arm, at-
tached at a right angle to the vertical brake shaft, breaks the electrical
circuit by contacting an auxiliary switch when the brake is applied. The
switch is attached to the back side of the machine frame at the right end
of the machine.
I6]
CALIBER .30 HEADING MACHINE
Machine Description

Pin Wheel Hopper
and Hopper Box


Hopper Box
~( ( T‘
J ' “ L1 . Pin Wheel Hopper
\ Switch


"'~‘-ea
END VIEW SHOWING PIN WHEEL HOPPER
The pin wheel hopper box is a one-piece casting with a bottom sloping
toward an adjustable gate, which leads into the pin wheel hopper. The
pin wheel hopper is attached to the front of the hopper box. The pin
wheel consists of a pin ring, an inner and an outer dish-shaped rim bolted
together to form a hopper assembly. The outer dish-shaped rim has
three spokes attached to a hub shaft on which the entire hopper revolves.
The hopper is driven by a V-type belt connected to a ,1./§ h.p. motor. The
motor is supported by an adjustable bracket to maintain proper belt
tension. The pin ring has a series of steel pins, spaced approximately 1"
apart on its inner circumference and set at an angle to the radii. A steel
band rake-off keeps the components that are not properly seated on the
pins from entering the bridge. As the hopper revolves clockwise, the
cases slide onto the steel pins and approach a vertical position, with the
mouth end down.
When the components approach the upper arc of the circumference, they
contact and are held on the pins by the bridge. In this position they are
nearly mouth end up. At the end of the pin wheel bridge they are in
a nearly vertical position and slide off the pins into an adjustable feed
tube mouth. They are then carried by gravity down a feed tube to the
feed sleeve.
[7]
CALIBER .30 HEADING MACHINE Mochine Description
Hopper Box
Steel Pins
Hopper Door
Latch
Dish-shaped
Hopper Door
I
\ _ \" ’ _
_ ‘F .____-—— Feed Tube
0 f1
i
\

l
CLOSE UP OF PIN WHEEL HOPPER
[8]
CALIBER .30 HEADING MACHINE MOCHIHG Description


Tool HoIder—- '
I " I Springs
Pocketing /
Punch
V Feed Tube
Feed Box r- ‘
Push Finger -— j
K _ Cap Screw
Case Slide / ti:
Die Block -- , Injecting Stem
.
DIE BLOCK AND FEED SLIDE ASSEMBLIES
Die Block and The die block is incorporated in the machine frame and is located be-
Feed Slide tween the two rams. A feed box is attached to the top surface of the die
block. The cases are fed from the feed tube into the feed box. From
the feed box they are pushed by a push ﬁnger which is actuated from the
eccentric cam. Each case is pushed by the succeeding cases from the
feed box, around the case slide until they drop into the case feed sleeve.
The stem ram moves forward injecting the case into the die. As the
heading punch travels forward striking the closed end of the case, it
forms the head, sizes the primer pocket, and stamps the identiﬁcation
on the head of the case.
[9]
CALIBER .30 HEADING MACHINE Tool Holder Description

Iniecring SM TOOL HOLDER DESCRIPTION
Assembly
9 F
Rear Spanner Adjusting Nut: The rear spanner
adjusting nut determines the forward adjustment of the
injecting stem holder, and is the same as the front span-
ner nut with the exception that it is thicker. Care
must be exercised in assembling theinjecting stern holder
to get the spanner nut placed properly.
Front Spanner Adjusting Nut: The front spanner
adjusting nut determines the backward adjustment of
the injecting stem holder. It contains equally spaced
holes to facilitate adjustment with a spanner wrench.
Injecting Stem Holder: The injecting stem holder isa
threaded bar that ﬁts in the back ram and is held in place
by two spanner adjusting nuts. The front end is hollow
to accommodate the anvil, bushing, and injecting stem.
Anvil: The anvil is a solid circular piece that ﬁts inside
the end of the injecting stem holder. The stem seats
against the anvil, which helps to absorb the shock on
the stem.
Bushing: The bushing is cylindrical with a hole
through the center through which the shouldered part
\ of the injecting stern ﬁts.
Cap Nut: The cap nut is a hexagonal shouldered nut
which is beveled inside to ﬁt the bevel on the shoulder
of the stem. The nut is placed on the injecting stem to
rest on the injecting stem shoulder. The stem is in-
serted in the injecting stem holder and the nut is screwed
in place.
Injecting Stem: The injecting stem is tapered on the
working end and has a beveled shoulder on the other
end. It ﬁts in a bushing in the injecting stem holder.
I
v


Injecting Stern
Cap Nut
Tool Holder
Injecting Stem


\
I
\
E
\
C\\\‘.:' W \
.\\_‘§‘\'\\\\\\\\\\\“


Anvil
Rear Spanner
Nut


Bushing Front Spanner
Nut


CROSS-SECTIONAL DRAWING or INJECTING srsm
I 10 l
CALIBER .30 HEADING MACHINE Tool Holder Description

Die Block Die: The die is cylindrical in shape, and is approximately 4" long and
Assembly 3" in diameter, with a longitudinal hole which tapers from the mouth to
the head of the die through the center.
Bushing: The bushing is a hollow cylinder that ﬁts in the die block and
is used as a spacer between the die block and the die.
Anvil: The anvil is designed as shown in the cross-sectional drawing be-
low. A hole through its center permits the feeding of the case into the die.
The anvil ﬁts in the die block directly behind the bushing. It absorbs
shock and prevents wear on the die block.

CROSS-SECTIONAL DRAWING OF DIE BLOCK ASSEMBLY
I 11 l
CALIBER .30 HEADING MACHINE
Tool Holder Description

Punch Holder
Assembly
Punch Holder


Rear Spanner Adjusting Nut: The rear spanner ad-
justing nut located on the bumping punch holder, de-
termines the forward adjustment of the bumping punch.
The spanner nut contains equally spaced holes around
its circumference to facilitate its adjustment with a
spanner wrench.
Front Spanner Adjusting Nut: The front spanner
adjusting nut determines the backward adjustment of
the bumping punch and is identical to the rear spanner
nut with the exception that it is thinner.
Punch Holder: The bumping punch holder is a
threaded bar that ﬁts in the front ram. It is held in
place by the two spanner nuts and a set screw which
screws through the front of the ram into a slot in the
bumping punch holder.
Anvil: The anvil is a circular piece that ﬁts on the
inside of the front of the bumping holder and absorbs
the shock of the bumping punch.
Bushing: The bushing is cylindrical, with a hole
through the center. It ﬁts in the front of the bumping
punch holder against the anvil and acts as a spacer
between the bumping punch holder and the bumping
punch.
Spacer Pin: The spacer pin determines the depth of
the heading punch. This depth is controlled by the
length of the spacer pin used. It is inserted in the
punch holder after the punch.
Sizing Punch: The sizing punch is funnel shaped.
It is inserted in the punch holder before the spacer pin.
Heading Punch: The heading punch is cylindrical
with a longitudinal hole through its center. It holds
the pocket sizing punch and spacer pin.


_
as Rs 2’ 8
wz ‘"2 E '-=,, '- tr '5
\- ‘E = 5 mg g
2 2 < m -5 o o.
_ o ._
,\\\‘k\\\g\\\\\\\\\\\\\\\\\ I -§
I


7/
/
I
R
____--
_‘—-
____d-
___-—
\
:5‘
‘-'-_,-_l---
,-
‘I
Hi
‘I
CROSS-SECTIONAL DRAWING or PUNCH HOLDER ASSEMBLY


I 12 I
CALIBER .30 HEADING MACHINE Tool Description
TOOL DESCRIPTION
Tool Name: Stem
Piece No.: E-2
Location: Held horizontally in back crosshead
ram
Normal Life: 200,000 pieces
Stem is made of tool steel, hardened, ground and pol-
ished. Point of stem is rounded and tapered.
Tool Name: Die
Piece No.: E-12
Location: Die block
Normal Life: 70,000 pieces
Die is made of tool steel, hardened, ground and pol-
ished. Mouth end of die is tapered and rounded.
Tool Name: Heading Punch
Piece No.: E-23
Location: Held horizontally in front crosshead
ram
Normal Life: 150,000 pieces
Heading punch is made of tool steel, hardened, ground
and polished. The working end of the heading punch
contains the raised markings which stamp the identi-
ﬁcation on the case head.

HEADING PUNCH
I13]
CALIBER .30 HEADING MACHINE
Process Sequence

Overhead Hopper
Pin Wheel
Hopper Box
Pin Wheel
Hopper
Coﬂ Spﬁng Feed
Tube
Push Block
Feed Sﬁde
Injecting Stem
Heading Punch
Headed Case
Knockoff and
Disposal
PROCESS SEQUENCE
The cases are fed by gravity from an overhead source into the overhead
hopper and drop through a feed pipe into the pin wheel hopper box.
Cases ﬂow from the pin wheel hopper box through an opening, past the
agitator, into the lower part of the pin wheel hopper.
As the pin wheel hopper rotates, cases are agitated and picked up by
pins on the inner circumference of the pin wheel and are carried up past
the rake-off springs, which knock off misaligned cases and push partly
set cases all the way onto the pins. As the cases are carried to the top -
of the pin wheel, they are held on the pins by the bridge. At the end of
the bridge, they drop off, one at a time, head down into mouth of the
coil spring feed tube.
Cases fall by gravity through the coil spring feed tube into a choke. The
choke prevents deformed cases from entering the curved feed pipe. These
deformed cases are removed by the operator so the ﬂow of cases can
continue through the curved feed pipe part way into the feed box where
they stop against the push block.
The push block moves backward, allowing one case at a time to enter
the feed box; then it moves forward, pushing the case past the feed gate
into the curved feed slide.
The curved feed slide conveys the cases in a horizontal position, one at a
time, into the feed sleeve.
The injecting stem moving in from right to left, enters the case, pushes
it into the die, and holds it there to wait for the heading punch.
The heading punch moves in, from left to right, to strike the case, form-
ing the head‘, sizing the primer pocket, and stamping the identiﬁcation
on the head.
As the heading punch and injecting stem move back from the die, another
case slides into the sleeve and the above operation is repeated. As the
succeeding case is pushed into the die by the injecting stem‘, it pushes the
headed case out.
The headed case is pushed out to a point where the knockoff wire strikes
it, knocking it downward quickly through a metal chute into a conveyor
underneath the press.
[14]
CALIBER .30 HEADING MACHINE
Process Sequence

FLOW CHART


Overhead Hopper
Cases are fed by gravity from an overhead source
into the overhead hopper, and through a feed pipe
into the pin wheel hopper box.


Pin Wheel Hopper Box
Cases ﬂow through an opening in the pin wheel
hopper box, past agitator, into bottom of the pin
wheel hopper.


Pin Wheel Hopper
Rotates and cases are picked up by pins and carried
past the rake-off spring to the top of the pin wheel
where they are held on the pins by the bridge. At
the end of the bridge, they fall off, one at a time,
through a choke and into coil spring feed tube.


Hopper is powered by a %;
h.p. reduction gear motor by
a V-type belt. Control is by
a toggle switch.


Coil Spring Feed Tube
Conveys the cases by gravity through a choke and
into curved feed pipe, part way into the feed box,
where they stop against the push block.


Push Block
Moves backward, allowing one case at a time to en-
ter feed box; then it moves forward, pushing the case
past feed gate into feed slide.


Backward motion by two coil
springs; forward motion by
cam follower, and by cam on
eccentric wheel from rocker
arm, from front crankshaft,
from ﬂywheel.


Feed Slide
Conveys case in a horizontal position, one at a time,
into the feed sleeve located in the die block.


Feed Sleeve
Holds the case in alignment with the injecting stem
and die.


Injecting Stem
Moves from right to left, pushing the case into the
die, and holding it there for the heading punch.


Stem is powered by ram
through connecting rod, from
toggle shaft, rocker arm, ec-
centric wheel, rocker arm,
crankshaft from ﬂywheel.


[15]
CALIBER .30 HEADING MACHINE Process Sequence
FLOW CHART (Cont.)


Heading Punch
Moves in from left to right to strike the case, forming
the head, sizing the pocket, and stamping the iden-
Heading punch is powered by
ram through connecting rod


tiﬁcation on the head. crankshaft‘
Heading Punch and Injecting Stem
Move back from the die and another case slides
into the sleeve and the above operation is repeated.
As the succeeding case is pushed into the die by
the stem, it pushes the headed case out.
Headed Case Knockoff wire is powered by
Is pushed out to a point where knockoff wire strikes cam in cam track on the ram
the case, knocking it downward into a chute to a through connecting rod, from
conveyor under the machine. crankshaft.


[16]
CALIBER .30 HEADING MACHINE Product Description
PRODUCT DESCRIPTION
The component, when received by the heading machine, is in the form of
a case as shown in Fig. 1.
The case is made of brass (70% copper, 30% zinc). The closed end of the
case is known as the bottom before the heading operation. It changes its
identity after the heading operation and is thereafter known as the head.
The open end of the case is known as the mouth.
The cases are received at the heading machine from the Washing Depart-
ment, where they are washed and dried. The cases are delivered to the
Washing Department from the pocketing machine.
The dimensions of the case are as follows:
Before Heading Operation After Heading Operation
_ _ .461?-.1603 , _ . - ‘Ti.
Outside Diameter Outside Diameter ~ ** *0
we-.' ‘ ‘ __ .
Web Thickness :i10:L—"% Web Thickness Jﬁélfia
Sidewall Variation .002 Sidewall Variation .002
After the heading operation, the cases are delivered to the Washing Depart-
ment, where they are washed and dried before being delivered to the
head turn machine.

[17]
CALIBER .30 HEADING MACHINE
Inspection
Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the heading operation, a careful visual in-
spection of the “cases must be made. The cases should be inspected for
scratches on the inside and outside walls, for deposits of metal on the
bottom, wrinkles on the side and mouth, and dents on the bottom. These
defects indicate an immediate adjustment of the machine is necessary to
correct the fault. Whenever defective cases are found, the lot from which
they come must be removed from the machine and properly identiﬁed
so the bad lot will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use, or carelessness in gaging may spring the gage or put a burr on it
which may affect its accuracy. Therefore, force should never be em-
ployed in matching a case to a gage. A protected location should be
used for storage of gages to prevent their being damaged when not in use.
The most accurate checks are made when the cases are cool since heat
causes expansion of the metal and results in a temporary variation in
the case size.
TWIN RING GAGE
The outside diameter of
the case is gaged with a
twin ring gage. Cases
must pass through the lar-
ger or “go” ring but must
not pass through the smal-
ler “no go” ring.


DIAL INDICATOR GAGE
The web thickness of the case is
checked on a dial indicator; varia-
tion in this dimension greatly af-
fects succeeding operations.
DIAL INDICATOR
_ _~-. .


The concentricity of the pocket
is checked by a dial indicator;
the concentricity of the pocket
in relation to the outside diam-
eter is very important.
[18]
CALIBER .30 HEADING MACHINE Inspection
Gages (Cont.) FLUSH PIN GAGE
The depth of the pocket is
gaged by a ﬂush pin pocket
depth gage.


DOUBLE PLUG GAGE
The diameter of the pocket
is gaged by a double plug
“go” and “no go” gage.
The “go" end of plug gage
must always enter the
pocket. The maximum “no
go” must not enter.


The above described inspection methods are those most commonly em-
ployed in the heading of the Caliber .30 case. However, other methods
may be developed to maintain the manufacturing standards.
[19]
CALIBER .30 HEADING MACHINE
Adjustments
Objective
Coutions
ADJUSTMENTS
To maintain satisfactory production, a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any trouble may be de-
tected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
No adjustments are to be made while the machine is in motion, or until the
ﬂywheel has stopped.
To insure proper adjustment of the machine, always turn the ﬂywheel over
by hand before applying power.
Inspect the machine periodically to determine whether or not all connec-
tions and adjustments are secure.
Turn off the power before applying the foot brake.
The brake should be applied in such a manner as to cause the ram to stop
on its back stroke.
Do not permit the ﬂywheel to make a complete revolution in reverse, since
this will throw the machine out of time and cause it to jam.
Before making adjustments on the machine, always lock the electric motor
stop button with the locking set screw.
[20]
CALIBER .30 HEADING MACHINE
Adjustments
Concentricity The die block should be adjusted so that the case is in direct line with

Ill l|ll|lllll'I

HIGH POINT TO THE RIGHT


I-4
the punch. If the punch and the case are not perfectly aligned, the head
of the case will not be concentric with the pocket.
Concentricity is attained by moving the die block either vertically,
horizontally, or both.’ In order to know which way the die block should
be adjusted, it is necessary to place a test case in the machine and operate
the machine until the case is headed. The machine is stopped before
the case is ejected from the die and the case and the die are marked with
5 vertical line across the face of the case head and the die, so that the
position of the case in the die is known after the case has been removed
from the die. Remove the case from the die and test the head for con-
centricity with a dial gage. Mark the high point of the head and place
the case in the die in the same position it was before it was removed. If
the high point is either to the right or left horizontally, the die block
must be adjusted correspondingly as shown by the arrows in the sketches
below.


II II llllllllll I ll‘;

_ --—--_--__—.--a


lll


HIGH POINT TO THE LEFT
If the high point of the head is on either the top or bottom of the case
when it is placed back into the die, vertical adjustment of the die block
is necessary as shown by the arrows in the sketches below.


I
I
|||||| ||||||||':'
I
I


HIGH POINT TO THE TOP

_—-__-_ --___1


ii
\

llll


HIGH POINT TO THE BOTTOM


I21]
CALIBER .30 HEADING MACHINE Adjustments

Concentricity The die block may be out of adjustment both vertically and horizontally.
(Cont.) If this is the case, the die block is adjusted as shown by the arrows in
the sketches below:

1 [HI
I:
I
<9 . .
I
I
I
I
I
_____


HIGH POINT TO TOP AND RIGHT HIGH POINT TO TOP AND TO LEFT


\‘
III III lllllllllli


HIGH POINT TO BOTTOM AND HIGH POINT TO BOTTOM AND
TO RIGHT TO LEFT
[22]
CALIBER .30 HEADING MACHINE
Adjustments

Die Block
(Vertical)
Tools:
Procedure:
The die block is adjusted vertically by adjusting the four adjusting screws
on top of the die block holder. The adjusting screws are hollow, permit-
ting the lock screws to pass through the center and to screw into the
machine bed.

2" wrench, 1" wrench, %” wrench.
1.
Use a screwdriver to remove the four screws from the guard and
remove the guard.
Use a %" wrench to remove the cap screws that hold the carriage to
the machine. Remove the carriage.
Use a 1 " wrench to loosen the four lock screws on top of the die block.
To raise the die block holder, use a 2” wrench to tighten the four
adjusting screws a fraction of a turn.
To lower the die block, use a 2" wrench to loosen the four adjusting
screws a fraction of a turn.
Caution: Each of the four adjusting screws must be t.urned a like
amount to keep the die block level.
I 23 l
CALIBER .30 HEADING MACHINE Adjustments
Procedure: (Cont.) 6. Tighten the four lock screws while holding the adjusting screw in place.
' Note: The above procedure must be repeated until concentricity of
the jacket is attained. '
7. Replace the carriage.
8. Replace the guard; insert and tighten the screws holding the guard in
place.
CALIBER .30 HEADING MACHINE
Adjustments

Die Block
(Horizontal)
Loclt Nuts
Three—5/16" Allen
Set Screws
Three—1%” Lock
Nuts
1 " Lock Screws
Lock Nuts
TOOIS:
Procedure: 1.
2.
99‘
V16” wrench, 1%” wrench.
The die block is adjusted horizontally by turning the three adjusting
screws on the machine at the side of the die block holder. One of the
adjusting screws is threaded into the die block and is used to move
the block toward the left. The other adjusting screws are threaded
into the machine, are forced against the die block and are adjusted to
move the die block to the right.

DIE BLOCK ASSEMBLY
Use a screwdriver to remove the four screws from the guard and remove
the guard. -
Use a 1%” wrench to loosen the lock nuts on the adjusting screws in
the machine at the side of the die block, while holding the adjusting
screws in place with a %” Allen wrench.
. To move the die block to the right, use a 1%" wrench to loosen the
center adjusting screw a fraction of a turn; use a 9/16" wrench to tighten
the two outside adjusting screws.
To move the die block to the left, loosen the two outside adjusting
screws a fraction of a turn and tighten the center adjusting screw.
Tighten the lock nuts on the adjusting screws against the machine.
Check the adjustment by operating the machine and inspecting the
cases on a dial gage.
Note: The above procedure should be repeated until concentricity of
the head of the case is attained.
Replace the guard; insert and tighten the screws holding the guard
in place.
r
[25]
CALIBER .30 HEADING MACHINE Adjustments
Heading Punch The heading punch forms the head of the case and sizes the pocket.
The size of the pocket and the diameter of the case head depend, there-
fore, upon correct adjustment of the punch. If the case head is too
small, the punch must be adjusted closer to the stem; if the head is too
large, the punch must be adjusted as there is more clearance between
the stem and the punch. The heading punch is adjusted by turning the
spanner nuts on the punch holder. Before any work is done on the head-
ing punch, the stem must be checked to see that it is properly adjusted.


Rear Spanner /
Nut ~
Front Spanner /
Nut
Set Screw
Punch Holder
HEADING PUCH HOLDER
Tools: 1/2" steel rod, screwdriver.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place and remove the guard.
2. Use a %" steel rod to loosen slightly the spanner nut closest to the
punch. Tighten the other spanner nut against the bracket to adjust
the punch closer to the stem.
3. Use a %” steel rod to loosen slightly the spanner nut farthest from
the punch. Tighten the other spanner nut against the bracket to
adjust the punch farther from the stem.
4. The above procedure must be repeated, and the diameter of the head
must be tested after each setting, until the desired head diameter is
attained.
5. Replace the guard; insert and tighten the screws holding the guard
in place.


[26]
CALIBER .30 HEADING MACHINE Adjustments

Injecting Stem The injecting stem pushes the case out of the die just far enough so that
the head of the case is pocketed by the action of the pocketing punch. If
the case is pushed too far out of the die, a ring will be formed on the case
by the outside edge of the die. If the case is not pushed far enough out of
the die, the pocketing punch will not make the pocket in the head of the
case deep enough. Adjustment is made by adjusting the two spanner
nuts on the injecting stem holder. The stem holder must be adjusted so
that the head of the case projects out of the die about 14;”.
Spanner
Nut
Injecting
Stem

INJECTING STEM AND HOLDER
Tools: 1/2" steel rod, screwdriver.
Procedure: 1. Use a screwdriver to remove the four screws that hold the guard in
place, and remove the guard.
2. Place a test case in the magazine and turn the ﬂywheel by hand until
the head of the case protrudes from the die.
3. If the head of the case does not protrude at least 14;” from the die, use
a %" steel rod to loosen slightly the spanner nut closer to the stem.
Tighten the other spanner nut against the brake.
4. If the head of the case protrudes more than X6”, use a 1/3” steel rod
to loosen slightly the spanner nut farther from the stem. Tighten the
other spanner nut against the bracket. (In either of the above cases
the adjustment must be repeated until the head of the case protrudes
V16" from the die).
[27]
CALIBER .30 HEADING MAcI-IINE , Adjustments
Procedure: (Cont.) 5. Remove the test case from the die and turn the ﬂywheel by hand
" until the ram is at its normal position.
6. Replace the guard; insert and tighten the screws which hold the guard
in place.
7. Operate the machine and test the web thickness of the cases with a
ﬂush pin gage.
[28]
CALIBER .30 HEADING MACHINE
Adjustments
Feed Finger

TOOlS:
Procedure:
The feed ﬁnger receives the case from the feed tube and places it in line
with the die. In order to adjust the feed ﬁnger so that it is in alignment
with the feed tube and the die it is necessary to loosen the cap screws
holding the carriage to the machine and to turn the feed ﬁnger one com-
plete revolution.
Allen Set Screw
FEED FINGER
%" wrench, %g" Allen wrench.
1. Use a screwdriver to remove the four screws that hold the guard in
place and remove the guard.
2. Use a 7/8" wrench to loosen the two cap screws, one on each side of
the carriage.
3. Use a %2'’ Allen wrench to remove the feed tube to observe whether or
not the feed ﬁnger is in line with the feed socket.
4. Turn the feed ﬁnger one complete revolution clockwise if the feed
ﬁnger is too far forward, or counterclockwise if the feed ﬁnger is too
far back to be in line with the feed socket.
5. Tighten the cap screws that hold the carriage to the machine.
6. Replace the feed tube and tighten the Allen screw.
7. Replace the guard; insert and tighten the screws holding the guard
in place.
[29]
CALIBER .30 HEADING MACHINE Adjustments
Hopper Feed As the cases are carried upward by the pin wheel, the case heads contact
Bridge (Horizontal) the hopper bridge which holds the cases on the pins until they reach the
feed tube mouth and fall down through the feed tube. The bridge should
be close enough to the seating spring that the cases do not fall from the
pins before they begin their travel on the bridge. The bridge can be moved
to the desired position by loosening the set screw which holds the bridge
to the hopper.


.
Horizontal _"";‘
Adjustment "
Located in
the Shaft .
Feed Tube
INTERIOR OF PIN WHEEL HOPPER
Tool: 11/4 ” wrench.
Procedure: 1. Release the latch and open the hopper door.
2. Use a 1/4" wrench to loosen the set screw on the left end of the hopper
bridge.
3. Move the bridge close to the seating spring and in line with the bottom
of the pins on the pin wheel.
4. Hold the bridge in position and tighten the set screw.
‘ 5. Close and latch the hopper door.
6
. Check the adjustment by operating the hopper and opening the hopper
inspection gate to see whether or not the cases remain on the pins un-
til they begin their travel on the bridge.
[30]
CALIBER .30 HEADING MACHINE Adjustments

Hopper Feed The feed bridge can be adjusted vertically by adjusting the nuts on the
Bridge (Vertical) vertical bolt connected to the bridge.
Tools: Two 1%” wrenches.
Procedure: 1. Use an 11/I/6" wrench to loosen the lock nut on the vertical bolt while
holding the adjusting nut.
Use an 11/16" wrench to turn the adjusting nut, either raising or lowering
the feed bridge until it is about %" from the pins on the pin wheel.
3. Hold the adjusting nut in place and tighten the lock nut.
4. Close and latch the hopper door.
N


Bridge _ Adjustment .~
— Feed Tube
Feed Tube Mouth The cases should fall from the pins into the feed tube mouth and down
through the feed tube. If they fail to do this, the feed mouth must be
aligned with the pins on the pin wheel.
Tool: 11/1/6” wrench.
Procedure: 1. Release the latch and open the hopper door.
2. Use an M5” wrench to loosen the bottom lock nut on the rod that
connects the feed tube mouth to the hopper bridge.
3. Use an 1%" wrench to adjust the top nut until the feed tube mouth is
in line with the pins on the pin wheel.
4. Hold the adjusting nut in place and tighten the lock nut.
5. Close and latch the hopper door.
I 31 I
CALIBER .30 HEADING MACHINE Adjustments

Pin Wheel Hopper When the pin wheel hopper motor belt becomes too loose through being
Motor Belt stretched, it is necessary to tighten the belt to assure proper operation of
the pin wheel.
Hopper
Loclr
Nul \

HOPPER MOTOR BELT ADJUSTMENT
Tools: 7/8" wrench, %_” wrench.
Procedure: 1. Use a 7/8” wrench to loosen the lock nut on the motor adjusting set
screw.
2. Use a 1/2" wrench to turn the adjusting set screw, moving the motor
away from the hopper pulley, thus tightening the belt.
3. Tighten the lock nut.
[32]
CALIBER .30 HEADING MACHINE Adjustments

Flywheel Motor When the motor belt becomes too loose, through being stretched, it is
Belt necessary to tighten the belt by raising the motor, to insure proper opera-
tion of the machine.
Top Nut
Nut
FLYWHEEL MOTOR BELT ADJUSTMENT
Tool: 2 ”‘ wrench.
Procedure: 1. Use a 2" wrench to loosen the three top nuts on the motor supporting
studs.
2. Use a 2" wrench to turn the three lower nuts to raise the motor, moving
it away from the ﬂywheel, thus tightening the belts.
3. Tighten the three top nuts.
l33l
CALIBER .30 HEADING MACHINE Adjustments
Flywheel Brake Two brake shoes press against the side of the ﬂywheel when the brake is
applied. If the ﬂywheel does not stop almost immediately upon applica-
tion of the brake, the brake shoes should be adjusted so that they press
more ﬁrmly against the ﬂywheel. Both shoes should be adjusted a like
amount.


if/ Brake shoe
11/4" Lock Nut
3/1" Adjusting
Screw
11/4" Lock Nuts‘
3/1;" Adjusting
Screws
BRAKE ASSEMBLY
Tools: 11/4" wrench, %” wrench.
Procedure: 1. Use a 11/4" end wrench to loosen the lock nuts on the brake shoes.
(The brake shoes are located at the bottom of the ﬂywheel.)
2. Use a 3/4" wrench to tighten each of the adjusting screws about one-half
turn.
3. Hold the adjusting screws in place and tighten the lock nuts.
4. Check the adjustment by operating the machine and applying the
brake.
I34]
CALIBER .30 HEADING MACHINE Troubles and Corrections

TROUBLES AND CORRECTIONS
Objective The adjuster will encounter many troubles and defects in the operation
of this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection
of the component, together with constant observation of the machine as
it operates.
Scratched or Visual inspection will reveal scratches on the inside or outside walls of
Scored Walls the case. Scratches on the outside wall can be detected by ﬁnger nail
inspection.
The causes are: The corrections are:
1. Rough die — die has excess 1. Lap and polish the die if pos-
brass coating on the inside sur- sible or replace with a new die.
face.
2. Chipped die—edge on inner 2. Replace with a new die.
surface of die has become
chipped.
3. Scratched die——scratch on the 3. Polish the die if the scratch is
inside surface of the die. not too deep, or replace with a
new die if necessary.
4. Foreign matter — (dirt, dried . 4. Send the cases to the Washing
soap, etc.) on the cases. Department to be rewashed.
Case Pulling Out Visual inspection discloses that the case does not ﬁt into the die properly
of Die and is pulled out of the die by the heading punch.
The causes are: The corrections are:
1. There is brass accumulation on 1. Polish the punch to remove
heading punch. - excess brass.
2. Die is worn or oversize. 2. Replace with a new die.
3. Component within gage but 3. Remove case and check source
too small for the die. of supply.
Pocket Out of Gaging discloses that the pocket is not concentric with the outside of
Concentricity the case.
The causes are: The corrections are:
1. The die block is out of align- 1. Adjust the die block properly.
ment.
I35]
CALIBER .30 HEADING MACHINE
Troubles and Corrections

Pocket Out of
Concentricity
(Cont.)
Inside Pocket
Marred
Large Pocket
Diameter
Small Pocket
Deep Pocket
Shallow Packet
2. Cases are crooked and defec- 2. Check source of supply; call
tive. the inspector. ‘
3. Bent injecting stem. 3. Replace with a new stem.
4. Die bushing is undersize. 4. Replace with a new bushing.
5. Loose gibs. 5. Call Maintenance Department.
6. Cases have variable sidewall 6. Check source of supply.
thicknesses.
Visual inspection discloses dents, scratches, or metal built up on head
of case.
The causes are: The corrections are:
Replace with a new heading
punch.
1. Worn heading punch—the 1.
punch is undersize.
2. Chipped heading punch—a 2. Replace with a new punch.
piece is broken off the end of
the punch.
3. Broken heading punch. 3. Replace with a new punch.
4. Skinned heading punch—the 4.
punch surface is marred or has
excessive coating of brass.
Polish the punch if it is not too
badly skinned. If it is beyond
repair, replace with a new
punch.
Gaging discloses that the pocket is too large in diameter.
The cause is: The correction is:
1. Brass is accumulated on the
heading punch.
1. Polish the punch and remove
the accumulation of brass.
Gaging discloses that the pocket is too small in diameter.
The causes are: The corrections are:
1. Polish the stem and remove
the accumulation of brass.
1. Injecting stem has an accumu-
lation of brass on it.
2. Heading punch is too small. 2. Replace with a new punch.
Gaging with the ﬂush pin gage discloses that the pocket is too deep.
The cause is: The correction is:
1. Place a shorter plug behind
punch.
1. Heading punch extends too far
out of holder.
Gaging with the ﬂush pin gage discloses that the pocket is too shallow.
The cause is: The correction is:
1. Heading punch does not extend
far enough out of holder.
1. Place a longer plug behind
punch.
[36]
CALIBER .30 HEADING MACHINE
Troubles and Corrections

Large Head
Small Head
Wrinkles in Case
Dented Mouth
Metal Deposit
Under Head
Metal Deposit
on Inside of Case
Gage inspection discloses that the head of the case does not pass through
the “go” hole in the gage.
The cause is: The correction is:
1. Case is pushed too far out of
die by the injecting stem.
1. Adjust the stem properly.
Gage inspection discloses that the head of the case passes through the
“no go” hole in the gage.
The cause is: The correction is:
1. Case is not pushed out of die
far enough.
1. Adjust the stem properly.
Visual inspection discloses wrinkles on the outside near the mouth of
the case.
The corrections are:
1. Lap and polish the die to the
proper speciﬁcations.
The causes are:
1. Undersize die—the mouth of
the die is too small.
2. Excessive oil or lubricant on 2. Remove the cases and send to
cases. the Washing Department to be
washed; or reduce ﬂow of lu-
bricant.
3. Insufficient lubricant. 3. Increase the ﬂow to required
amount.
Visual inspection discloses that the mouth of the case is dented.
The cause is: The correction is:
1. Adjust the knockoff wire prop-
erly.
1. Knockoff wire is out of time.
Visual inspection discloses that there is a deposit of metal under the
head.
The causes are: The corrections are:
1. Cracked die—there is a crack
on the inside surface of the die.
2. Chipped die—the edge on the
inner surface of the die has
become chipped.
1. Replace with a new die.
2. Replace with a new die.
Visual inspection discloses that there is a deposit of metal inside of the
case.
The causes are: The corrections are:
1. Replace with a new injecting
stem.
1. Injecting stem is cracked.
2. Replace with a new injecting
stem.
2. Injecting stem is chipped.
[37]
CALIBER .30 HEADING MACHINE
Troubles and Corrections

Oversize
Diameter
Cases Cut Oﬁ‘
Case Mashed
Against Die
Cases Fed
Improperly in
Machine
Uneven Flow of
Cases from
Hopper
Gaging discloses that the body of the case is too large.
The cause is: The correction is:
1. The die is too large. 1. Replace with a new die.
Visual inspection discloses that the head of the case has become out in
half, bent or severed by the injecting stem.
The causes are: The corrections are:
1. Remove the long case and check
the source of supply.
1. Case feeding into feed box is
too long.
2. Remove the case and check the
source of supply.
2. Case injected into die improp-
erly.
3. Partially ﬁlled feed box. 3. Adjust to get proper ﬂow of
cases to feed box.
Visual inspection discloses that a case has become mashed against the
die.
The causes are: The corrections are:
1. Adjust the knockoff wire prop-
erly.
1. The knockoff wire is out of ad-
justment.
2. Knockoff wire is broken. 2. Replace with a new knockoff
VV11‘€.
Visual inspection discloses that the cases are not feeding properly through
the feed block and cradle.
The causes are: The corrections are:
1. Remove the cases and check
the source of supply.
1. The cases are too long or too
short.
2. Remove the feed block or cra-
dle and clean.
2. Foreign matter—(dirt, scrap,
etc.) in feed block or cradle.
3. Bent case in feed block. 3. Remove the bent case and
check the source of supply.
Visual inspection discloses that the hopper is not feeding cases to machine
properly.
The causes are: The corrections are:
1. Remove cases from the hopper
and check the source of supply.
1. Cases from fourth draw are
too long or defective.
2. Remove the case and clear the
feed tube.
3. Clean the hopper and check
the source of supply.
2. Cases jammed in feed tube.
3. Foreign matter —— (dirt, shav-
ings, etc.) in the hopper.
I38]
CALIBER .30 HEADING MACHINE
Troubles and Corrections

Uneven Flow of
Cases from
Hopper (Cont.)
Machine Stops
on Dead Center
4. Overloaded hopper-—too many 4. Remove excess cases.
cases in hopper.
5. Bridge is out of adjustment.
6. Belt slips——loose belt, oily belt.
5. Adjust the bridge properly.
6. Tighten the belt if it is loose;
clean the belt if oily.
Visual inspection discloses that the machine has stopped on dead center.
The cause is: The correction is:
1. The injecting stem and the
heading punch are locked
against the case in the die.
1. Adjust the machine properly.
I39]
CALIBER .30 HEADING MACHINE
Tool Servicing
Objective
Servicing of New
Dies
Lapping Procedure
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the
bumping, pocketing, and heading of the cases.
Dies and punches are
costly and great care must be exercised in the servicing of these tools.
Adjusters will be concerned primarily with the removal of brass and small
scratches that appear on working surfaces of dies and punches; they must
be careful, however, when using an abrasive on any tool, not to alter its
dimensions materially.
All tools that cannot be corrected by polishing or minor straightening
must be returned to the Tool Service Department.
1.
Dies as received from the tool room are normally undersize to allow
for expansion pressure, and for lapping to a desired size when necessary.
The size of the die may be checked by a die plug gage, but a test run
should be made before any lapping is performed.
As a precaution, before a test run is made, the die bore should be
inspected for roughness and polished if necessary.
The product from the test run should be carefully gaged and in-
spected. Then, and then only, if an undersize or out of true die is
indicated, should the die be lapped.
When lapping is necessary, proceed as follows: Use a lap stick made
of ﬁber or wood about the same diameter as the die hole.
Tear off strips of 220 emery cloth about 1" wide and wrap the emery
cloth around the end of the lap stick until it makes a snug ﬁt in the
head of the die.

FIG. 1
OVER-ALL VIEW OF SPEED LATHE
I40]
CALIBER .30 HEADING MACHINE
Tool Servicing

Servicing
Scratched Dies
Servicing the
Injecting Stem
Servicing the
Heading Punch

3.
4.
5.

FIG. 2 FIG. 3
CORRECT WAY TO PLACE DIE INCORRECT WAY TO PLACE
IN CHUCK DIE IN CHUCK
Chuck the die in the speed lathe, head out. Care must be taken to
get the die in the lathe properly. See Fig. 2.
Insert the lap stick in the head of the die.
Run the lathe on low speed; hold the lap stick in your hand and move
it in and out to prevent cutting grooves in the die.
Extreme care must be taken to guard against cutting too much metal
out of the die, thus making it too large.
Remove the die from the lathe, wipe out with a cloth and gage with
a plug gage.
When a die becomes scratched on the inside, the above procedure will
be used for eliminating the scratch providing the scratch is not too deep.
In case of exceptionally deep scratches, the die must be returned to the
tool room.
When the injecting stem has an accumulation of brass on it, remove the
stem and polish it with 220 emery cloth, by hand, until the brass is
completely removed. Then polish the stem with crocus cloth.
When the heading punch is serviced, the following procedure should be
used.
1.
2.
3.
Remove the punch from the punch holder.
Place the punch in the tool servicing holder and place the holder in
the chuck in the speed lathe.
Start the speed lathe and hold a small oil stone against the circum-
ference of the punch until the brass is removed.
Polish the punch with a piece of crocus cloth.
I41]
CALIBER .30 HEADING MACHINE
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
MACHINE LUBRICATION
The eﬂiciency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of '
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby ‘reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[42]
CALIBER .30 HEADING MACHINE
Machine Lubrication
,__—
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.q.°‘.°‘!f=‘.¢*’.l\'>'-‘
Frequency of lubrication.
I 43 I
CALIBER .30 HEADING MACHINE
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
. Bottle oiler.
. Ring oiler.
. Plain oil cups.
2
3
4
5. Drop feed cups.
6. Wick feed cups.
7. Mechanical, force feed, central lubricating system.
8. Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
[44]
CALIBER .30 HEADING MACHINE Machine Lubrication
LUBRICATION CHART


. . N 0. of Fittings, Frequency of
I/ubmcant Machine Part Grease Cups, etc. Lubrication Hours
Crankshaft bearings . . . . . . . 4 8
Connecting rods . . . . . . . . . 7 8
LIGHT GREASE Rams . . . . . . . . . . . . . 4 8
(Blue Gun) Hopper shaft . . . . . . . . . . 1 1 wk
Knockoff cam . . . . . . . . . . 1 8
Gibs . . . . . . . . . . . . . . 4 4
Rocker arm eccentric . . . . . . 1 8
Rocker arms . . . . . . . . . . 4 8
Cam on eccentrics . . . . . . . . 1 8
Knockoff shaft . . . . . . . . . 2 8
MEDIUM OIL Push block . . . . . . . . . . . 2 8
(Red Oiler) Push block conveyor . . . . . . . 4 8
Cam rollers . . . . . . . . . . . 2 8
Knockoff wire assembly . . . . . 2 8
Brake assembly . . . . . . . . . 6 24

I45]
CALIBER .30 HEADING MACHINE
Index
Adjustment, Concentricity, 21
Die Block, Horizontal, 25
Die Block, Vertical, 23
Feed Finger, 29
Feed Tube Mouth, 31
Flywheel Brake, 34
Flywheel Motor Belt, 33
Heading Punch, 26
Hopper Feed Bridge, Horizontal, 30
Hopper Feed Bridge, Vertical, 31
Injecting Stem, 27
Pin Wheel Hopper Motor Belt, 32
Anti-friction Bearings, 42
Anvil, 10, 11, 12
Brake, 2, 3, 6
Lever, 6
Shoe, 3, 6
Bushing, 10, 11, 12
Cap Nut, 10
Case Mashed Against Die, 38
Pulling Out of Die, 35
Cases Cut Off, 38
Fed Improperly in Machine, 38
Concentricity, 18
Adjustment, 21
Crankshaft, 2, 3, 4
Speed, 1
Deep Pocket, 36
Dented Mouth, 37
Dial Indicator Gage, 18
Die, 11, 13
Block, 9, 21
Block Assembly, 11
Block, Horizontal Adjustment, 25
Block, Vertical Adjustment, 23
Disposal, 14
Double Plug Gage, 19
Eccentric Cam, 3, 4
Feed Box, 9
Finger Adjustment, 29
Motor, 1
Sleeve, 15
Slide, 9, 14, 15
Tube, 9, 14, 15
Tube Mouth Adjustment, 31
Floor Space, 1
INDEX
Flow Chart, 15, 16
Flush Pin Gage, 19
Flywheel, 2, 6
Brake Adjustment, 34
Motor Belt Adjustment, 33
Friction, 42
Front Spanner Adjusting Nut, 12
Gage Care, 18
Grease, 43
Headed Case, 14, 16
Heading Punch, 12, 13, 14, 16
Punch Adjustment, 26
Ram, 3
Height, 1
Hopper Feed Bridge, Horizontal
Adjustment, 30
Feed Bridge, Vertical
Adjustment, 31
Injecting Spanner Adjusting Nut, 10
Stem, 5, 10, 14, 15, 16
Stem Adjustment, 27
Stem Assembly, 10
Inside Pocket Marred, 36
Knockoff, 14
Wire, 3
Lap Stick, 41
Lapping Procedure, 40
Large Head, 37
Pocket Diameter, 36
Lubricating Film, 42
Lubrication, 3, 42
Chart, 45
Hints on, 44
Methods, 44
Machine Motor, 1
Stops on Dead Center, 39
Manufacturer, 1
Metal Deposit on Inside of Case, 37
Deposit Under Head, 37
Methods of Getting Lubricant to
Bearing Surface, 44
Motor, 2
Outside Diameter, 17
Overhead Hopper, 14, 15
Oversize Diameter, 38
Pin Wheel Hopper, 3, 7, 14, 15
Pin Wheel Hopper Box, 7, 14, 15
Wheel Hopper Motor Belt
Adjustment, 32
Pocket Out of Concentricity, 35
Power, 2, 3, 4, 15
Primer Pocket, 2, 9
Production, 1 _
Punch Holder, 12
Holder Assembly, 12
Push Block, 14, 15
Ram, 5
Rear Spanner Adjusting Nut, 10, 12
Rocker Arm, 3, 4
Scored Walls, 35
Scratched Walls, 35
Selecting Lubricant for Given
Bearing, 43
Servicing Heading Punch, 41
Injecting Stem, 41
Of New Dies, 40
Scratched Dies, 41
Shallow Pocket, 36
Sidewall Variation, 17
Sizing Punch, 12
Small Head, 37
Pocket, 36
Spacer Pin, 12
Speed Lathe, 40
Stem, 13
Ram, 3
Stroke, 1
Switch, 2
Tools, 1
Transmission, 2
Twin Ring Gage, 18
Type of Feed, 1
Uneven Flow of Cases from
Hopper, 38, 39
V-belt, 2, 7
Visual Inspection, 18
Washing Department, 17
Web Thickness, 17, 18
Weight, 1
Wrinkles in Case, 37
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Head Turn
BY
Training Department

Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 194-1
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the.
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAI. CORRECTIONS—CAI.lBER .30 CASE HEAD TURN
LOCATION ERROR CORRECTION
e 6—Fig Bevel Gears Spur Gears
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘ 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
III

CALIBER .30 CASE HEAD TURN MACHINE
IV
CALIBER .30 CASE HEAD TURN
Catalogue Data

Manufacturer
Machine
Description
Type of Feed
Production
Speed of Spindle
Line Shaft Motor
Tool
Height
Weight
Floor Space
CATALOGUE DATA
Owens-Illinois Co., Toledo, Ohio
Special horizontal single spindle automatic. Belt
driven from line shaft.
Auto-pin wheel hopper mounted on work table.
Belt drive line shaft to hopper pulley.
52 per minute
3600 R.P.M.
5 h.p.; 3 phase; 60 cycle; 220/440 volts; s65 R.P.M.
I Piece No.
Form tool R-5
7 ft. 4 in.
1000 lbs.
5 ft. X 3 ft. 9 in.
CALIBER .30 CASE HEAD TURN Machine Description

MACHINE DESCRIPTION
The Caliber .30 Case Head Turn Machine cuts the extractor groove and
trims the case head to the speciﬁed size.
Hopper Box


Pin Wheel Hopper __ i- -
I“-'
\ I
0» "'
Hopper Stand \
'M“\,\\\l._, '
\
\
i, ‘ I 7
Case Magazine \ .- , Line Shaft
F: ' ,_ ; Injecting Stem
______ :" ' \. - . Ii
Clutch Lever
Feed Tube


Camshaft
Pulley Wheel
Cam
CALIBER .30 CASE HEAD TURN MACHINE
Power and The Owen-Illinois Single Spindle Head Turn Machine, illustrated above,
Transmission is powered from a line shaft which extends along the back of the machines
and is mounted to the machine table. The line shaft may extend to
drive as many as nine to twelve machines and is driven by a 10 h.p.
motor through ﬁve V-type belts.
The collet assembly and driveshaft are connected to and driven from the
line shaft by means of ﬂat type leather belts. Power is applied to the
driveshaft and controlled by a manually operated jaw-type clutch.
I2]
CALIBER .30 CASE HEAD TURN
Machine Description
Power and
Transmission
(Cont.)
Pin Wheel Hopper
Driveshaft
Barrel
Camshaft
Camshaft
Case Magazine
Injecting Stem
Collet Assembly
The pin wheel hopper, mounted above the machine, is also driven by
means of a ﬂat type leather belt from the line shaft. Power is controlled
_ to the hopper by a manually operated friction type clutch. The machines
are mounted on the forward edge of ﬂat topped benches whose legs are
bolted to the ﬂoor.
The pin wheel hopper is supported directly above the center of the ma-
chine on a metal stand whose four legs are bolted to the table top. The
pin wheel hopper box receives cases from an overhead source through a
feed chute. The pin wheel hopper consists of an inner and outer rim and
a mid section of pin rings and spacer rings, bolted together in a hopper
assembly. The pins pick up the cases and carry them to the top of the
hopper where they enter the feed tube leading to the case magazine.
The driveshaft is held in a horizontal position below and to the rear of
the machine bed by two bearings. The driveshaft has two spur gears
attached which mesh with mating spur gears to drive the barrel camshaft
and the eccentric camshaft. The right end of the driveshaft extends
through the machine bed, and has attached to its outer end the pulley
wheel through which power is applied to the driveshaft from the line
shaft. The jaw-type clutch is located between the machine bed and the
pulley wheel.
The barrel camshaft is held in a horizontal position below the machine
bed by two ﬁtted bearings and is driven by the driveshaft through
mating spur gears.
The end face camshaft is held in a horizontal position below the machine
bed by two ﬁtted bearings. The camshaft is driven by the driveshaft
through mating bevel gears. The camshaft consists of two end face
cams, a spur gear, and a barrel cam. These cams, through linkage, ac-
tuate the various working parts of the machine.
The case magazine is held in a vertical position above and to the right
of the collet head. The case magazine receives the cases from the feed
tube and allows them to fall through the magazine to a position in align-
ment between the injecting stem and the collet jaws. As each case is
ejected from the collet jaws, the magazine swings forward, actuated
through linkage from the camshaft, to position the next case between
the injecting stem and collet.
The injecting stem is actuated by the barrel cam and travels back and
forth in a dovetailed gib arrangement which is bolted to the right end
of the machine bed. The injecting stem travels forward to push the
case from the case magazine into the collet jaws. The tip end of the
injecting stem is free to rotate as the case is injected into the spinning
collet. This arrangement keeps the case head from being scratched.
The collet assembly is bolted to the left end of the machine bed. The
collet spindle is held in a horizontal position above the machine bed by
two roller bearings. The driven pulley is mounted on the collet spindle
between the two bearings and is connected to and driven by a leather
[3]
CALIBER .30 CASE HEAD TURN
Machine Description
Collet Assembly
(Cont.)
Tool Carriage
belt from the line shaft. The mechanism which operates the collet jaws
is located- on the left end of the collet spindle and is actuated, through
linkage, from the barrel cam on the left end of the camshaft.
The tool carriage travels back and forth in a dovetailed gib arrangement
which is bolted _to the back edge of the machine bed. The tool carriage
moves back and forth at right angles to the case as it is held in the collet
jaws. The tool carriage is actuated, through linkage, from an end face
cam on the camshaft. When the collet jaws receive a case, the tool
carriage travels forward with the cutting tool which trims away the
head, and cuts the extractor groove in the case.
[4]
CALIBER .30 CASE HEAD TURN Machine Description


Mouth
/ Adjustment
Hopper
Feed
Mouth
_ Bridge
Adjustment
- Feed Tube


-:1‘ i '
INTERIOR OF PINWHEEL HOPPER
Pin Wheel Hopper The pin wheel hopper box is a one-piece casting whose bottom slopes
toward an opening into the pin wheel hopper. The pin wheel hopper is
attached to the front of the hopper box. The pin wheel consists of a pin
ring, and an inner and outer dish-shaped casting bolted together in a
hopper assembly. The outer dish-shaped casting has three spokes at-
tached to a hub shaft on which the entire hopper revolves. The pin ring
has a series of steel pins spaced approximately 1" apart on its inner cir-
cumference and set at an angle to the radii. A steel spring rake-off keeps
the components that are not properly seated on the pins from entering
the bridge.
As the hopper revolves clockwise, the cases slide on the steel pins approach-
- ing a vertical position. When the components approach the upper arc
of the pin wheels’ circumference, they contact and are held on the pins
by the pin wheel bridge. At the end of the pin wheel bridge, they are in
a vertical position and slide off the pins into the feed tube mouth. They
are gravity fed through the feed tube to the case magazine.
The pin wheel shaft extends through the hopper box and has a spur gear
attached to its outer end. A horizontal cross-shaft is attached to the rear
of the hopper box and rotates in two ﬁtted bearings. The outer end of the
cross-shaft has a pulley wheel attached for the connection of the leather
belt from the line shaft. The friction clutch is located between the pulley
wheel and the hopper box. A worm gear is attached to the opposite end
of the cross-shaft and meshes with the spur gear on the hopper shaft. A
manually operated shaft extends vertically through the bottom of the
hopper box and is used to agitate the cases in the event a jam occurs.
I5l
CALIBER .30 CASE HEAD TURN _ Machine Description


Jaw-
~ T
, 1-5 CYIFIZII

CLUTCH ASSEMBLY DRIVESHAFT ASSEMBLY
Driveshaft The driveshaft rotates in two ﬁtted bearings and is equipped with two
small bevel gears which drive the barrel camshaft and the camshaft
operating the tool carriage and the case magazine. The camshaft driving
gear is located on the left end of the driveshaft. The gear which drives
the barrel camshaft is located on the right end of the driveshaft just
inside the machine housing.
The jaw clutch is mounted on the driveshaft outside the machine bed and
is operated by a hand lever which extends forward to the front of the
machine. The driven pulley is mounted on the right end of the drive-
shaft and is connected to the line shaft by a ﬂat type leather belt. By
using the clutch, the driveshaft may be stopped independently of the
line shaft.
[6]
CALIBER .30 CASE HEAD TURN Machine Description
. ~ __ Spur
'_ -, Gear
I L. i o I‘
Track /
Barrel -_ “I . . , ,. ll} . : .‘ I SPUI‘
Cam . -\ " . ‘ ' . Gear
_ that
; Drives
, -. , ' 4 . 3 ._ I. gclrrel
Spur I - ._ 7 , _ I am
Gearp , ' . -, g‘ .“?“:g' (“'3 ‘
w R. ’ \’ . ‘

1* I
FRONT VIEW SHOWING BARREL CAM AND GEARS
Barrel Cam The barrel cam is supported on a shaft below the machine bed and
rotates in two ﬁtted bearings. A large spur gear is attached to the right
end of the shaft and meshes with the spur gear on the driveshaft. The
barrel cam actuates the injecting stem through a cam follower.
Barrel
~ - i,
. '_ Cam


Spur
Gears

Camshaft -"
OVER-ALL VIEW SHOWING BARREL CAM IN RELATION TO THE REST
OF MACHINE
l7]
CALIBER .30 CASE HEAD TURN Machine Description
Camshaft The camshaft is supported by and rotates in two ﬁtted bearings below
the machine bed. The camshaft extends the length of the machine bed
and has a barrel cam attached to the left end outside the machine frame.
Through linkage, this cam actuates the collet mechanism.
The end face cams, operating the tool carriage and the case magazine,
are mounted on the camshaft in the middle of the machine. The spur
gear is mounted to the right of the end face cam which operates the case
magazine. The spur gear meshes with the spur gear on the driveshaft
to drive the camshaft.
Clutch
/ Lever

Cy ‘__
‘-
VIEW OF BARREL CAM AND INJECTING STEM
Injecting Stem The injecting stem travels from right to left and is guided in a dovetailed
gib assembly which is bolted to the machine bed. The injecting stem is
actuated by the barrel cam through a cam follower arm which extends
through the machine bed to ride in the track of the barrel cam. As the
case magazine positions a case between the injecting stem and the collet,
the injecting stem, actuated by the cam, travels forward to push the
case from the magazine into the collet jaws.
[8]
CALIBER .30 CASE HEAD TURN Machine Description

Feed Tube


Rocker


Collet -—-_ Am
Retaining -‘
Cup
T'p of I .ed.
Eielding /"R : s'iLm "'9
Stern
COLLET ASSEMBLY, INJECTING STEM AND CASE MAGAZINE
Case Magazine The cases slide from the feed tube onto a slide which is machined at the
top of the magazine, from which they are knocked into the magazine
feed channel by a small trip hammer. The cases drop through the maga-
zine and are held at the bottom of the magazine until the magazine
brings them forward into alignment between the injecting stem and the
collet. The case magazine is actuated in its rocking motion by one of
the end face cams located on the camshaft. The cam follower arm is held
on a bracket by a wrist pin arrangement which allows a free movement
of the arm. The lower end of the arm has a cam roller attached which
follows in the cam track. The upper end of the arm is connected to a
turnbuckle rod which allows an adjustment to be made on the swing
of the magazine.


REAR VIEW SHOWING ROCKER ARM
Rocker Arm _
I 9 I
CALIBER .30 CASE HEAD TURN Machine Description

Cutting
Flat / Tool
Pulley Block


Collet E- t-
Retaining — Sjzfnmg
Cap
' " ‘T-Bi
_,_p.
VIEW SHOWING TIP OF EJECTING STEM PROTRUDING FROM THE COLLET CAP
Ejecting Stem The ejecting stem is contained within the collet spindle. When a case is
inserted in the collet, it strikes against the ejecting stem forcing it back
against a coil tension spring. The spring is located behind the ejecting
stem head. The collet jaws close around the case holding the coil spring
in a compressed state. When the jaws are released, the spring recoils
against the ejecting stem head which forces the case from the collet.


Collet
Lock Spindle
Nut
Spring
Ejecting
Stem
Adjustment Eiecting
Stem
INSIDE SPINDLE AND EJECTING STEM REMOVED FROM MACHINE
I 10 l
CALIBER .30 CASE HEAD TURN Machine Description

Tool Carriage The tool carriage travels back and forth in a dovetailed gib arrangement
actuated through linkage from the end face cam on the camshaft. The
cam follower rocker arm is attached to a bracket on the rear edge of the
machine by a wrist pin arrangement which allows a freedom of action. The
lower end of the arm is equipped with a cam roller which rides in the track
of the end face cam. The upper end of the rocker arm is pinned to the back
end of the tool carriage. The tool carriage travels back and forth ac-
tuated by the cam to perform the cutting operation on the case head.
Tool Carriage Cam Follower Rocker Arm
_
—-
_-__.
Illllll
\
Collet Ejecting Stem Tool Corn Follower Cam
Retgjging
TOP VIEW OF FEED SLIDE REAR VIEW OF TOOL CARRIAGE
I11]
CALIBER .30 CASE HEAD TURN Machine Description
Collet
Retaining
Cap


Spindle
/ Shaft
Cam
Collet
COLLET ASSEMBLY
REMOVED FROM
MACHINE
VIEW SHOWING SPINDLE AND CAMS
Collet The collet is held inside the right end of the collet spindle by a collet.
The inside of the retaining cap is tapered to a central opening into which
the collet jaws ﬁt. The collet ﬁts into the spindle shaft and contacts
a tubular sleeve, which extends through the spindle to the opposite end.
A set of ﬁngers is attached to the left end of the collet spindle and is
curved to allow the ﬁnger ends to contact the tubular sleeve.
An expander cone is mounted on the left end of the collet shaft and slides
back and forth alternately to release and expand the ﬁngers which,
through the above linkage, opens and closes the collet jaws. The ex-
pander cone is actuated through a cam follower arm whose lower end is
provided with a cam roller which rides in a barrel cam on the camshaft.
The upper end of the rocker is provided with a yoke which is attached
to the expander cone to allow a freedom of action. The rocker arm is
pinned at its pivotal center to a bracket attached to the left end of the
machine.
[12]
CALIBER .30 CASE HEAD TURN Tool Holder Description
TOOL HOLDER DESCRIPTION
Tool Slide - Set Screw: A square-headed set screw is threaded, horizon-
Assembly tally, through the rear end of the block. The set screw extends
through-the block into a square cut hole to contact and hold
the rocker arm in place.
Lock Nut: The set screw is provided with a hexagonal lock
nut which locks the set screw in proper position.
Tool Slide: The tool slide is a rectangular block with dove-
tailed sides. A square hole is cut from top to bottom of the
slide near the rear end.
Adjusting Screw and Block: The adjusting screw block is
mounted on top of the tool slide at a position barely past
center toward the rear of the tool slide. The adjusting screw
is threaded through the block in a position parallel to the tool
slide, with the threaded end extending toward the forward
end of the tool slide.
Cutting Tool Housing: The cutting tool is held in a raised
gib arrangement on the top side of the tool slide. A shoulder
on one of the gibs protrudes beyond the side of the tool slide. A
threaded stud extends vertically through the tool slide and gib
shoulder. The cutting tool is placed between the gibs and
held down by a metal plate which is placed on the vertical
stud and extends out over the cutting tool. The plate is held
securely in place by a lock washer and square-headed nut.

Cutting Tool: The cutting tool is a rectangular shaped bar
of tool steel which has been carefully machined to cut the
case to form the head and produce the extractor groove.


/J”


Illﬁhlﬂiiiiiiiiiiiii\\\\\\\\\\\\\I\\i\l\\\\\\\i\i\i\\|_i
\\\\\\\\\I\\l\\\\\\\\\\\\i
A
LONGITUDINAL CROSS-SECTION or TOOL suns ASSEMBLY


I 13 l
CALIBER .30 CASE HEAD TURN Tool Description
TOOL DESCRIPTION

' Tool Name: Form tool
Piece No.: R-5
\ Location: Tool holder on tool slide
Normal Life: 100,000 pieces
Form tool is made of tool steel, hardened and ground.
FORM TOOL
I14]
CALIBER .30 CASE HEAD TURN
Process Sequence

Overhead Hopper
Pin Wheel Hopper
Box
Pin Wheel Hopper
Coil Spring Feed
Tube
Hammer and
Magazine
Case Raising
Finger
Injecting Stem
Collet
Cutting Tool
PROCESS SEQUENCE
The cases are gravity fed from an overhead source into the overhead
hopper, and drop through a feed pipe into the pin wheel hopper box.
Cases ﬂow from the pin wheel hopper box through an opening, past the
agitator, into the lower part of the pin wheel hopper.
As the pin wheel hopper rotates, the cases are agitated and picked up by
pins on the inside circumference of the pin wheel, and are carried up past
the rake-off springs which knock off misaligned cases and push partly
set cases all the way onto the pins. As the cases are carried to the top
of the pin wheel, they are held on the pins by the feed track. At the
end of the feed track they drop off, one at a time, head ﬁrst, down into
the mouth of the coil spring feed tube.
The cases fall by gravity down through the coil spring feed tube, through
a brass slotted feed tube, past the hold down spring. The hold down
spring prevents the cases from piling up in front of the magazine hammer.
The cases then enter the magazine slide, in a horizontal position, and
stop directly in front of the hammer.
As the magazine swings back, the bumper block strikes the magazine
hammer arm, pushing the hammer forward, and ejecting the case from
the slide into the magazine. The magazine, which holds six cases, is kept
full while the machine is in operation.
As the magazine swings forward, the case raising ﬁnger inserts itself
between the case on the lip and the balance of the cases above it in the
magazine, raising them upward. These cases are lifted to allow clear-
ance for the injecting stem. The bottom case is now in the lip directly in
line with the injecting stem and collet.
The injecting stem moves in from right to left, pushing the case from the
lip into the spinning collet, where it encounters the ejecting stern. As
the case enters the collet, it forces the ejecting stem back into the spindle.
As the ejecting stern, which is actuated by a spring inside of the spindle,
is being forced back into the spindle, the inner spindle moves forward
closing the collet jaws ﬁrmly on the case. This places the case directly
in front of the cutting tool. The revolving tip of the injecting stem spins
with the case in the collet to avoid scratches.
The case is held by the collet and supported by the injecting stem for the
cutting operation. The cutting tool moves toward the case and sizes the
head thickness and diameter, cutting a cannelure and chamfering the
outside rim of the case. As the cutting tool moves backward, the maga-
zine also starts, to swing backward, away from the case raising ﬁnger
which allows another case to enter the lip; then the above operations are
repeated.
[15]
CALIBER .30 CASE HEAD TURN
Process Sequence
Knockout Rod
and Disposal
On the backward movement of the cutting tool and magazine, the inner
spindle also moves back, allowing the collet jaws to open. As the collet
jaws open, the ejecting stem forces the case out of the collet by spring
action. The ejected case strikes a metal guide and leather bumper, then
falls through a chute into a conveyor. The scrap falls through another
chute into a container.
[16]
CALIBER .30 CASE HEAD TURN Process Sequence


FLOW CHART
Overhead Hopper
Cases are gravity fed from an overhead source into A 5 h.p. motor furnishes
overhead hopper through feed pipe into the pin power to the line shaft.
wheel hopper box.


Pin Wheel Hopper Box
Cases ﬂow through opening in pin wheel hopper


box, past agitator, into bottom of pin wheel hopper.


Pin Wheel Hopper
Rotates, and cases are picked up by pins and -

carried up past rake-off spring to the top of pin wheel Hopper powered by a ﬂat
hopper, where they are held by the feed track. At leather belt to the line shaft.


the end of the feed track they fall off, one at a time,
into mouth of coil spring feed tube.


Coil Spring Feed Tube
Conveys cases by gravity through slotted feed
tube, past slow down spring, into magazine slide. -


Magazine
As the magazine swings backward in a vertical
position, the hammer pushes a case from the slide
into the magazine where it slides down to the
magazine lip.
Actuated by turn-buckle to
rocker arm, cam, camshaft,
gear, jackshaft, pulley, ﬁat
leather belt to line shaft.


Magazine Lip
As the magazine swings forward, the case raising
ﬁnger inserts itself between the case on the lip and
the cases above it. As the magazine swings back-
ward, it releases the ﬁnger and allows another case
to drop onto the lip, in alignment with the injecting
punch and collet.
I


[17]
CALIBER .30 CASE HEAD TURN
Process Sequence
FLOW CHART (Cont.)
I
Injecting Stem
Moves from right to left, pushing the case from the
lip into the spinning collet where it encounters the
knockout rod. As the case enters the collet, it
forces the knockout rod back into the spindle.


Actuated by cam roller, cam,
camshaft, gears to jackshaft,
pulley, ﬂat leather belt to
line shaft.


Collet
As the case forces the ejecting stem back into the
spindle, the inner spindle starts to move forward,
closing the collet jaws ﬁrmly on the case, and align-
ing it directly in front of the cutting tool.


Collet is actuated by inner
spindle, ﬁnger assembly, cone
claws, cam lever, cam fol-
lower, cam, camshaft, gears
to jackshaft, pulley, flat
leather belt to line shaft.


Cutting Tool
Moves forward, sizing case head thickness and
diameter, and cutting cannelure and chamfering
outside rim of case. The magazine moves back with
the tool, allowing another case to enter the magazine
lip and repeats the above operation.


Actuated by cam follower,
cam, camshaft, gears to jack-
shaft, pulley, ﬂat leather belt
to line shaft.


Knockout Rod and Disposal
As the cutting tool and magazine move back, the
inner spindle also moves back, allowing the collet
jaws to open. The knockout rod forces the case
out into a slide to a conveyor under the machine,
out of the way of the next case entering the collet.
The scrap falls through another chute into a con-


Actuated by coil spring be-
hind knockout rod.


tainer.
CALIBER .30 CASE HEAD TURN Product Description

PRODUCT DESCRIPTION
The component, when received by the head trim machine, is in the form
of a case as shown in Fig. 1.
The case is made of brass (70% copper, 80% zinc). The closed end of the
case is known as the head and the open end as the mouth.
The cases are received at the head turning operation from the Washing
Department where they are washed and dried. The cases are delivered to
the Washing Department from the heading machine. The dimensions of
the case are as follows:
Before head turn operation After head turn operation
Outside head diameter .515 Outside head diameter .467—.471
Outside diameter of case body Outside diameter of case body
.4645—.4670 .4645—.4670
Web thickness .()60-.068 Web thickness .060—.068
Pocket depth .125—.129 Pocket depth .125—.129
Pocket diameter .2093—.2098 Pocket diameter 2093-2098
Over-all length of ease 2.50 Over-all length of case 2.50
Head thickness .043—.O48
Cannelure dia. .403—.407
After the head turning operation (See Fig. 2) the cases are sent to the
Annealing Department for annealing of the bodies.


21.1
it
Q _ _
FIG. 1 FIG. 2
BEFORE HEAD TURN OPERATION AFTER HEAD TURN OPERATION
[19]
CALIBER .30 CASE HEAD TURN
Inspection

Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the head turn operation, a careful visual inspec-
tion of the cases must be made. The cases should be inspected for too
much radius on top of the head, rough edges or burrs on top or underneath
head, and dents on the head or body of the case. These defects when
found, require an immediate adjustment of the machine in order to correct
the fault. Whenever defective cases are found, the lot from which they
come must be removed from the machine and properly identiﬁed so they
will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool—since heat causes expansion of
the metal and results in a temporary variation in the case size.
TRIPLE RING HEAD DIAMETER GAGE The head of the case is gaged
with a triple ring head diameter
gage. There is a “go,” “no go”
and an “intermediate” section
on the gage. The case head
must enter the “go” section
and must not enter the “no go"
section. The case head must be
tight in the “intermediate” sec-
tion.


HEAD THICKNESS GAGE
“G
L.
The head thickness of the case
is gaged in a snap head thick-
ness gage. The case head must
enter the maximum slot and
must not enter the minimum
slot.
EXTRACTION DEPTH GAGE The depth of the extraction groove is
gaged with an angle snap gage. The ease
head must enter the maximum slot and
. must not enter the minimum slot.
IL.
The above described methods are those most commonly employed in the
head turning of a Caliber .30 case. However, other methods may be
developed to maintain the manufacturing standards.


[20]
CALIBER .30 CASE HEAD TURN
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be clean and free from all
foreign objects at all times.
No adjustments are to be made on this machine while it is in motion or
until the handwheel has stopped.
In order to insure proper adjustment of the machine and alignment of its
tools, always turn the machine over by hand before engaging clutch.
Safety guards must be in their proper place on the machine except when
repairs or inspections are being made.
Inspect the machine periodically during the day’s run to determine
whether or not all connections and adjustments are secure.
I21]
CALIBER .30 CASE HEAD TURN Adjustments
Collet The collet is a socket which holds the case ﬁrmly and turns it while the
cutting tool cuts the extractor groove on the case head. The collet can be
adjusted to grip the case more ﬁrmly or less ﬁrmly as the case demands.


Expander
Cone \
Spanner
Spanner
Adjusting /
Collar
Rocker
COLLET ADJUSTMENT AND OPERATING CAM
Tools: 8" screwdriver, two 23/4" spanner wrenches.
Procedure: 1. Use an 8" screwdriver to remove the guard over the collet operating
assembly at the extreme left of the machine.
2. Use two 23/4" spanner wrenches to loosen the lock collar on the outer
spindle of the head assembly at the left of the machine.
3. Use a 2% ” spanner wrench to turn the adjusting collar until the collet
will hold the case ﬁrmly.
4. Use two 2 34 ” spanner wrenches to tighten the lock collar on the outer
spindle of the head assembly at the left of the machine.
5. Use an 8” screwdriver and replace the guard over the collet operating
assembly at the extreme left of the machine.
[22]
CALIBER .30 CASE HEAD TURN
Adjustments
Hopper Bridge The cases are seated on the pins of the pin wheel and travel along the
hopper bridge to the feed tube mouth. The bridge must be adjusted so
that the cases are held on the pins until they reach the feed tube mouth.
The bridge should be adjusted so that there is about % " clearance between
the bridge and the pins on the pin wheel.
Hopper Bridge /
Adjustment
Tools:
L Procedure 1.
2.
INTERIOR VIEW OF PIN WHEEL HOPPER SHOWING POSITION OF THE


HOPPER BRIDGE
Two % " wrenches.
Unlatch and open hopper door.
Use two 194;" wrenches to loosen the lock nut on the vertical adjust-
ment shaft.
Turn the adjusting nut with a 1%” wrench until there is about %"
space between the bridge and the pins of the pin wheel near the feed
tube mouth.
Use two 1%” wrenches to tighten the lock nut on the vertical adjust-
ment shaft.
Close and latch the hopper door.
Open the hopper inspection gate, turn on the motor and observe the
travel of the cases along the bridge.
Note: To check adjustment, operate the hopper, then open the inspec-
tion gate and observe the action of the cases as they slide along the
hopper bridge.
I 23 l
CALIBER .30 CASE HEAD TURN Adjustments
Hopper Feed The feed tube mouth receives the cases after they travel the length of the
Tube Mouth pin wheel bridge. The mouth should be in line with the pins on the pin
wheel so that the cases will drop from the pins into the feed tube mouth.
If the mouth is not properly adjusted, the cases will jam at the feed mouth.
Adjustment is made on the adjusting bolt that connects the feed tube
mouth _to the pin wheel bridge.
Feed
Mouth
Feed
hdoulh
AdWﬂmeM

CLOSE-UP VIEW OF HOPPER FEED TUBE MOUTH
Tools: Two 19/32" wrenches.
Procedure: 1. Unlatch and open the hopper door.
2. Use two 1%" wrenches to loosen the lock nut on the mouth of the feed
tube adjustment bolt.
3. Turn the feed tube adjusting nut until the feed tube mouth is in line
with the pins of the pin wheel.
4. Use two 19/313" wrenches to tighten lock nut.
5. Close and latch the hopper door.
Note: To check adjustment, operate the hopper, then open inspec-
tion gate and observe the action of the cases as they slide from the
pins and hopper bridge into the feed tube mouth.
[24]
CALIBER .30 CASE HEAD TURN
Adiustments
Cutting Tool

Tools:
Procedure:
The cutting tool, which cuts the extractor groove in the case, can be
adjusted in two ways to regulate the depth of the extractor groove. One
method is to regulate the length of the stroke of the cutting tool toward
the case. The second adjustment, a more precise one. is made on the
tapered gib.
‘A " Gib Adjusting
Screw
VIEW OF CUTTING TOOL AND ADJUSTMENT
%" wrench, 1/4" wrench.
1. Use a %” wrench to loosen the set screw that holds the lug over the
cutting tool in the tool slide.
2. Operate the machine by hand until the tool slide is at the end of its
forward stroke.
3. Use a 14 " wrench to turn the adjusting set screw on the top of the tool
slide, until the cutting edge of the cutting tool is aligned with the center
of the case in the collet.
Note: This adjustment is a rather crude one, and may not bring the
cutting tool in the exact position for cutting the extractor groove. In
that case a more exact adjustment can be made on the tapered gib.
4. If the diameter of the extractor groove is approximately .001" too
small, use a 1/4 " wrench to turn the tapered gib adjusting screw a com-
plete turn in a counterclockwise direction. If the extractor groove
diameter is approximately .001 ” too large, turn the adjusting screw a
complete turn in a clockwise direction. The proper position can only
be determined by running the cases through the machine and checking
the product. This trial and error method is also applied to. the ﬁrst
cutting tool adjustment.
I25]
CALIBER .30 CASE HEAD TURN Adjustments
Knockout Rod The purpose of this rod is to eject the case from the collet when the cutting
operation on the head is completed. The ejecting stem can be adjusted to
remain close to the head of the case when the case is in the collet for the
cutting operation, and yet provide enough tolerance to allow the injecting
stem to travel its extreme delivery stroke without coming in contact with
the ejecting stem.

LEFT END OF MACHINE SHOWING KNOCKOUT ROD ADJUSTMENT
Tools: 8" screwdriver, 5 8 ” wrench, %” wrench.
Procedure: 1. Use an 8" screwdriver to remove the guard over the collet operating
assembly at the extreme left of the machine.
2. Place a % " wrench on the ejecting stem adjusting nut, and with a 3/4 "
wrench loosen the lock nut on the right of the adjusting nut.
3. Turn the adjusting nut until the ejecting stem rod is about 1/3; ” extend-
ed to the right of the collet when the collet is closed.
4. Place a %" wrench on the ejecting stem adjusting nut, and with a ”
wrench tighten the lock nut.
Note: In checking, operate the machine ﬁrst, with a case, then with-
out a case. Check for clearance between the ejecting stem and the
injecting stem, when the injecting stem is at the extreme end of its
delivery stroke.
[26]
CALIBER .30 CASE HEAD TURN Adjustments

Positive Stop Screw The positive stop screw is the adjustable set screw which the injecting
stem block contacts when it reaches the extreme end of its stroke
towards the collet. The purpose of this stop screw is to eliminate slop-
piness of cam movement. If all other causes of variation in head thick-
ness have been eliminated, it is possible that by readjusting this stop
screw variation in head thickness may be overcome.
Injecting


‘ M
w
- \ 1 I!
n‘! /2 Screw
. "
Nut
VIEW SHOWING POSITIVE STOP SCREW
Tools: %" wrench, 1%” wrench.
Procedure: 1. Use an U4/6” wrench to loosen the lock nut on the bumper bolt.
2. Turn the driveshaft by hand until the injecting stem is at the extreme
end of the delivery stroke.
3. Use a 1%" wrench to adjust the bumper bolt until it contacts the
injecting stern block ﬁrmly enough to overcome any sloppy or inac-
curate movement of the injecting stem block.
4. Use an 1146" wrench to tighten the lock nut.
5. Run the machine under power to see that it functions smoothly.
_ 11/16" Lock ‘
I27]
CALIBER .30 CASE HEAD TURN
Adjustments

Tool Slide Rocker
Arm

Tools:
Procedure:
The tool slide rocker arm actuates the cutting tool to and from the cutting
operation. It is equipped witha set screw to remove any back and forth
movement of the tool slide while the cutting tool is acting on the case.
This adjustment will eliminate any variation on the head diameter of
the case which may occur at the head turning operation.
3/5 " Set
Screw
Lock Nut
Rocker
Arm
REAR VIEW OF MACHINE SHOWING ROCKER ARM
%” wrench, ll/1/6” wrench.
1. Use an 1%” wrench to loosen the lock nut at the rear of the tool slide,
where the rocker arm is connected.
2. Turn the adjusting screw with a %" wrench until the play in the back
and forth movement of the slide is removed.
Note: Be careful not to make the set screw too tight.
3. Use an 1}/f5" wrench to tighten the lock nut at the rear of the tool slide
where the rocker arm is connected.
and ‘1/16!!
[28]
CALIBER .30 CASE HEAD TURN
Adjustments
Dovetail Gib The dovetail gib adjusting screw is located on the left side of the cutting
tool slide. If the head of the case has chatter marks, or variations in head
thickness, the tool slide has too much play in it. The dovetail gib adjust-
ment will help to eliminate play in the slide.

Collet
Retaining
Cap ""
Cutting
Tool ''
Tools:
Procedure:
TOP VIEW OF TOOL SLIDE WITH FEED TUBE REMOVED
5/16” Allen wrench, '/32" Allen wrench, 8" screwdriver, %" wrench, 1/4 "
wrench.
1. Use a M " wrench to remove the case lifting ﬁnger on the front of the
magazine.
2. Remove the magazine rocker arm guard directly behind the magazine
with an 8" screwdriver.
3. Use a 1/Z " wrench and screwdriver to remove the magazine turnbuckle
pivot screw.
4. Use an 8" screwdriver to remove the magazine pivot screw and lift
the magazine out.
5. Use a X2" Allen wrench to remove the feed tube bracket from ma-
chine.
6. Use a .5/16" Allen wrench to remove the four set screws and lift out the
tool slide assembly.
7. Use a 1/4 " wrench to turn the dovetail gib adjusting screw on the left
of the assembly until it removes all play in the slide.
I 29 I
CALIBER .30 CASE HEAD TURN
Adjustments
Procedure:
(Cont.)
8.
Replace the slide assembly.
9. Use a 5/16" wrench to replace the four Allen screws that hold the
10.
11.
12.
13.
14.
assembly to the bed of the machine.
Use a 7/32 ” Allen wrench to replace the feed tube and bracket.
Replace the magazine and pivot screws.
Use an 8" screwdriver and a %” wrench to replace the magazine
turnbuckle pivot screw.
Use a screwdriver to replace the magazine rocker arm guard.
Replace the case lifting the ﬁnger on the front of the magazine.
[30]
CALIBER .30 CASE HEAD TURN Adjustments

Cam Timing Each cam on the machine has a position in which it must be maintained.
There is a certain relationship that cams should have with each other.
When any one of these cams changes its relative position, it is out of tim-
ing. This condition quite often develops when the machine jams.
Collet Clutch
Operating Lever
Fingers
Magazine
Cam
Collet
Operating
Cam Barrel
Cam
Cutting
Tool
Camshaft Cam

FRONT VIEW OF MACHINE SHOWING THE CAMS
Procedure: 1. The barrel cam which actuates the injecting stem, is brought manually
into a position where the line on its outer surface labeled with a small
6‘ L?
o rests midway between the slot in which the injecting stem slides
back and forth.
2. When the injecting stern cam is correctly positioned, the next step is to
check the position of the magazine cam, the cutting tool cam, and the
collet cam.
Note: On the outer surface of each cam there is a line with an 0 on
it. This is the spot the cam rollers of each cam should contact or align
with when the injecting stem cam is in the position described in the
ﬁrst step. If any cam is out of position, loosen the set screw. Place
the cam in the proper position, then tighten the set screw. When this
is done, the cams are in correct timing.
l31l
CALIBER .30 CASE HEAD TURN
Adjustments
Magazine


The magazine is the chamber which receives the cases as they slide from
the feed tube of the pin wheel hopper. This magazine is designed to pivot
to a position where the injecting stern will enter at the bottom to push the
bottom case from the magazine into the collet of the machine. The maga-
zine has an adjustment on the rocker arm that pivots the magazine to
place it in proper alignment with the injecting stem.
11/16” Lock Nuts
-P
"-- Turnbuckle
I; -~-. Rocker Arm
REAR TOP VIEW OF MAGAZINE SHOWING TURNBUCKLE
Tools:
Procedure:
8” screwdriver, two 1%,” wrenches.
T.
2.
Use an 8" screwdriver to remove the turnbuckle guard.
Use an 14;” wrench to loosen the lock nuts on each end of the turn-
buckle.
Turn the turnbuckle by hand until the magazine is in line with the
injecting stem when the magazine is at the extreme end of its delivery
stroke.
Use two 1%," wrenches to tighten the lock nuts on each end of the turn-
buckle.
Note: Be sure the turnbuckle remains in position while the lock nuts
are being tightened.
Use 8" screwdriver, replace turnbuckle guard.
I 32 l
CALIBER .30 CASE HEAD TURN
Adjustments
Injecting Stern
Tools:
Procedure:
The injecting stem delivers the case to the collet from the magazine of the
feed tube. The distance the injecting stem travels toward the collet con-
_ trols the head thickness of the case. An adjustment can be made to allow
the injecting stem to be nearer the collet or farther from the collet when it
reaches the extreme end of its delivery stroke.

Adjusting
Screw
Barrel
.>-"'
5 " BB-29
INJECTING STEM AND BARREL CAM
8" screwdriver, '§-/12;” brass rod.
1.
2.
3.
Use an 8" screwdriver to remove the guard over the injecting stem.
Use a 3&1}: " brass rod to loosen the injecting stem lock collar.
Use an 8" screwdriver to turn the adjusting screw at the right end of
the injecting stern block until the injecting stem permits the case to
extend out of the collet about '9’/8”.
Note: The proper position of the injecting stem can be determined
only by operating the machine, checking the product and readjusting
the stem until the proper adjustment is attained.
Use an 8" screwdriver to tighten the injecting stem lock collar.
Use an 8" screwdriver to replace the guard over the injecting stem.
I33l
CALIBER .30 CASE HEAD TURN Troubles and Corrections

TROUBLES AND CORRECTIONS
Objective The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may con-
front an adjuster, but the production troubles that most commonly occur,
their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as it
operates.
Head of Case is Gaging reveals that the head of the case is being cut too thick.
i00 Thick The correction is:
1. Adjust the stem. Loosen the
spanner lock nut at the back
end of the stem. Turn the stem
adjusting screw to force the
stem toward the collet. Tighten
the spanner lock nut.
The cause is:
1. The injecting stem does not
force the case far enough into
the collet.
Head of Case is Gaging reveals that the head of the case is being cut too thin.
too Thin
The causes are: The corrections are:
1. Adjust the stem. Loosen the
spanner lock nut at the back
end of the stem. Turn the stem
adjusting screw and pull the
stem away from the collet.
1. The injecting stem forces the
case too far into the collet.
Head Diameter
foo Large
. Burr on the cutting edge of the
cutter. This is usually the re-
sult of a dull tool or improper
tool servicing.
The cause is:
1. The wedge on the cutter is
adjusted too far to the right.
It does not hold the cutter far
enough toward the center.
. Remove the cutter by ﬁrst
loosening the cutter clamp
screw. Remove the burr on the
cutter with a ﬁne oil stone; or
refer cutter to the Tool Serv-
icing Department for reserv-
icing.
Gaging reveals that the head diameter is too large.
The correction is:
1. Adjust the cutter toward the
center of the collet by turning
the wedge adjusting screw
toward the left. Check and
readjust the cutter if necessary.
[34]
CALIBER'.30 CASE HEAD TURN
Troubles and Corrections
Head Diameter
too Small
Head Diameter
Variation
Head Thickness
Variation
Gaging reveals that the diameter of the head is too small.
The causes are:
1.
The tapered gib on the cutter
is adjusted too far to the left.
It holds the cutter too far up
toward the center of the collet.
. Burr on the cutting edge of the
cutter. This is usually the re-
sult of improper tool servicing.
The corrections are:
1. Adjust the cutter away from
the collet by turning out the
tapered gib adjusting screw,
moving the gib to the right.
After the adjustment is made
turn the adjusting screw until
it is snug against the tapered
gib. Check and readjust if
necessary.
. Remove the cutter by ﬁrst
loosening the cutter clamp
screw. Remove the burr on the
cutter with a ﬁne oil stone, or
take the cutter to the Tool
Servicing Department for re-
servicing.
Gaging reveals that the head diameter varies.
The causes are:
1.
The adjusting screw on the
wedge is loose. This allows the
cutter position to vary.
. Cutting tool is loose.
Cutting tool is dull.
The corrections are:
1. Adjust the cutter to cut the
case head to the correct diam-
eter and turn the adjusting
screw so that it is snug against
the tapered gib.
.Tighten the clamp on the
cutting tool holder.
. Remove the cutting tool by
loosening the clamp screw that
holds it in place. Replace with
a new cutter and tighten the
clamp screw.
Gaging reveals that there is variation in the head thickness of the cases.
One head may be cut too thin and another too thick.
The causes are:
1.
The stem forces the case too
far or not far enough into the
collet because of the play in
the cam that actuates the stem.
The corrections are:
1. Adjust the positive stop screw
that determines the position of
the stem. To adjust, turn the
pulley wheel until the stem is
at its farthest forward position.
Loosen the lock nut on the
positive stop screw and turn
the screw until it seats against
the stem block. Tighten the
lock nut.
[35]
CALIBER .30 CASE HEAD TURN
Troubles and Corrections

Head Thickness
Variation (Cont.)
Extractor Groove
Is Too Large
in Diameter
Extractor Groove
Is Too Small
in Diameter
2.
Revolving button or tip on the
injecting stem is worn. Foreign
matter gets between the tip and
the stem and causes the case to
be forced too far into collet at
times. When the foreign matter
drops from between the tip and
the stem, the case is not forced
far enough into the collet.
The tool slide has side play.
The tool moves from side to
side during cutting operation.
. Injecting stem block slides are
too tight. This causes the stem
block to stick; therefore the
injecting stem does not inject
the case far enough into the
collet.
2. Remove and replace the in-
jecting stem. Remove the guard
over the stem and remove the
deﬂector shield. Remove the
tool guide at the left of the
stem. Turn the spanner nut at
the back end of the stem to
unscrew the stem from the
block. Replace the new stem
in reverse order.
. Adjust the dovetail gibs on the
tool slide. Loosen the lock nuts
in the gib adjusting screw.
Turn the adjusting screws un-
til the tool slide has a snug but
free sliding ﬁt. Tighten the lock
nuts on the adjusting screws.
. Remove the stem block slides
by ﬁrst removing the screws
that hold them in place. Place
shims under the block slides or
have the face of the slides
ground and polished. Replace
the block slides and tighten the
screws that hold them in place.
Gaging reveals that the extractor groove is being cut too shallow but the
head diameter is correct.
The causes are:
1.
The cutting tool is dull.
2. The cutting tool is not properly
shaped.
The causes are:
1. There are burrs on the edge of
the cutting tool.
2. The cutting tool is not shaped
properly.
The corrections are:
1. Remove the cutting tool by
loosening the clamp nut and
taking out the tool. Replace
with a serviced cutter and
tighten the clamp.
. Remove and replace the cut-
ting tool.
Gaging reveals that the extractor groove is being out too deep, but the
head diameter is correct.
The corrections are:
1. Remove the burr with a ﬁne
grade of emery cloth or a ﬁne
oil stone.
2. Remove and replace the cut-
ting tool.
I 36 I
CALIBER .30 CASE HEAD TURN
Troubles and Corrections

Extractor Groove 3. Burr on the cutting edge of the
Is Too Small
in Diameter (Cont.)
Nicked Heads
Scored or
Burned Heads
Cases Are Stuck
in Magazine
3. Remove cutter by ﬁrst loosen-
ing cutter clamp screw. Re-
move burr on cutter with a ﬁne
oil stone, or take cutter to
Tool Servicing Department for
reservicing.
cutter. This is usually the re-
sult of improper tool servicing.
Visual inspection has revealed that the heads of the cases are nicked.
The cause is: The correction is:
1. The shield deﬂector is pitted. 1. Remove the deﬂector shield by
removing the screw that holds
it in place. Remove the pits
with a ﬁne grade of emery
cloth. If it is too badly pitted,
replace with a new deﬂector
shield.
Visual inspection reveals that the head of the case is scored or burned.
The cause is: The correction is:
1. Remove and replace the in-
jecting stem. Remove the guard
over the stern and remove the
deﬂector shield. Remove the
tool guide at the left of the
stem. Turn the spanner nut at
the back end of the stem to
unscrew the stem from the
block. Replace in reverse order.
1. Revolving tip on the injecting
stem does not revolve with the
case.
Visual inspection reveals that the cases are not feeding through the maga-
zine to the collet. They are stuck in the magazine at an angle.
The causes are: The corrections are:
1. Mouth of the case is ﬂared.
This condition allows the head
of the case to slide downward
but the mouth will not slide and
the case is left tilted at an angle.
1. Remove the defective case from
the magazine. If the condition
arises too frequently, check the
source of supply.
Head of the case is too large.
This condition allows the mouth
of the case to slide downward
but the head will not slide and
the case is left tilted at an
angle.
. Remove the defective case from
the magazine and check the
source of supply.
[37]
CALIBER .30 CASE HEAD TURN
Troubles and Corrections

Improper Feeding
of Cases to the
Magazine
Cases Jamming at
the Collet
Visual inspection reveals that the cases are not being fed from the hopper
to the magazine.
The causes are:
1. A defective case is stuck in the 1.
feed tube, preventing the suc-
ceeding cases from traveling
through to the magazine.
The corrections are:
Remove the defective case from
the feed tube. First remove the
feed tube at the magazine and
force out the defective case.
Replace the feed tube at the
magazine.
Check the hopper bridge posi-
tion. If it is not properly ad-
justed, adjust the bridge by
turning the nuts on the vertical
adjusting bolt until the bridge
is about 3/41” from the pins on
the pin wheel. Check the feed
tube mouth. If it is improperly
adjusted, turn the nuts on the
mouth adjusting screw until the
mouth is-in line with the pins on
the pin wheel.
Remove the defective case from
the magazine.
Visual inspection reveals that the cases are jamming at the mouth of the
2. The cases are not being fed 2..
down into the feed tube.
3. The casesare stuck in the mag- 3.
azine.
collet.
The causes .are:
1. Dirty collet. Cases stick in the
collet and are not ejected. This
causes the succeeding case to
jam.
2. The ejecting stem spring is not 2.
functioning properly. It does
not eject the case from the col-
let; this causes the succeeding
case to jam.
The corrections are:
1. Remove and clean the collet.
First remove the left front of
the magazine by removing the
Allen screws. Remove the scrap
separator by removing the Allen
screws. Remove the cutter by
loosening the clamp bolt. Hold
the back end of the collet shaft
and remove the collet by un-
screwing it from the shaft. Dis-
assemble and clean the collet.
Reassemble in reverse order.
Remove the ejecting stem spring
and replace with a new spring;
remove the spanner nuts at the
end of the collet shaft. Take
out the ejecting stem rod. Re-
move the spring and replace it.
Reassemble in reverse order.
CALIBER .30 CASE HEAD TURN
Troubles and Corrections

Cases Jamming at
the Collet
(Cont.)
Scratches on the
Outside of the Case
Head or Extractor
Groove Is Not
Being Cut
3.
Working end of the ejecting
stem is too small in diameter.
The cases slide over the stem
rod which causes the succeed-
ing cases to jam.
. The collet jaws are too tight.
The case is forced against the
collet jaws causing a jam.
. Remove and replace the eject-
ing stem. Remove the spanner
nuts at the end of the collet
shaft. Take out the ejecting
stem rod and replace.
. Loosen the collet jaws by turn-
ing the spanner nuts at the end
of the collet shaft to bring the
collet ﬁngers away from the
collet cone.
Visual inspection reveals that the outside of the case is scratched.
The causes are:
1.
The cases are slipping in the
collet. The collet does not hold
the case ﬁrmly enough for the
operation.
. Burrs on the bottom of the
magazine. The case is
- scratched as it is pushed from
the magazine into the collet
jaws.
. Burrs on the deﬂector shield.
As the case is being ejected, it
is scratched by the burrs on the
deﬂector shield.
The corrections are:
1. Tighten the collet by turning
the spanner nuts at the end of
the collet shaft, bringing the
collet ﬁngers closer to the collet
cone. Check the adjustment
and readjust the collet if neces-
sary.
. Remove the burrs with a ﬁne
grade of emery cloth.
. Remove the burrs from the de-
ﬂector shield with a ﬁne grade
of emery cloth.
Visual inspection of the case reveals that the machine is failing to per-
form its function of cutting the extractor groove and head on the case.
The causes are:
1.
Broken cutter.
. The collet belt is too loose. The
case in the collet is not being
turned against the cutter.
. Case is slipping in the collet.
The case is not being turned
against the cutter.
. Remove the belt.
The corrections are:
1. Remove and replace the cutter
by ﬁrst loosening the cutter
clamp bolt and then removing
the cutter. Replace with new
cutter and tighten the clamp
bolt.
Remove a
small portion from the belt,
connect the belt and replace.
. Tighten the collet by turning
the spanner nuts at the end of
the collet shaft to bring the
collet ﬁngers closer to the collet
cone.
[39]
CALIBER .30 CASE HEAD TURN Troubles and Corrections
Scrap Piling Up at Visual inspection reveals that the scrap is piling up at the scrap separator
Scrap Separator and interferes with the cutting operation.
The cause is: The correction is:
1. There is too little space be- 1. Loosen the scrap separator by
tween the scrap separator and ﬁrst loosening the two Allen
the cutter. screws. Set the separator away
from the cutter edge about % ”.
CALIBER .30 CASE HEAD TURN
Tool Servicing

Objective
TOOL SERVICING
It is essential to maintain a sharp cutting edge on the head turn cutter tool
at all times. This is necessary in order to obtain the speciﬁed dimension of
the extractor groove and thus insure that the cartridge will function with
maximum efficiency in the gun.
The servicing or sharpening of the cutter tool is accomplished by use of a
power grinding wheel and a jig or ﬁxture in which the tool is held. Under
no circumstance should the sharpening be attempted by manually holding
it against a grinding wheel. Extreme care must be exercised not to grind
away more metal than necessary in developing the new cutting edge as this
will decrease the useful life of the cutter. Ordinarily, the removal of some-
what less than a sixty-fourth of an inch should be sufficient to recondition
a cutter, but, when for any reason the cutter has become chipped, a greater
amount may have to be removed.


n—./65 —~ 050
052 036 ‘j n-— '
J .052 I 45”
I-_ _ _ _ _. _. __ I I I
62 -2 60
Th -F ~ 0
/\i/ .055 -- K
506
20‘ P
ix/"/'0/at
3 % Clearance .g__ 3/; ___Q_

DRAWING ILLUSTRATING CORRECT ANGLES OF CUTTING EDGE
Cutter
The above drawing illustrates the dimensions, shape and correct front
clearance angle of the Caliber .30 case head turn cutting tool as supplied
by its manufacturer. This tool, as shown in the illustration, is sharpened
with a front clearance angle of 20°. Its dimensions are 3.3125 x .306 x .311.
When the cutter becomes dull through usage, it fails to cut the extractor
groove to the required speciﬁcation and must therefore be replaced with a
new or reconditioned cutter.
I41]
CALIBER .30 CASE HEAD TURN Tool Servicing

ONE OF THE APPROVED METHODS OF RECONDITIONING A CUTTER
Reconditioning 1. Reconditioning of cutters must take place in the tool shop. When a
Cutter _ cutter is turned in to the tool shop for reconditioning, it is reground ac-
cording to the speciﬁcations and the directions indicated on the blue
print for that cutter.
2. In grinding a new cutting edge, a 20° front clearance must be main-
tained.
3. Each grinder willremove about .002 " and leave a new cutting edge.
Under normal conditions this tool can be reconditioned ﬁfty or sixty
times.
4. The cutter can be ground on a surface grinder. The grinding wheel
should be a crystolon vitriﬁed type, grain 120, grade P., structure 8,
which is a soft grinding wheel. Surface speed of surface grinder is ﬁxed
at between 2750 F.P.M. and 3000 F.P.M. which is sufficient speed for
this type of work. If the grinding wheel feed exceeds .0003 ", the metal
will be distorted due to its hardness.
I42]
CALIBER .30 CASE HEAD TURN Tool Servicing

-
. > ~ ‘-
INCORRECT METHOD OF GRINDING A CUTTER
The above picture illustrates the wrong method of grinding a cutter tool.
Adjusters and operators must exercise extreme care in the servicing of
tools. A jig or ﬁxture should always be used when grinding a cutter. This
insures safety to the hands and enables the adjuster to maintain the proper
cutting angles on the surface of the cutter.
[43]
CALIBER .30 CASE HEAD TURN
Mochine Lubricotion

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubricotion
Anti-friction
Beoﬁngs
MACHINE LLIBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefﬁciency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating film between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
- 1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap. ~
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[44]
CALIBER .30 CASE HEAD TURN
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm. strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.Q.@.U‘!F‘.°°.l\"
Frequency of lubrication.
I45]
CALIBER .30 CASE HEAD TURN
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
. Bottle oiler.
. Ring oiler.
. Plain oil cups.
2
3
4
5. Drop feed cups.
6. Wick feed cups.
7. Mechanical, force feed, central lubricating system.
8. Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
[46]
CALIBER .30 CASE HEAD TURN
Machine Lubrication
LUBRICATION CHART


. . . N o. of Fittings, Frequency of
I/“bmcam Machine Part Grease Cups, etc. Lubrication Hours
Main shaft bearings . . . . . . . 3 8
LI(jI]§jEeGéiuEril‘;*SE Idler wheel . . . . . . . . . . . 1 24
Head spindle . . . . . . . . . . 2 2 wks.
Hopper . . . . . . . . . . . . 3 8
Pin wheel hopper clutch . . . . . 1 8
Magazine pivot screws . . . . . . 2 8
Magazine turnbuckle pivot screws 2 8
Magazine cam operating pivot screws 1 8
Tool slide lever pivot screw . . . . 1 8
Tool slide . . . . . . . . . . . . 2 8
Injecting stem gibs . . . . . . . 6 8
LIGHT OIL Injecting stem revolving tip . . . 1 as necessary
(Brown Oiler) Injecting stem cam roller . . . . . 1 8
Injecting stem . . . . . . . . . 1 as necessary
Case lifting ﬁnger . . . . . . . . 1 as necessary
Collet operating ﬁnger cone . . . . 1 as necessary
J ackshaft assembly . . . . . . . 3 8
J ackshaft controls . . . . . . . . 3 8
Injecting clutch operating gear 1 8
Injecting stem cam gears . . . . . 2 8
Collet operating cam . . . . . . . 1 8
(I;El1i)YvYO(i)lg.J) Hopper drive gear assembly . Res 1 wk.
[47]
CALIBER .30 CASE HEAD TURN
Index
Adjusting Screw and Block, 13
Adjustment, Cam Timing, 31
Collet, 22
Cutting Tool, 25
Dovetail Gib. 29
Hopper Bridge, 23
Hopper Feed Tube Mouth, 24
Injecting Stem, 33
Knockout Rod, 26
Magazine, 32
Positive Stop Screw, 27
Tool Slide Rocker Arm, 28
Anti-friction Bearings, 44
Barrel Cam, 7
Camshaft, 3
Burnt Heads, 38
Cam Timing Adjustment, 31
Camshaft, 3, 4, 6, 8, 11
Cannelure Depth, 19
Case Magazine, 3, 9
Cases Are Stuck in Magazine, 37
Jamming at the Collet, 38, 39
Clutch, 2, 3, 5, 6
Assembly, 6
Coil Spring Feed Tube, 15, 17
Collet, 15, 18
Adjustment, 22
Assembly, 2, 3, 4, 9
Jaws, 12
Mechanism, 8
Spindle, 10
Crap Piling Up at Scrap Separator, 40
Cross-shaft, 5
Cutter, 41
Tool, 43
Cutting Tool, 13, 15, 18
Tool Adjustment, 25
Tool Housing, 13
Disposal, 16, 18
Dovetail Gib Adjustment, 29
INDEX
Driveshaft, 2, 3, 6, 7
Ejecting Stem, 10
Extraction Depth Gage, 20
Extractor Groove too Deep, 36
Groove too Shallow, 36, 37
Feed Chute, 3
Tube, 9
Tube Mouth, 5, 23
Floor Space, 1
Flow Chart, 17, 18
Form Tool, 14
Friction, 44
Gage Care, 20
Grease, 45
Hammer, 15
Head Diameter too Large, 34
Diameter too Small, 35
Diameter Variation, 35
of Case too Thick, 34
of Case too Thin, 34
or Extractor Groove Not Being
Cut, 39
Thickness, 19
Thickness Gage, 20
Thickness Variation, 35, 36
Height, 1
Hopper Bridge Adjustment, 23
Feed Tube Mouth Adjustment, 24
Improper Feeding of Cases to
Magazine, 38
Injecting Stem, 3, 7, 8, 9, 15, 18, 27
Stem Adjustment, 33
Knockout Rod, 16, 18
Rod Adjustment, 26
Line Shaft, 2, 4
Shaft Motor, 1
Lock Nut, 13
Lubricating Film, 44
Lubrication, 44
Chart, 47
Lubrication, Hints on, 46
Methods, 45
Magazine, 15, 17
Adjustment, 32
Lip, 17
Manufacturer, 1
Method of Getting Lubricant to
Bearing Surface, 46
Nicked Heads, 37
Outside Diameter, 19
Head Diameter, 19
Over-all Length, 19
Overhead Hopper, 15, 17
Pin Wheel Bridge, 5
Wheel Hopper, 3, 5, 15, 17
Wheel Hopper Box, 3, 5, 15, 17
Pocket Depth, 19
Diameter, 19
Positive Stop Screw Adjustment, 27
Power, 2, 3
Production, 1
Raising Finger, 15
Reconditioning Cutter, 42
Rocker Arm, 11, 12
Scored Heads, 37
Scratches on Outside of Case, 39
Selecting a Lubricant, 45
Set Screw, 13
Speed of Spindle, 1
Tool, 1
Carriage, 4, 11
Slide. 13
Slide Assembly, 13
Slide Rocker Arm Adjustment, 28
Transmission, 2
Triple Ring Head Diameter Gage, 20
Type of Feed, 1
V Belt, 2
Visual, 20
Web Thickness, 19
Weight, 1
[48]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Body Anneal
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5,1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public N o. 443, 76th Congress, 3rd Session).
II
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reason for the Body Anneal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 2
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Index. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
III

CALIBER .30 CASE BODY ANNEAL MACHINE
CALIBER .30 CASE BODY ANNEAL Catalogue Data

CATALOGUE DATA
Manufacturer Peters Engineering Co., Philadelphia, Pa.
Machine Horizontal twin screw conveyor type machine with
Description dual feed, equipped with gas burners and water
reservoir.
Machine Q Gear head motor; 1/4 h.p. ; 1 phase; 60 cycle; 115/230
Motor volts; 4.4/2.2 amps.; 1725 R.P.M. Countershaft
speed 345 R.P.M. Belt drive to geared shaft.
Type of Feed Pedestal type paddle wheel hopper. Belt driven
from countershaft.
Production 240 per minute.
Conveyor Speed 120 R.P.M.
Tools None.
Height 5 ft. 10 in.
Weight 1000 lbs.
Floor Space 4 ft. x 6 ft.
[1]
CALIBER .30 CASE BODY ANNEAL Reason for the Body Anneal

REASON FOR THE BODY ANNEAL
When brass is cold worked, as it is in the case drawing operations, the
grain size of the metal becomes smaller which makes the brass harder.
The harder brass resists being formed to a new shape and shows a tendency
to spring back and to fracture. The purpose of the body anneal is to
soften the brass which has been hardened by the fourth draw operation
in preparation for the taper and plug operation in which the case is
tapered to form the shoulder and neck.
While annealed brass is more pliable and responds more readily to a
forming operation than unannealed metal, it is not as strong as it was
before being annealed. For this reason the body anneal should not extend
closer to the head than one inch, on the Caliber .30 case, as greater
strength in this region is required to withstand the strain caused by ﬁring
the cartridge. Since it is not desirable to anneal the head and that portion
of the case from the head to about an inch up on the body, the head
portion of the case is kept submerged in water while the case is carried
through the gas ﬂames by the conveyor screw. The ﬂames darken the
color of the case down to the “break” line, while the head portion remains
light in color, indicating that the head area was not annealed. The
“break” line is not precisely a line, but rather a region, about %” long
which marks the transition from the comparatively hard metal of the head
portion to the comparatively soft and elastic metal of the remainder of
the case body.


FIG. 3
The above pictures illustrate one of the many results of improper anneal-
ing. Fig. 1 shows a cartridge which had been loaded into the breach of a
gun containing part of a case that had not been ejected. This results in
a serious jam of a machine gun or riﬂe. Fig. 2 shows the cartridge as it
would appear in the gun breach, jammed through the section remaining
of the previously ﬁred cartridge. Fig. 3 illustrates the line of cut off or
break which resulted from the explosion of ﬁring the improperly annealed
cartridge.
[2]
CALIBER .30 CASE BODY ANNEAL Machine Description
MACHINE DESCRIPTION
The Caliber .30 body anneal heats the body of the case in order to soften
that portion of the case which is to be tapered by the taper and plug
machine.
Paddle ,_ Paddle
Wheel Hopper Wheel Hopper
Feed Tube -
— Metal Head
Clutch Lever —
-- Gas Burner
Feed Block -
__ Machine
Frame
Motor
__ Overflow
Pipe

CALIBER .30 CASE BODY ANNEAL
Motor The Caliber .30 Peters Horizontal Twin Screw Body Annealing Machine is
powered by a }/.1 h.p. gear reduction motor. The motor is mounted at the
left front end of the machine and can be moved back and forth to tighten
or loosen the motor belt.
Power and Power is transmitted through a V-type belt to two friction wheels
Transmission which, in turn, transmit the power to a friction drive wheel. The friction
drive wheel is keyed to one end of a shaft which has a driving gear on the
other end. The driving gear meshes with a gear on one end of the conveyor
[3]
CALIBER .30 CASE BODY ANNEAL
Machine Description
Power and
Transmission (Cont.)
Machine Frame
Gas Burners
and Metal Hood
Conveyor
Screws and
Reservoir
Paddle Wheel
Hopper
screws. This gear, in turn, meshes with the gear on the other conveyor
screw.
The framework of the body annealing machine is formed by two I
beams, each approximately four and one-half feet long, which run parallel
to each other and are welded together on the ends with steel plates. This
rectangular framework is supported about three feet from the floor by
means of two channel iron brackets to which the framework is welded.
The I beams, which form the bed of the machine, support two rows of
gas burners. An asbestos covered sheet metal hood is suspended above
the burners.
Between the I beams which are approximately 10" apart are set the
conveyor screws. These screws, which are parallel to each other, extend
nearly the full length of the machine framework. The conveyor screws are
submerged in a shallow tank of running water; this tank or reservoir is
equipped with an overﬂow by which the level of the running water is
controlled.
This machine is equipped with two paddle wheel hoppers, one for each
conveyor screw. A hopper is located at each end of the machine in order
that the conveyor screws may feed the cases in opposite directions.
CALIBER .30 CASE BODY ANNEAL
Machine Description

Paddle
Pulley Wheel
Drive Belt
Paddle Wheel
Hopper

Hopper
Idler
Feed Tube
Pedestal
PADDLE WHEEL HOPPER
The cases are fed into the hopper box through a chute from an overhead
source and are picked up by a series of paddles which lift them to the
conveyor belt. The conveyor belt carries the cases to an opening where
they pass into the feed throat. The paddle wheel is driven by a horizontal
cross-shaft at the front of the hopper box.
A pinion gear is attached to the right end of the cross-shaft which meshes
with the ring gear attached to the outer end of the paddle wheel shaft.
A pulley wheel is attached to the left end of the cross-shaft which is
connected to the driveshaft by a round leather belt. The hopper pulley
wheel is equipped with a dog clutch which is manually operated by a
knob at the end of the cross-shaft. This arrangement allows the hopper
to be stopped independently of the driveshaft. The paddles on the paddle
wheel lift the cases to the conveyor belt, which carries them to the feed
throat. The cases enter the feed throat head ﬁrst, and drop by gravity
through the feed tube down to the feed block.
l5l
CALIBER .30 CASE BODY ANNEAL Machine Description


Coil Spring
Feed Tube
Gas
Conduit .» "-
Conveyor
_ Screw
Case
Guide "
Tl'UCk Gus
=- Burners
GUS J‘?-~. I, ' A. I cf .. .
Conduit,’ ‘ ‘ l I ~ _' ~-. 1 " Gus
Conduit
Supporting
Bracket
VIEW SHOWING GAS BURNERS
Gas Burners There are two rows of burners, facing each other, which direct their
ﬂames across the longitudinal axis of the machine. The gas burners are
of the generator type and have ceramic refractory liners. There are 9
burners in each of the two rows. They are individually adjustable about
the horizontally mounted support which acts as the conduit for the gas
mixture. The burners of each row are set at various levels. The ﬂames
from the ﬁrst ﬁve burners impinge upon the area near the mouth of the
case, the next two heat the body and the remaining six burners direct
their ﬂame to the region above the “break." During this operation the
head of the case is in the water.
[6]
CALIBER .30 CASE BODY ANNEAL Machine Description


‘,_\ ~P\
L
\ zt
{R},
I".
Kr
"


Gas
Burner


Conveyor
Screws
VIEW SHOWING CONVEYOR SCREWS
Conveyor Screw The conveyors are two threaded shafts which extend lengthwise through
the machine between the I beams. The thread or spiral groove on the
conveyor screw is approximately %g'” deep and just wide enough to
accommodate the head of a Caliber .30 case. The screw is equipped with
a gear on one end through which the power is transmitted.
While the cases are still in the feed block they fall onto the conveyor
screw; as they emerge from the feed block the cases, revolving on their
axes, are carried by the rotary screw past the gas burners. The cases are
guided between and supported by two horizontal bars, placed parallel to
each other, which act as case guide tracks to keep the cases upright. The
gas burners are carefully adjusted so that the flames are directed to all
parts of the body of the case except the submerged head portion.
[7]
CALIBER .30 CASE BODY ANNEAL
Process Sequence

Overhead
Hopper
Case Paddle
Wheel Hopper
Conveyor Belt
and Coil Spring
Feed Tube
Conveyor Screw

j Cases J
I Overhead Hopper I


j Feed Pipe j
I
PROCESS SEQUENCE
The cases are fed by gravity from a truck or conveyor into an overhead
hopper and ﬂow down through a pipe, into the paddle wheel hopper.
The cases ﬂow down the incline of the paddle wheel hopper to the paddle
wheel by gravity. The paddle wheel rotates, picks up the cases, and
conveys them up to the edge of the hopper, where they roll onto the
conveyor belt, in a horizontal position.
The conveyor belt carries the cases to an opening where they pass from
the conveyor belt into the feed throat. The cases enter the feed throat
head ﬁrst, and drop by gravity through a coil spring feed tube to the feed
block, then onto the spiral screw.
From the feed block the cases are conveyed past the gas burners by the
conveyor screws. During the annealing operation, the heads of the cases
are submerged in water to keep them from being annealed as the cases
pass before the gas burners and the bodies are annealed. At the end of the
conveyor screw the cases pass a counter and drop through a chute to the
conveyor belt at the back of the machine.
FLOW CHART

Paddle Wheel
Hopper

Conveyor
Belt


I
I Feed Throat


Feed Tube Gas Burners
I Feed Block j——j Conveyor Conveyor
Screws Screws
Water Chute Conveyor Belt


[8]
CALIBER .30 CASE BODY ANNEAL Product Description
PRODUCT DESCRIPTION
When the component arrives at the Caliber .30 body annealing machine,
it is a case with straight sidewalls. It is made of cartridge brass, 70%
copper and 30% zinc. The closed end of the case is called the head and
the open end is the mouth. The case comes to the body anneal machine
from the head turning operation where the head has been turned to size.
After the annealing operation, during which the case is heated from the
mouth to a line approximately an inch from the head, the annealed
portion of the case gives evidence of the anneal by its darker, duller color
as contrasted to the comparatively lighter and shinier appearance of the
unannealed head portion. This area of the case which shows the dividing
line between the annealed and unannealed portions of the case is called
the “break” line and is important because it marks the boundary between
the hard metal and the metal that has been softened by the anneal.
The dimensions of the case before the annealing operation are as follows:
Outside head diameter .467 —.471
Outside diameter of case body .4645—.4670
Web thickness .060 —.068
Pocket depth ‘ .125 -.129
Pocket diameter 2093-2098
Over-all length of case 2. 50
Head thickness .043 —.048
Cannelure depth .403 —.407
There is no appreciable change in dimensions of the case after the anneal.
After the annealing operation the cases are sent to the Soap and Dry
Department and from there to the Taper and Plug Department.


8
H11 '
FIG. 1 FIG. 2
BEFORE BODY ANNEALING AFTER BODY ANNEALING
OPERATION OPERATION
l 9 I
CALIBER .30 CASE BODY ANNEAL Inspection

INSPECTION
The annealed cases are tested and inspected by the Metallurgy Department. Every ﬁfteen min-
utes the inspector selects a sample annealed case from each conveyor screw and makes a Rockwell
test on it. The Rockwell hardness tester is a machine which determines the hardness of the metal.


103-110


1 00-1 08
SKETCH SHOWING ROCKWELL READING SPECIFICATIONS ROCKWELL HARDNESS TESTER
A representative sample from each row is a case that has traversed the entire anneal, preceded
and succeeded by at least ﬁve or six cases. Also the test case must not have been subjected to the
unobstructed ﬂame from the other row of burners. When there is a break in the flow of cases in
one row, too much heat is directed upon the cases in the other row.
There are so many variable factors which inﬂuence the anneal that a continuous check on the
annealed cases must be carried on by the Finish Laboratory.
One factor inﬂuencing the anneal is the degree of ﬂame heat on the cases, which depends upon
the relative positions of the burners. When cartridge cases are subjected to an uneven distribution
of heat, the result is an uneven distribution of hard and soft metal; that is, the metal is softened
in irregular patches. The position of the burners is regulated by the machine adjuster when he is
advised that certain portions of the case fail to meet speciﬁcations in regard to case hardness.
[10]
CALIBER .30 CASE BODY ANNEAL Inspection
,—
Another variable factor affecting the anneal is the level of water in the reservoir. If a sudden
change in the Rockwell readings, taken at the “break” line, occurs on both rows of cases, simul-
taneously, it indicates a change in the water level in the reservoir. The desired water level must
be re-established.
Another important factor in annealing is the available gas pressure. There is a distinct drop in
gas pressure about an hour prior to normal meal times, due to the heavy demands of the domestic
trade. A corresponding increase in pressure is noted upon the completion of meal preparation.
This situation necessitates that a close control be maintained by the adjuster with the aid of
frequent and accurate reports from the Finish Laboratory.
A factor which disturbs even annealing is the interruption of the feed in one row of cases which
means that only one row of cases is going through the annealer at a time, and this row is receiving
all the heat from the unobstructed ﬂames in the other row.- Interruption of the feed is usually
due to an obstruction in the ﬂexible feed tube, or may be caused by cases with oversized heads,
or by turnings from the head turn operation.
Another thing that affects the anneal is the speed of the conveyor screw. The friction clutch drive
sometimes develops a slippage which decreases the speed of the conveyor screw and causes an
over-anneal. Improper adjustment of the clutch lever lock by the adjuster can also cause the
conveyor screw to turn too slowly. The clutch surfaces are subject to wearing smooth or to
becoming coated with grease and dirt; the machine must be shut down and the surfaces must be
roughened or cleaned to overcome the slipping of the friction wheels.
[11]
CALIBER .30 CASE BODY ANNEAL
Adjustments
Objective
Caution
ADJUSTMENTS
To maintain satisfactory operation of this annealing machine both the
product and the machine should be inspected at frequent intervals.
This section of the manual with its illustrations, photographs and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged
is not necessarily the preferred sequence. It is impossible to predict all
the machine troubles that will be encountered; therefore certain adjust-
ments may be required that have not been described in this section.
Thorough analysis of the troubles will indicate what corrective measures
must be taken other than those included in this manual. Adjustments
and repairs requiring special equipment and knowledge should be referred
to the Maintenance Department.
The machine and surrounding ﬂoor space must be free from all foreign
matter at all times.
Do not make any adjustments while the machine is in motion.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
Check the ﬁttings to see that they are being oiled and greased properly
by the lubrication engineer.
Make certain that the air currents around the machine are as nearly
normal as it is possible to keep them.
[12]
CALIBER .30 CASE BODY ANNEAL > Adjustments

Gas Burners The gas burners are the jets by means of which proper shape is given to
the gas ﬂame and a comparative steadiness of burning is assured. These
gas burners must be adjusted to direct their ﬂame on different sections
of the case body in order that the cases being annealed will meet the
specification of the Rockwell Test. Each burner is held in position by a
lock nut; and the position of the burner can be changed by loosening the
lock nut and moving the burner.


Gas _,h
Conduit

VIEW SHOWING GAS BURNER ADJUSTMENT
Tools: 1%” wrench, 18" pry bar.
Procedure: 1. Use a 34" wrench to loosen the locking nut on the gas burner.
2. If necessary, use the pry bar to raise the burner for higher annealing
or to lower the burner for lower annealing.
3. Use a 34" wrench to tighten the lock nut on the gas burner.
[13]
CALIBER .30 CASE BODY ANNEAL Adjustments
Clutch The clutch lever lock is the bolt that holds the friction driving wheel
Lever Lock ﬁrmly against the two power friction wheels. This clutch lever lock can
be readjusted by holding the friction drive wheel in a position where the
friction power causes it to rotate faster or slower. By this method the
speed with which the cases are conveyed along the conveyor screw is
regulated.


Clutch Lever
‘ . " " i—-- 1/8" Lock Nut
Friction Drive 5 I 5 _. , @ I ,. .
Wheel "‘*--. Clutch Lever
Lock
/ Machine Frame
Power Friction
Wheels


VIEW SHOWING CLUTCH LEVER LOCK
Tools: Two 7/8” wrenches.
Procedurei 1. Use two 7/8” wrenches to loosen the lock nut on the clutch lever lock.
2. Use a %" wrench to turn the adjusting nut clockwise until the clutch
lever lock holds the clutch lever in a position where it transmits power
to the conveyor screw at the desired speed.
3. Use two 7/8" wrenches to tighten the lock nuts.
[14]
CALIBER .30 CASE BODY ANNEAL
Adjustments

Feed Tube
Throat
Idler
Tools:
Procedure:
The feed tube throat is the opening of the feed tube into which the cases
fall from the conveyor belt of the paddle wheel hopper. This feed tube
throat should be in alignment with the conveyor belt so that the cases
will slide in freely. The feed tube throat can be adjusted to different
positions by loosening the Allen head holding bolts and placing the feed
tube throat in the desired position.
Conveyor
Belt
ii-U’/’
VIEW SHOWING FEED TUBE THROAT
%,>" wrench, 3/8" wrench.
1. Use a 542” Allen wrench to loosen the locking bolts on the feed tube
throat.
2. Raise the feed tube throat to the desired position.
3. Use a %" wrench to keep the nuts of the lock bolts from turning
while you tighten the bolts with a %2" Allen wrench.
4. Operate the machine and check the adjustment.
I15]
CALIBER .30 CASE BODY ANNEAL Adjustments

Feed Block The purpose of the feed block is to assist the cases to start their travel
along the conveyor screw. If the opening in the feed block does not line
up with the two horizontal bars known as the case guide track, it can be
loosened and shifted into the proper position.

VIEW SHOWING FEED BLOCK CLOSE UP SHOWING
FEED BLOCK ADJUSTMENT
Tool: 8” Screwdriver.
Procedure: 1. Use an 8" screwdriver to loosen the locking screws on the feed blocks.
2. Slide the feed block into a position where the slot in the feed slide
lines up with the case guide track of the conveyor screw.
3. Use an 8" screwdriver to lock the screw on the feed block.
[16]
CALIBER .30 CASE BODY ANNEAL Adjustments

Intake Valve The intake valve is the regulator for the ﬂow of the water into the reser-
and Drain Valve voir. The drain valve is the regulator for the draining of water from the
reservoir. The two valves must be regulated to maintain an even ﬂow
and a constant level of the water in the reservoir. This is accomplished
by opening or closing the valves manually until the water level remains
constant.
Inlet
Valve

VIEW SHOWING INLET VALVE AND DRAIN VALVE
Procedure: 1. Open the drain valve by hand by turning it counterclockwise.
2. Open the intake valve by hand, leaving it open until the water has
reached the overﬂow pipe. Then tighten the intake valve to a point
where water will maintain a level and even ﬂow.
I17]
CALIBER .30 CASE BODY ANNEAL Adjustments
_—_———_—_—_‘——_—___—_——
Idler The idler tightens the hopper conveyor belt. The hopper conveyor belt
should be taut in order to give a maximum amount of efficiency. If the
flow of cases is uneven, the belt probably is not taut. The stud that
holds the idler pulley bracket should be loosened and the idler pulley
should be pressed more ﬁrmly against the conveyor belt to make it taut
and to prevent slippage of the belt.


P II
V\l’heee)I " Conveyor
/ Belt
Clutc M3" Bolt
- F d T b
( Tllfoatu e
Feed Tube
VIEW SHOWING IDLER
Tool: 7/16" wrench.
Procedure: 1. Use a 7/16" wrench to loosen the bolt on the idler bracket on the hopper.
2. Raise the knurled idler pulley up against the belt to take the slack
out of the belt.
3. Use a 7/16” wrench to lock the adjusting nut.
[18] .
CALIBER .30 CASE BODY ANNEAL
Troubles and Corrections
Objective
Cases fail to
turn as they are
conveyed past
gas burners
Cases turn
faster in one
row than in
other row
TROUBLES AND CORRECTIONS
The adjuster will encounter troubles and defects in the operation of this
machine. ' It is impossible to anticipate all the problems that may confront
an adjuster, but the production troubles that most commonly occur,
their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection,
together with constant observation of the machine as it operates.
Visual inspection reveals that the cases are not turning as they are
conveyed past the gas burners.
The causes are: The corrections are:
1. The conveyor screw becomes
greasy or oily from an oil scum
collected on the top of the
water in the -reservoir.
1. Drain the reservoir and clean
the conveyor screw with a
cloth, making sure to clean the
angles of the square threads;
clean the reservoir thoroughly.
If the bottom of the square
thread channel seems to be
very smooth, roughen it slight-
ly with coarse emery cloth.
2. When the water is too low in . Keep the water in the reservoir
the reservoir, the guide bars high enough to touch the under
may warp out of alignment due side of the guide bars to pre-
to extreme heat; this causes vent an uneven expansion of
the track space to become too the bars.
narrow.
3. The space between the guide . Set the guide bars so that
bars is too wide or too narrow.
there is about .020 clearance
between the case and guide
bars. If necessary, experiment
for the clearance that works
best.
Visual inspection reveals that the cases in one row turn faster than the
cases in the other row, causing an uneven anneal.
The causes are:
The corrections are:
1. The guide bar spaces may not 1. Check the guide bar spaces for
be the same. uniformity and adjust them if
necessary.
2. Guide bar spaces may not be . Space the middle guide bar
centered over or parallel with
the conveyor screws.
evenly between the two con-
veyor screws.
[19]
CALIBER .30 CASE BODY ANNEAL
Troubles and Corrections
Cases fall over
teed block
Conveyor screws
jam and stop
Some of the cases fall over immediately after leaving the feed block.
when leaving The cause is:
1. There is an uneven tension on
The conveyor screws jam and stop.
the ball stops in the side of the
feed block.
The causes are:
1.
Some cases that have not been
head turned get into the feed
track and cause a jam.
There are damaged cases in the
feed track.
There is too much oil on the
surface of the friction drive
wheels which causes the wheels
to slip.
The drive belt is too loose or
oily.
A case has fallen down and
caused a jam at the curved
track outlet.
The correction is:
1. Remove the ball stops and
springs and clean thoroughly.
Test for free movement. Check
the spring for possible loss of
strength due to overheating.
Increase the pressure on the
lower ball just enough to cause
a slight jerk by the case as it
emerges from the feed block.
Then adjust the pressure on
the upper ball so that the case
leans slightly as it is pulled out
of the feed block by the con-
veyor screw.
The corrections are:
1. Clear the jam. More care
should be taken at the head
turn machine so that the cases
not head turned will not be
mixed with those that are.
2. Clear the jammed cases from
the case track and keep the
scrap cases out of the hopper.
3. Wipe off the surplus oil. If
slipping still occurs, roughen
the friction wheels slightly with
emery cloth. These friction
wheels should not be run en-
tirely dry however as they will
become worn. Apply a little
thin oil to prevent wearing and
slipping.
4. Wipe off all the oil and tighten
the belt slightly if necessary.
Do not tighten too much as the
belt should slip if bad jams
occur.
5. Adjust the feed block ball stop.
The operator should remove a
fallen case before it reaches the
curved track.
[20]
CALIBER .30 CASE BODY ANNEAL
Troubles and Corrections

Break is
too high
Rockwell tests by the Inspection Department reveal that the break is too
far from the head.
The causes are: The corrections are:
1. The water is too high in the 1. Regulate the water level so
reservoir. that the water does not rise
more than 1/1/6” on the guide
bars.
2. Too many gas burners are set 2. Test cases annealed with the
high. two ﬁrst burners directed near
the mouth of the cases; then
gradually drop the next four or
ﬁve burners to the level of the
desired break. Several of the
last burners should be set in
line with the break. These
burners will help heat the up-
per portion of the case, but
burners set higher than the
“break” level will not help
much to form the break. If the
break is still too high, lower
more burners to the level of the
break. Burners set too low
lose much of their effect due to
cooling by the water.
CALIBER .30 CASE BODY ANNEAL
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefﬁciency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬁat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[22]
CALIBER .30 CASE BODY ANNEAL
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
:q.®..°‘r‘>.°°.l\°
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
:‘~l?‘.°ltP‘.°°!\'>
Frequency of lubrication.
I23]
CALIBER .30 CASE BODY ANNEAL
Machine Lubrication
Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
. Bottle oiler.
. Ring oiler.
. Plain oil cups.
2
3
4
5. Drop feed cups.
6. Wick feed cups.
7. Mechanical, force feed, central lubricating system.
8. Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—-except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
[24]
CALIBER .30 CASE BODY ANNEAL Machine Lubrication

LUBRICATION CHART


. . N o. of Fittings, Frequency of
I/ubmcam Machine Part Grease Cups, etc. Lubrication Hours
GEAR COMPOUND Feed drive gears . . . . . . . . 1 24
(Red Can)
Driveshaft . . . . . . . . . . 2 8
Clutch lever mechanism and drive 3 8
MEDIUM OIL Hopper drive shaft . . . . . . . 2 8
(Red Oiler) Hopper idler pulleys . . . . . . 2 8
Hopper drive pulleys . . . . . . 2 8
Hopper paddles . . . . . . . . 4 8


I25]
CALIBER .30 CASE BODY ANNEAL
Index
Adjustment, Clutch Lever Lock, 14
Drain Valve, 17
Feed Block, 16
Feed Tube Throat, 15
Gas Burner, 13
Idler, 18
Intake Valve, 17
Anti-friction Bearings, 22
Available Gas Pressure, 11
Body Anneal, 2
Annealing Operation, 9
Break is Too High, 21
Cannelure Depth, 9
Case Drawing Operation, 2
Paddle Wheel Hopper, 8
Cases Fail to Turn as They Are Con-
veyed Past Gas Burners, 19
Fall Over When Leaving Feed
Block, 20
Turn Faster in One Row Than in
Other Row, 19
Clutch Lever Lock Adjustment, 14
Coil Spring Feed Tube, 8
Conveyor Belt, 5, 8
Screw, 4, 6, 7, 8
Screws, 4, 6, 7, 8
Screws Jam and Stop, 20
Speed, 1
INDEX
Cross-shaft, 5
Drain Valve Adjustment, 17
Drive Wheel, 3
Feed Block, 5
Block Adjustment, 16
Tube Throat Adjustment, 15
Finish Laboratory, 10
Floor Space, 1
Flow Chart, 8
Friction, 22
Gas Burners, 4, 6, 8
Burners Adjustment, 13
Grease, 23
Head Thickness, 9
Height, 1
Hints on Lubrication, 24
Hopper Box, 5
Idler Adjustment, 18
Intake Valve Adjustment, 17
Lubricating Film Reduces Friction, 22
Lubrication, 22
Chart, 25
Methods, 23
Machine Description, 1
Frame, 4
Motor, 1
Manufacturer, 1
Metal Hood, 4
Methods of Getting Lubricant to
Bearing Surface, 24
Motor, 3
Belts, 3
Objective of Troubles and Correc-
tions, 19
Outside Diameter of Case Body, 9
Head Diameter, 9
Over-all Length of Case, 9
Overhead Hopper, 8
Paddle Wheel Hopper, 4, 5
Wheel Shaft, 5
Pinion Gear, 5
Pocket Depth, 9
Diameter, 9
Power, 3, 4
Production, 1
Reservoir, 4
Rockwell Hardness Tester, 10
Reading Speciﬁcations, 10
Test, 10
Selecting a Lubricant for a Given
Bearing, 23
Tools, 1
Transmission, 3, 4
Type of Feed, 1
V-type Belt, 3
Web Thickness, 9
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Taper and Plug
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 194-]
United States GlW('l‘IlfIlt'l'lIZ (‘-ontract
W-ORD-4-81, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenalearly in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, he ﬁned not more than
$10,000.”
(June 5, 1917 , C30,Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public N o. 443, 7 6th Congress, 3rd Session).
II
MANUAL CORRECTIONS—CALIBER .30 CASE TAPER AND PLUG
LOCATION
Page 2- 112
Page 5- ‘j 2
Page 11 — ‘J 1
Page 1.2- 1 5
and Fig
Page 16- II 1
Page 17- 1] 6
Page 18- ll 5
Page 20- 115
ERROR
4 V-Belts
The inner ram is counterbalanced by 2 coil
springs
The stripper arm is actuated through a
rocker arm from a cam surface on the
ram
Detector Punch Holder
2nd Forming
4 V-Belts
2nd Forming
After Taper and Plug, cases are sent to
Finish Trim
CORRECTION
3 V-Belts
The outer ram is counterbalanced by 2 coil
springs
The stripper arm is actuated through a cam
rocker arm from a roller on the ram
Ejecting Stem Holder
Omit-not used
3 V-Belts
Omit-not used
After Taper and Plug, cases are sent to
Washer to remove lubricant
MANUAL CORRECTIONS—CALIBER .30 CASE TAPER AND PLUG (Cont.)
LOCATION ERROR
Page 21 —Fig 3
Page 26- ‘J 1 Seven Stations
Page 33- ‘I 1 When the clutch is engaged
Page 35 — ‘I 1 Plug Punch on left front of ram
Page 40—-Crooked
Heads No. 2
CORRECTION
Omit
Six Stations
When the clutch is disengaged
Plug Punch on right front of ram
Omit—does not apply
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tool Servicing. . . . . . . . . I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
III

CALIBER .30 CASE TAPER AND PLUG MACHINE
IV
CALIBER .30 CASE TAPER AND PLUG
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Feed Motor
Production
Crankshaft Speed
Stroke
Tools
Floor Space
Height
Weight
CATALOGUE DATA
E. W. Bliss Co., Brooklyn, New York
E. W. Bliss No. 162 vertical frame, double action,
crank press. 3 V belt drive, motor to ﬂywheel on
crankshaft.
Geared head motor; 3 h.p. ; 3 phase; 60 cycle; 220/
440 volts; 1725 R.P.M.
Paddle wheel hopper
Geared head ;1 / 15 h.p.; 1 phase; 60 cycle; 115 volts.
94 per minute
94 R.P.M.
4 in.
Piece No.
First Taper
Shoulder die M- 1
Body die M- 2
Ejecting stem M-11
Second Taper
Shoulder die M- 3
Body die M- 4
Ejecting stem M-12
Plug
Plugging punch M- 5
Mouth expander punch M-14
3% ft. x 4 ft.
7 ft. 11 in.
8,000 lbs.
CALIBER .30 CASE TAPER AND PLUG Machine Description

MACHINE DESCRIPTION
The Caliber .30 Case Taper and Plug Machine reduces the size of thg
mouth end of the case, to form the neck and shoulder.
. H O I . V
‘< '=" 1 = .
T . " " g _
9 ‘I > n 0 - .-s . I I
T‘ Wu I |tI\‘v-‘Mill .»mm. .-
...._ _
‘Q . _'_ 0 .
1 I 4 - . W
' Q , _ .- -'_ .
~. - _..
_ ,, . ‘_ ‘
Machine Motor
I
o
'0
'0
2


Springs
Feed Tube
' Guard Covering
‘ Flywheel
Brake ‘ H
T
in
'___'- Crankshaft
. I
>
I
'-
Feed Finger
Assembly
Ram
CALIBER .30 CASE TAPER AND PLUG MACHINE
Power and The E. W. Bliss vertical crank press, illustrated above, is powered by a
Transmission three h.p. motor through four V-type leather belts connecting the motor
to the ﬂywheel.
The motor is mounted directly above the ﬂywheel on an adjustable bracket
which allows proper adjustment of belt tension. The motor bracket is
bolted to the top of the machine frame.
The ﬂywheel is mounted to the right end of the crankshaft and incorporates
a rolling key clutch for the transmission of power from ﬂywheel to crank-
shaft.
[2]
CALIBER .30 CASE TAPER AND PLUG
Machine Description

Power and
Transmission (Cont.)
Crankshaft
Ra ms
Index Dial
Liberty Paddle
Wheel Hopper
Feed Block
Index Mechanism
Case Kickoff
The motor is controlled by a push button type switch; the red button stops
the motor, and the black button starts it.
The crankshaft is of the double throw type incorporating two eccentric
cams which operate the inner ram and the indexing dial rocker arm. A two
shoe brake is attached to the left end of the crankshaft, outside the ma-
chine frame, and operates in conjunction with the clutch. When the clutch
is released, the brake is applied and vice-versa. The brake at all times
applies a slight drag to the crankshaft to reduce backlash to a minimum.
The ram is held by and guided in its vertical stroke by two V-shaped gibs.
The outer ram is actuated by, and connected to, the crankshaft throw by
two connecting rods. The outer ram is machined to hold the case forming
dies. The inner ram is actuated through a cam follower arm from an
eccentric cam on the crankshaft. The inner ram is machined to hold the
ejecting stems which position and release the cases from the dies on the up
stroke of the outer ram.
The index dial is mounted on a vertical hub about which the dial rotates.
The dial is equipped with a number of carrier plates which support the
cases in an upright position as they move through the various stations.
The index dial is actuated through linkage from an eccentric cam on the
crankshaft. The dial moves one space at a time with every complete
stroke of the crankshaft. The index dial is held in, and rotates in, the dial
block.
The liberty paddle wheel hopper is mounted on the left side of the machine
frame above the crankshaft. The hopper is driven through a V-type leather
belt from a 1/15 h.p. electric motor which is mounted on the hopper bracket
below the hopper shaft. The cases are fed into the hopper box through a
chute from an overhead source. The cases are picked up by a series of
paddles which lift them to the conveyor belt. The conveyor belt carries
the cases to an opening where the cases enter the opening which leads to
the feed tube mouth. The cases drop head ﬁrst through the feed tube to
the feed block.
The feed block is bolted to the machine bed at the eight o’clock position in
relation to the index dial. The cases drop from the feed tube into the feed
block and are inserted into the carrier plate by the feed ﬁnger. The feed
ﬁnger is actuated through linkage from the outer ram.
The lower face of the dial is equipped with pawl ring teeth into which the
pawl ﬁnger ﬁts to rotate the dial.
The indexing mechanism is bolted to the machine bed at approximately
the two o’clock position in relation to the dial plate. A dial check arm is
bolted to the machine bed at the twelve o’clock position in relation to the
dial plate and is operated through linkage from the indexing mechanism.
The check arm acts to hold the dial plate in position as the rams lower to
perform each operation.
The case kickoff is mounted to the hub of the dial plate and extends for-
ward in the six o’clock position to the outer circumference of the dial plate.
The case kickoff face, at a position above the carrier plates, is curved to
push the cases from the carrier plates as the dial rotates, bringing the cases
to the conveyor chute.
I3]
CALIBER .30 CASE TAPER AND PLUG Machine Description

Cam Indexing Rocker Eccentric
Follower Arm Cam
Eccentric Carn for
Crankshaft Inner Rarn Clutch
I
A _ ,. . < I ll"jj‘|"‘l"‘."lit§§-
iml mfllm lllllu I .
I .. 7 ‘ I I -V "'I';'?';*:"’|’:I]l"u|'F.:I"
j " “ V !II"II
' ll“iIi'Ill*,"IIl
<21“ _ -Iihjliiljjl rm

Connecting Ram Eccentric Eccentric Cam for Crankshaft Connecting
Rod Cam Inner Ram Rod
FRONT VIEW OF CRANKSHAFT REAR VIEW OF CRANKSHAFT
Crankshaft The crankshaft is held in a horizontal position above the machine bed by
two bearings. The crankshaft consists of two throws to which the connect-
ing rods are attached. An eccentric cam operating the indexing rocker arm
is mounted on the crankshaft just inside the machine frame. A second
eccentric cam is mounted between the connecting rod throws and actuates
the inner ram of the press.
The machine brake is mounted around a small brake drum on the outside
of the machine frame at the left side. The rolling key clutch is incorporated
in the ﬂywheel which is mounted on the right end of the crankshaft.
Power is controlled from the ﬂywheel to the crankshaft through the man-
ually operated clutch. The brake works in conjunction with the clutch to
stop the machine when the clutch is disengaged.
l4l
CALIBER .30 CASE TAPER AND PLUG Machine Description
-|1I||'
“II
'|iii,,l"'l"lll"
"Hill"
, mil -"l||,“l
. II ""‘IIi '1'
.,|"'lII',- "U! Eccentric
mI‘|:mhl'I“g'/e‘ Cum


Crankshaft ii.“
\i
. ‘ ‘ .
- - Y ’ §ZZI'IBCtII“IQ
Brake __
V Gib -\
FRONT VIEW OF RAM
Ra ms The press incorporates two rams, one working inside the other. The outer
ram is connected to the crankshaft by two connecting rods which are
attached by bearings and wrist pin arrangements. The outer ram travels
in its vertical stroke in two V-shaped gib plates. The gibs are adjustable to
reduce to a minimum the opportunity of back lash and wear to cause undue
damage to the tools. The face of the outer ram is machined to hold the
forming dies.
The inner ram travels in its vertical stroke inside the outer ram. The
action of the eccentric cam on the crankshaft is transmitted to the inner
ram through a cam follower piston. The upper end of the piston has at-
tached a cam roller wheel which follows the eccentric cam. The piston
operates in a vertical motion in a sleeve which is a machined part of the
outer ram. The inner ram is counterbalanced by two coil springs which
are held on two metal rods and are compressed against a bracket, bolted
to the top of the machine frame, on each down stroke of the ram. The
inner ram is machined to hold the ejecting stems.
l5l
CALIBER .30 CASE TAPER AND PLUG Machine Description

Stripper
Feed Finger Fingers
Operating
Arm
Index Dial
Feed Finger
Feed Finger
Block

INDEX DIAL AND FEED ASSEMBLY
Index Dial The dial mechanism consists of the following parts: dial block, dial ring,
dial head, and sixteen dial carrier plates. The dial block is attached to the
bed of the machine by four bolts. The dial ring is attached to the inner
circumference of the dial block by four Allen head screws. The dial head
revolves carrying the cases, which are held upright by the carrier plates,
from station to station. The dial is attached and rotates inside the dial
ring by a stud running through the center of the head to the machine bed.
The dial carrier plates are evenly spaced around the circumference of the
dial head. The dial head is machined to seat the carrier plates ﬂush with
the dial head surface. The forward edge of the carrier plates are notched
to receive the cannelure groove of the case head. An anvil is provided in
the dial head beneath each forming station to support the case as the form-
ing operation is completed. A button anvil is provided in the dial head
beneath the oiler and plug punch stations.
[6]
CALIBER .30 CASE TAPER AND PLUG
Machine Description
Cam Follower ‘- .
Eccentric Cam -__- A . ;
I
Indexing Dial Arm —
Spring _____
Indexing
Mechanism


$0
Crankshaft
O
REAR VIEW SHOWING INDEXING MECHANISM
The dial head is actuated about its hub through linkage from the eccentric
cam on the crankshaft. The pawl arm travels back and forth in a gib ar-
rangement which is bolted to the machine bed facing the dial head at the
two o’clock position. The pawl arm is actuated through a rocker arm
which is attached at its pivotal point to the machine frame. The upper end
of the rocker arm is ﬁtted with a cam roller which rides against the eccen-
tric cam. A pawl ﬁnger is attached to the forward end of the pawl arm and
, engages notches beneath the dial head to move the dial one space with
every revolution of the crankshaft.
l7l
CALIBER .30 CASE TAPER AND PLUG Machine Description

_ Die Holders


6.
Indexing Paw! ____ _
-_.. Eiecting
Stems
“‘- Dial
I Ierlocking
n Fingers ’ -__ Check Arm
Block
__ Spring Over
Check Arm
REAR VIEW OF DIAL SHOWING CHECK ARM
Check Arm The check is a bar actuated from the pawl arm, which enters in specially
cut notches in the dial head to hold the dial head secure as the ram is
brought down by the crankshaft. The check arm is held to the machine
bed by two check arm blocks. One block is bolted to the machine bed close
to the dial head. The other is spaced about eight inches back, holding the
check arm parallel to the pawl arm. The check arm is actuated through an
interlocking ﬁnger arrangement Which inserts the check arm into the dial
head as the indexing pawl comes back from its forward stroke.
[3]
CALIBER .30 CASE TAPER AND PLUG
Machine Description
Hopper Motor
Belt Guard
Hopper
Motor

Machine
Brake
Paddles
SIDE VIEW OF PADDLE WHEEL
HOPPER
Paddle Wheel
Hopper
Hopper Belt
Guard
Hopper
Hopper Feed
Motor
Pipe
T\/Iotor
Bracket
Hopper Wheel
Housing
Feed
Tube
Hopper
Bin
TOP VIEW OF PADDLE WHEEL HOPPER
The paddle wheel hopper is mounted on a bracket which is bolted to the
top of the machine frame on the left side. The paddle wheel is mounted
on a shaft which extends through the hopper to mount a pulley wheel.
The pulley is belt-driven from the motor, which is mounted to a bracket
below the pulley wheel.
The cases are fed through a chute from an overhead source, and are picked
up by a series of paddles which lift them to a conveyor belt. The cases
roll from the paddles lengthwise onto the conveyor belt. The belt con-
veys them to the feed tube opening where they fall head ﬁrst into the
feed tube mouth. The feed tube mouth is so arranged, that if a case is con-
veyed mouth ﬁrst to the feed tube, the mouth end will overshoot the open-
ing, allowing the case head to drop into the feed tube. -
I9]
CALIBER .30 CASE TAPER AND PLUG Machine Description


— Feed Tube
Feed Finger
Feed Block
________2-“l:1’—':L"m"""‘!""'""mItmn
Sprmg C t _.
L _4.
SIDE VIEW OF FEED BLOCK ASSEMBLY
Feed Block The cases are fed through the feed tube from the hopper to the feed block.
The feed block houses the feed ﬁnger, which is made up of two parts. The
upper part of the ﬁnger is adjustable while the lower part is not. The feed
ﬁnger is guided by two feed ﬁnger guides which are attached to the bed of
the feed block by two bolts in each guide. At the end of the feed block
there are two guide plates which are attached to the bed of the feed block.
The head of the case slides through the guide plates into the carrier plates.
The feed ﬁnger is cam-operated and uses two springs, for pressure, to feed
the cases into the carrier plates. The springs pull the feed ﬁnger forward
and the feed ﬁnger arm pulls the ﬁnger back. The feed ﬁnger arm is
actuated by a rocker arm which strikes against a roller attached to a
bracket on the ram.
Operating __
Arm Feed
Finger
Spring
Feed Block
TOP VIEW OF FEED BLOCK
I 10 I
CALIBER .30 CASE TAPER AND PLUG Machine Description


Cam
Plug Punch _I
Holder
—Rocl<er Arm
‘ f Y‘ Stripper Arm
FRONT VIEW SHOWING STRIPPER ASSEMBLY
Stripper The stripper is cam operated and has a stripper block which covers the
stripper ﬁnger, stripper arm and two springs. The stripper arm is actuated
through a rocker arm from a cam surface on the ram. The stripper arm is
brought back by the rocker arm and is pulled forward by the two coil
springs. The stripper block is attached to the machine bed by two bolts.
Its purpose is to hold the case securely as the plug punch is withdrawn from
the case.
[11]
CALIBER .30 CASE TAPER AND PLUG
Tool Holder Description
TOOL HOLDER DESCRIPTION
Die Holder
Assembly
Q
i
\
LI.
1' .
. .12 V,
k3‘;
Plug Punch Holder
Assembly
“4
(
ll
5
Detector Punch
Holder Assembly
Die Holder: The die holder is cylindrical and threaded its entire
length on its external surface. The die holder is tubular for the inser-
tion of the dies. A spanner wrench shoulder is machined on the die
holder at a point near its lower end. A spanner nut is threaded
on the external surface of the die holder above the spanner shoulder.
Six evenly spaced holes are drilled in the outer circumference of
the spanner nut and spanner shoulder for the application of a
spanner wrench.

Die Holder Gap: The die holder cap is cup shaped; the enclosed
end has a hole drilled through the center longitudinally for the
entrance of the case into the forming die. Six evenly spaced holes are
drilled along the outer circumference for the application of a spanner
wrench. The lower shoulder of the cap is machined to form a con-
cave groove. The opening end of the cap is internally threaded for
application to the die holder to secure the die inside the holder.
Plug Punch Holder: The plug punch holder is cylindrical with a
hexagonally machined head. The plug punch holder is threaded ex-
ternally from the lower end to hexagon head. A hexagonal head
nut is threaded on the holder to lock it into the punch holder bracket.
The plug punch holder is drilled longitudinally through its center
for the insertion of the plug punch. The plug punch rests on a
shoulder, machined within the punch holder.

Anvil Stud: The hexagonal headed anvil stud is longitudinally
drilled through its center for the passage of a lubricant to the plug
punch. The anvil stud is externally threaded from beneath the
hexagon head for a distance equal to one third of its over-all length.
The stud is machined to a slightly smaller diameter from the thread
ends to the lower end of the stud.
Detector Punch Holder: The hexagonal head detector punch holder
is externally threaded from the head to the lower end. The hexagon
head of the detector punch holder is longitudinally drilled for the
insertion of the detector punch. The punch is locked into the hol-
der by a screwdriver slotted set screw which is threaded through
one land of the hexagon head.

[12]
CALIBER .30 CASE TAPER AND PLUG
Tool Description


TOOL DESCRIPTION
MOUTH EXPANDER PUNCH


FIRST SHOULDER DIE
FIRST BODY DIE


SECOND SHOULDER DIE


Tool Name:
Piece No.: M-14
Location: Tool head on ram
Normal Life: 200,000 pieces
Mouth spreader is made of tool steel, hardened,
ground and polished.
Mouth Expander Punch
Tool Name: First Shoulder Die
Piece No.: M-1
Location: Tool head, above ﬁrst body die on ram
Normal Life: 100,000 pieces
First shoulder die is made of tool steel, hardened,
ground and polished.
Tool Name: First Body Die
Piece No.: M-2
Location: Tool head, below ﬁrst shoulder die on
ram
Normal Life: 45,000 pieces
First body die is made of tool steel, hardened, ground
and polished.
Tool Name: Second Shoulder Die
Piece No.: M-3
Location: Tool head, above second body die on
ram
Normal Life: 100,000 pieces
Second shoulder die is made of tool steel, hardened,
ground and polished.
I13]
CALIBER .30 CASE TAPER AND PLUG
Tool Description


SECOND BODY DIE


PLUGGING PUNCH
~wm
FIRST EJECTING STEM
SECOND EJECTING STEM
Tool Name: Second Body Die
Piece No.: M-4
Location: Tool head, below second shoulder die
on ram
Normal Life: 45,000 pieces
Second body die is made of tool steel, hardened,
ground and polished.
Tool Name: Plugging Punch
Piece No.: M-5
Location: Bracket bolted on side of ram
Normal Life: 166,000 pieces
Plugging punch is made of tool steel, hardened, ground
and polished.
Tool Name: First Ejecting Stem
Piece No.: M-11
Location: Secondary ram in center of die
Normal Life: 400,000 pieces
First ejecting stem is made of drill rod, hardened
and ground.
Tool Name: Second Ejecting Stem \
Piece No.: M-12
Location: Secondary ram in center of die
Normal Life: 400,000 pieces
Second ejecting stem is made of drill rod, hardened and
ground.
.[14|
CALIBER .30 CASE TAPER AND PLUG
Process Sequence

Overhead Hopper
Paddle Wheel
Hopper
Conveyor Belt and
Feed Throat
Feed Throat
Coil Spring Feed
Tube
Feed Finger
Dial Index Head
Station I
Oiling and
Detector
Station 2
Mouth Spreader
Station 3
First Forming Die
PROCESS SEQUENCE
Cases are fed by gravity from an overhead source down into the overhead
hopper and flow through a feed pipe to the paddle wheel hopper.
The cases ﬂow down an incline into the bottom of the paddle wheel hop-
per, passing under the baffle plate to the paddle wheel. As the paddle
wheel rotates clockwise, the paddles pick up the cases and convey them
up to the side edge of the hopper where they roll off onto the conveyor
belt.
The cases‘ are conveyed horizontally, in a single ﬁle, to the feed throat at
the end of the conveyor belt.
Because the head end is heavier than the mouth, the cases fall into the
feed throat head ﬁrst. Cases are assisted through the feed throat by a
leather friction disc, then drop into the coil spring feed tube.
The cases ﬂow by gravity through the coil spring feed tube into the bush-
ing where they stop in a vertical position, head down, and rest on top of
the feed ﬁnger.
As the feed ﬁnger moves back, the case drops down onto the feed ﬁnger
base. As the feed ﬁnger moves in, the cases are pushed past the spring stop
which keeps them upright. The cases then pass into the carrier, one at a
time. ‘
The carrier plate and rim of the dial head hold the cases in an upright
position as they travel, clockwise, past each one of the six stations. The
dial head moves on the upward stroke of the ram after the dies clear the
case.
As the dial head conveys the case to the ﬁrst station, the case is lubricated
inside and outside by felt pads covered with a soap solution. As the ram
moves down, the detector pin enters the inside of the case to detect foreign
matter or a thick web. If the detector pin strikes the web or any foreign
matter, it will stop the machine at the top of the stroke, by throwing out
the clutch. Defective cases can be removed through a gate in the edge of
the dial head. The dial head conveys the case to station 2 on the upward
stroke of the ram, after the tools leave the case.
The mouth expander punch enters the mouth of the case as the ram moves
down and slightly flares and sizes the mouth. The dial head conveys the
case to station 3 on the upward stroke of ram.
At this station, the ejecting stem enters the mouth of the case to help pre-
vent its collapsing as the ﬁrst forming dies descend upon the case to begin
the formation of the neck and shoulder. As the ram moves up, the ejecting
stem holds the case ﬁrmly in place until the dies are free from the case.
The dial head conveys the case to station 4.
I15}
CALIBER .30 CASE TAPER AND PLUG
Process Sequence
Station 4
Second Forming
Die
Station 5
Finish Forming Die
Station 6
Plug Punch
Ejection and
Disposal
At this station, the ejecting stem enters the mouth of case to help prevent
its collapsing while the second forming die makes the neck and shoulder
taper more pronounced. As the ram moves up, the ejecting stem holds the
case ﬁrmly in place until the dies are free from the case. The dial head
then conveys case to station 5.
At this station, the ejecting stem enters the mouth of the case to help pre-
vent its collapsing while the ﬁnish forming die completes the forming of
the neck and shoulder. As the ram moves up, the ejecting stem holds the
case ﬁrmly in place until the dies are free from the case. The dial head
then conveys the case to station 6.
At this station, the plug punch enters the mouth of the case and sizes it
to the correct diameter. As the plug punch enters the case, the stripper
moves in and holds the carrier plate down while the plug punch withdraws.
The plug punch is oiled with lard oil to decrease friction.
As the dial head continues to turn, the case comes in contact with the
curved ejecting bar which forces the case out of carrier and onto a con-
veyor under the press. The dial head continues to turn, picking up another
case from the feed ﬁnger, and repeats the above operation.
[16]
CALIBER .30 CASE TAPER AND PLUG
Process Sequence

FLOW CHART


Overhead Hopper
The cases are fed by gravity from an overhead
source, down into the overhead hopper and then
ﬂow through a feed pipe down to the paddle wheel
hopper.


Paddle Wheel Hopper
The cases flow down an incline past the baffle plate
into the bottom of the paddle wheel hopper. Paddles
pick up the cases and convey them up to the edge
of hopper where they roll off onto the conveyor belt.


A 1/15 h.p. reduction gear mo-
tor powers the paddle wheel
through bevel gears, shaft,
pulley and V-type belts.


Conveyor Belt
Conveys the case, in a horizontal position to the
feed throat which is located at the end of the con-
veyor.


Conveyor belt is powered
from the pulley, through a
ﬂat leather belt, shaft, and
pulley.


Feed Throat
The cases fall into the mouth of the feed throat,
head end ﬁrst, and are assisted through the feed
throat by a leather friction disc, after which they
fall into the coil spring feed tube.


Coil Spring Feed Tube
The cases ﬂow by gravity through the coil spring
feed tube, into the bushing where they stop in a
vertical position, head down, and rest on the top of
the feed ﬁnger.


The friction disc is powered
through a pulley at the end
of the conveyor belt.


Feed Finger
As the feed ﬁnger moves back, the case drops down
onto the feed ﬁnger base. It then moves forward,
pushing the cases past the spring stop, one at a
time, into the slot in the carrier plate which is on
the dial head.


“ l

Actuated by spring action
through horizontal rocker
arm, to vertical rocker arm,
roller on ram through con-
necting rod crankshaft,
clutch, ﬂywheel, and four V-
type belts from a 3 h.p. mo-
tor.


[17]
CALIBER .30 CASE TAPER AND PLUG Process Sequence

FLOW CHART (Cont.)

Dial Head Powered through lever, slide,
The carrier plate and the rim of the dial head hold links to rocker arm, cam fol-
cases ﬁrmly in an upright position, as they travel lower, to cam on crankshaft,
clockwise to the different stations. and clutch from flywheel.


Station 1—Oiling and Detecting
As the ram moves down, the detector punch enters
the case to detect foreign matter or a thick web. At
this station, the outside of the case and the inside
of the case mouth are oiled. As the ram moves up,


the dial head conveys the case to the second station.


Station 2—Mouth Spreader

As the ram moves down, the mouth expander punch Powered through ram, con-
enters the mouth of the case, slightly ﬂaring and necting rod, crankshaft, and
sizing the mouth. As the ram moves up, the dial clutch, from the ﬂywheel.


head conveys the case to the third station.


Station 3—First Forming Die

At this station the ejecting stem enters the mouth
of the case to help prevent its collapsing while the
ﬁrst forming die starts to form the neck and shoulder.
The stem holds the case ﬁrmly in the carrier plate
while the die moves up. The dial head turns, con-
The stem is powered through
a secondary ram, cam follow-
er, cam on crankshaft, and
clutch, from the ﬂywheel.


veying the case to station 4.


Station 4—Second Forming Die
At this station the ejecting stem enters the mouth
of the case to help prevent its collapsing while the
second forming die makes the neck and shoulder
taper more pronounced. As the ram moves up the
stem holds the case ﬁrmly in the carrier plate. The
dial head turns, conveying the case to station 5.


I [18]
CALIBER .30 CASE TAPER AND PLUG Process Sequence

now CHART (Cont.)
l
Station 5—Finish Forming Die
At this station, the ejecting stem enters the mouth
of the case to help prevent its collapsing while the
ﬁnish forming die completes the forming of the
neck and shoulder. As the ram moves up the stem
holds the case ﬁrmly in the carrier plate. The dial
head turns, conveying the case to station 6.


Station 6——Plug Punch
At this station the plug punch enters the mouth
of the case, sizing it to proper diameter. As the
plug punch withdraws, the carrier plate is held
down by a stripper bar which has a slot to enclose
Powered through ram, con-
necting rod, crankshaft, and
clutch, from the ﬂywheel.


the case.


Ejection and Disposal
As the dial head continues to index, the case is
forced out of the carrier plate by a curved ejecting
bar. The case drops onto a conveyor under press.
The dial continues around, picks up another case
from the feed ﬁnger and repeats the above oper-
ations.


CALIBER .30 CASE TAPER AND PLUG Product Description

PRODUCT DESCRIPTION
The component, when received by the taper and plug machine, is in the
form of a case as shown in Fig. 1.
The case is made of brass (70% copper 30% zinc). The closed end of the
case is known as the head, and the open end as the mouth.
The cases are received by the Taper and Plug Department from the Body
Annealing Department where the bodies are annealed. The cases are de-
livered to the Annealing Department from the head turn machine.
The dimensions of the case are as follows:
Before taper and plug After taper and plug
Operation Operation
Outside diameter of the head Outside diameter of the head
.467—.471 .467-.471
Head thickness .043-.048 Head thickness .O43—.048
Cannelure depth .403—.407 Oannelure depth .403-/107
Pocket depth .125—.129 Pocket depth .125—.129
Pocket diameter .2093—.2098 Pocket diameter .2093-.2098
Over-all length approx. 2%" Over-all length approx. 2%”
Inside diameter of mouth .3070-
.3078
Length of case from head to bot-
tom of shoulder 1.950—1.9558
Length of neck from mouth to
shoulder .3832
Diameter at bottom of shoulder
.4330—.4385
Diameter at top of shoulder .3393
—.3397
Outside diameter at mouth .3373
Inside of taper on outside wall
from head to bottom of shoulder
.0165
After the taper and plug operation the cases are sent to the ﬁnish trim
machine for ﬁnal trimming of the case to length.
[20]
CALIBER .30 CASE TAPER AND PLUG Product Description
\
The stages through which the case progresses in the formation of the
mouth, neck and shoulder are:


ls-4 ‘-

ii-' '
= ‘~l"l*'*s‘ ‘~iI;’“'.$’ .2- of
FIG. 1 FIG. 2 FIG. 3 FIG. 4
BEFORE TAPER AFTER FIRST AFTER FINAL AFTER FINAL
AND PLUG FORMING OPERATION FORMING OPERATION SIZING OPERATION
I21]
CALIBER .30 CASE TAPER AND PLUG
lnspecﬁon
Visual
Gage Cure
Gages
INSPECTION
At frequent intervals, after the taper and plug operation a careful visual in-
spection of the cases must be made. The cases should be inspected for marks
on the body and head, split necks, wrinkled necks, and bulges on the body.
These defects indicate an immediate adjustment of the machine is neces-
sary to correct the fault. Whenever defective cases are found, the lot from
which they come must be removed from the machine and properly iden-
tiﬁed, so they will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use, or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool since heat causes expansion of
of the metal and results in a temporary variation of the case size.
The inside of the mouth of the case is PLUG GAGE
gaged with a “go” and a “no go" plug
gage. The “go” plug must enter the
mouth of the ease and the “no go” must
not enter.
TAPERING GAGE
The diameter of the body is
gaged with two tapering gages;
one is the “go” and the other,
“no go.” The case must enter
the “go” tapering gage all the
way to the head, but must enter
the “no go” gage only part way.
If the case enters the “no go”
gage all the way, it indicates
that the case is too small.


RING GAGE
The depth of the shoulder is gaged with a
ring gage. The gage is tapered and the case
must enter all the way to the extractor groove.


[22]
CALIBER .30 CASE TAPER AND PLUG
Inspection
Gages (Cont.)
HEAD-TO-SHOULDER GAGE
The head-to-shoulder gage is used to
check the distance between the head
and the shoulder of the case. The
case must pass the “go” step and
must not pass the “no go” step.


PROFILE GAGE
The proﬁle of the case is checked
by a proﬁle gage. The case must
lie ﬂush in the proﬁle slot.


The above described methods are those most commonly employed in the
taper and plug operation of a Caliber .30 case. However, other methods
may be developed to maintain the manufacturing standards.
[23]
CALIBER .30 CASE TAPER AND PLUG
Adjustments
ADJUSTMENTS
Objective To maintain satisfactory production a machine must be adjusted to com-
Cautions
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than the starting button to determine
whether the clutch is disengaged.
Make frequent inspection to determine whether proper and suflicient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
No adjustments are to be made on this machine until it has been deter-
mined that the componants received by the machine are within allow-
able tolerances.
[24]
CALIBER .30 CASE TAPER AND PLUG
Adjustments

Index Dial


Spﬁng
Tools:
Procedure:
The index dial located on the machine bed carries the cases through their
successive steps in the tapering and plugging operations. The dial must
stop at each station where an operation is performed. If the dial fails
to stop directly on station, the cases in the dial will not be directly under
their respective dies or punches. To insure the dial’s stopping on station,
the pawl that turns the dial can be shortened or lengthened in its stroke.
REAR VIEW SHOWING INDEX DIAL ADJUSTMENT
3/4" Cop Screw
/ Pawl Bloclc
_/K ‘ ____,..- Adjusting Screw
*x)~____1/2" Lock Nuts
Q
Q, '
d"'~|“ .


3 " wrench, 1/” wrench, 1/ " in wrench, ﬂ wheel bar.
4 2 8 Y
1.
2.
Remove the rear guard.
Engage the clutch and use ﬂywheel bar to turn the ﬂywheel until the
ram reaches the end of its stroke.
. Use a 1/2" wrench to loosen the lock nuts on the rear of the pawl
block adjusting screw.
Use a 34 " wrench to loosen the cap screw on the pawl block.
Use a }/8" pin wrench to turn the pawl block adjusting screw until the
dial check is all the way in the dial.
Note: When the dial check is all the way in the dial, the dial is on
station.
Use a 3/4 " wrench to tighten the cap screw on the pawl block.
Use a }/2" wrench to tighten the lock nuts on the rear of the pawl
block adjusting screw.
Replace the rear guard.
I 25 I
CALIBER .30 CASE TAPER AND PLUG Adjustments
Carrier Plate The purpose of the carrier plates on the indexing dial is to carry the cases
Replacement to the seven stations on the machine. The carrier plates can be replaced
when they are worn or damaged. If the carrier plates become worn or
chipped, the cases will tend to lean instead of remaining in an upright
position as they are carried to the seven stations.

. ' Screws
lndexmg /
Pawl 7
Index
/ Dial
. Cartier
; _ Plates
Interlocking
Fingers
if Dial
> _-- Check
Housing
REAR VIEW SHOWING INDEX DIAL AND CARRIER PLATES
Tool: 8" screwdriver.
Procedure: 1. Remove the guard on the front of the machine.
2. Use an 8" screwdriver to remove the set screw in the carrier plate.
Then remove the carrier plate.
3. Replace with a new carrier plate and tighten the set screw with an 8"
screwdriver.
4. Replace the guard on the front of the machine.
[261
CALIBER .30 CASE TAPER AND PLUG
Adjustments
Body Anvils

TOOI5:
Procedure:
Body anvils are the small steel buttons that force the cases against the
carrier plates at the ﬁrst and second forming stations. The purpose of
these anvils is to hold the cases in an upright position so that when the
dies are brought down to form the case they will not strike the edges
and damage the case. These anvils are equipped with a spring and an
adjusting bolt which will regulate the pressure exerted on the heads of
the cases.
1%" Lock Nuts
3/4” Anvil
_ Adjusting Bolts
- -it-*$'~ :
BOTTOM VIEW OF MACHINE SHOWING THE THREE
ANVIL ADJUSTING BOLTS
1%" wrench, % ” wrench, offset screwdriver, flywheel bar.
1. Remove the front guard and the ﬂywheel guard gate.
2. Engage the clutch; use the ﬂywheel bar to turn the ﬂywheel until the
dial moves to a position on station.
3. Use the offset screwdriver to remove the carrier plate and screw.
4. Use a 11/4 " wrench to loosen the lock nut on the anvil adjusting bolt.
Note: The adjusting bolt is underneath the machine, directly under
the anvils.
5. Use a 1%" wrench to turn the anvil adjusting bolt until the anvil is
slightly extended above the dial ring level when the spring beneath
it is compressed.
Use a 1% " wrench to tighten the lock nut on the anvil adjusting bolt.
Replace the carrier plate and screw. Tighten with a screwdriver.
Replace the guards and disengage the clutch.
.==>s><>.-we
Run a few cases through the machine to see that the anvil is holding
the cases ﬁrmly against carrier plates.
[27]
CALIBER .30 CASE TAPER AND PLUG Adjustments

Die Holder The die holders, located in the ram, contain the forming dies which form
the taper on the case. If the head-to-shoulder length of the case does
not meet speciﬁcations, it indicates that the die holder is positioned too
high or too low in the ram. The die holder of each station is equipped
with an adjustment to raise or lower it. This adjustment enables the
die to be placed in a position to develop the correct case head-to-shoulder
length.


I/4" Allen
" Set
Screw
“_ 2%" Lock
Collar
FRONT VIEW OF MACHINE SHOWING DIE HOLDERS
Tools: %” wrench, 21/4 ” spanner wrench.
Procedure: 1. Remove the front guard.
2. Use a 2% " spanner wrench to loosen the lock collar on the die holder.
3. Use a % " Allen wrench to loosen the die holder set screw.
4
. Use a 2% " spanner wrench to turn the die holder adjusting collar to
raise or lower the die whichever is necessary to develop proper head
to shoulder length.
Note: Proper position cannot be determined until the product is
run through the machine.
Use a 2%” wrench to tighten the lock collar on the die holder.
Use a % ” Allen wrench to tighten the die holder set screw.
Replace the guard.
9°$'9‘P‘
Check the adjustment by running the component through the ma-
chine and checking it.
[28]
CALIBER .30 CASE TAPER AND PLUG Adjustments

Die Replacement There are two forming stations that taper the cases. Each station has
two dies in it. The bottom die forms the body taper and the top die
forms the shoulder taper. If the proﬁle of the case is not within speciﬁca-
tion, the die is worn. The bottom die of each station wears out ﬁrst and
must be replaced. The top die of each station can be turned over and
used on the other end.


1;: Three Dre
5 "' Holders
:
Rocker E
Arm ‘
. __ 21/4" Lock
';_ T Collar
Dial
FRONT VIEW OF MACHINE SHOWING DIE HOLDERS
Tool: 1/4 " spanner wrench.
Procedure: 1. Use a % ” spanner wrench to remove the die cap on the bottom of the
die holder.
2. Remove the dies and replace the worn die with a new one. Replace
both dies.
Note: Bottom dies of each station are good for approximately 45,000
cases. The top dies can be reversed and used on the other end and
are good for approximately 100,000 cases. Before placing the dies
in the holder, clean with a shop towel and oil.
3. Use a 1/4" spanner wrench to replace the die cap and tighten it.
4. Run the product through the machine and check for accuracy of ac-
tion on the case.
[29]
CALIBER .30 CASE TAPER AND PLUG Adjustments

Hopper Motor The motive power of the hopper is transmitted from the hopper motor
Belt to the hopper by a belt. If the belt slips frequently during operation of
the machine, a loose belt and irregular transmission of power is indicated.
To insure a smooth transmission of power, the motor mount has an
adjustment bolt that regulates the tension on the belts by raising or
lowering the motors.

TOP VIEW OF PADDLE WHEEL HOPPER
Tools: 1/2” wrench, 7/8” wrench.
Procedure: 1. Use a 7/8 ” wrench to loosen the lock nut on the motor mount adjust-
ment bolt.
2. Use a 1/H/’ wrench to turn the adjustment bolt until the belt is taut.
l30l
CALIBER .30 CASE TAPER AND PLUG Adjustments
Conveyor Belt The conveyor belt delivers cases from the paddle wheel of the hopper to
the feed tube mouth. If the belt becomes loose, it develops a jerky move-
ment and the cases fall off the belt. The conveyor belt is equipped with
an adjustable idler by means of which the tension of the belt can be
regulated.

Conveyor Belt
Bottom of
Hopper Box
_'"*~ 9/16" Cup Screw
\ Idler Pulley
Feed Tube

BOTTOM VIEW OF HOPPER
Tool: 946” wrench.
Procedure: 1. Use a 946" wrench to loosen the cap screw on the idler bracket.
2. Raise or lower the idler bracket until the proper tension is reached.
Note: To ﬁnd the proper tension for the belt make trial and error
adjustments on the idler until the cases travel smoothly on the con-
veyor belt.
3. Use a 9/11;” wrench to tighten the cap screw on the idler bracket.
l31l

CALIBER .30 CASE TAPER AND PLUG Adjustments
Motor Belt Tension The motive power of the machine is transmitted from the motor to the
machine by V-type belts. If the belt slips frequently during operation of
the machine, a loose belt and irregular transmission of power is indicated.
To insure a smooth transmission of this power, the motor mount has an
adjustment nut that regulates the tension on the belts by raising or lower-
ing the motor.

2
§ Guard
: Covering
Machine - Flywheel
Motor
Motor
Bracket
11/4!:
Lock
-_
-
.-
-_
_
._...
- '
--.
‘ V
*.
.-
-~
_
E“
-
-
-
‘e
..
.-
-.
-_
i
’
‘Q
‘
-
_~
-. .
‘Is
‘-
.1‘-IIIH
FRONT VIEW OF MACHINE MOTOR
Tool: 1%" wrench.
Procedure: 1. Use a 1%" wrench to loosen the top lock nut on the motor mount
adjusting bolt.
2. Use a 1% ” wrench to turn the adjusting nut until the belt has proper
tension.
3. Tighten the top lock nut.
[32]

CALIBER .30 CASE TAPER AND PLUG
Adjustments

Brake The brake of the machine has a two-fold purpose. One is to stop the move-
ment of the ram when the clutch is engaged; the other is to create a slight
drag on the shaft that motivates the ram. To stop the movement of the
ram, the brake has a spring tension that can be increased or decreased.
To create a constant drag on the shaft that motivates the ram, adjust the
two set screws so that the brake shoes will be brought closer to the brake
drum by the tension of the brake spring.


Ad‘ :78”
US In
I Nil \
Tools:
Procedure:
“‘ Brake Shoes
1I/16" Lock Nuts
3/3" Set Screw
BRAKE ASSEMBLY
1%” wrench, 5%” wrench, 7/3” wrench.
1.
2.
Use two A, " wrenches to loosen the lock nut on the spring tension bolt.
To create more tension on the brake, use a 7/8" wrench to turn the ad-
justment nut clockwise.
Note: Use the trial and error method to determine how much to turn
the adjustment nut.
Use two %” wrenches to tighten the lock nut on the spring tension
adjustment bolt.
Use an 1%," wrench to loosen the lock nut on the two adjustment set
screws.
Use a 38" wrench to turn the adjustment set screws until the brake
releases when the clutch is engaged.
Note: The brake must release but not completely. There must be a
slight drag on the shaft that operates the ram to reduce backlash to a
minimum.
Use an 1%,” wrench to tighten the lock nut on the two adjustment set
screws.
l33l
CALIBER .30 CASE TAPER AND PLUG
Adiusfmenis
Feed Finger


The feed ﬁnger is the mechanism located at the left of the index dial. The
purpose of the feed ﬁnger is to slide the cases into the carrier plates of the
index dial. As the moving parts of the feed ﬁnger mechanism become worn,
the feed ﬁnger fails to feed the cases far enough into the carrier plate. To
overcome this condition,.the feed ﬁnger can be made longer by loosening
two Allen lock screws and lengthening the feed ﬁnger.
¥egd lsclex
u e ' 1
Bracket m
Bolts
___ 3/16" Allen
Lock
Feed Screws
Finger
Tools:
Procedure: 1.
2.
3.


INDEX DIAL AND FEED FINGER ASSEMBLIES
6" screwdriver, 3/{;” Allen wrench, ﬂywheel rod.
Use a 6" screwdriver to remove the guard over the feed ﬁnger.
Open the ﬂywheel guard gate.
Use a ﬂywheel bar to turn the ﬂywheel by hand until the ram travels
half its downward stroke and the feed ﬁnger rocker arm is free.
Use a 34;" Allen wrench to loosen the two lock screws on the feed ﬁnger.
Insert two cases in front of the feed ﬁnger.
. Move the feed ﬁnger forward until the front case moves into the carrier
plate.
Use a §'1’ﬁ" Allen wrench to tighten the feed ﬁnger screws.
Use a 6 ” screwdriver to replace the guard over the feed ﬁnger and close
the ﬂywheel guard gate.
[34]
CALIBER .30 CASE TAPER AND PLUG Adjustments

Plug Punch The plug punch is a sizing tool located on the left front of the ram. The
Adjustment and plug punch spreads the mouth of the case to the correct diameter after
Replacement the case has passed the forming stations. If the cases do not have the
proper mouth diameter after they leave the plug punch station, it is an
indication that the plug punch has become worn. To remedy this condi-
tion the plug punch can be lowered so that a portion of the punch
which is not worn will actually perform the plugging operation. This
adjustment can be made approximately ﬁfteen times before the punch
must be replaced with a new one.


Hollow Tool
Holder
\
Plug Punch Holder ——:
1%" Loclc Nut "T"
.s_-1
,_.
éc A
Pl g P h
Holdeli Br<:C|I(cet /
/ Rocker Arm
___..-— Stripper Finger
FRONT VIEW OF RAM AND PLUG PUNCH HOLDER
Tool: 1% " wrench.
Procedure: To Adjust.
1. Remove the front guard.
2. Use a 11/4 ” wrench to loosen the lock nut on the plug punch holder.
3. Use a 11/4 " wrench to turn the plug punch holder until it is lowered
enough to give proper opening to the mouth of the case.
Note: Proper position can only be attained by making the adjust-
ment, running the product through the machine and checking; then
readjust until the proper position is reached. V8 turn will lower the
punch approximately .002".
4. Use a 1% ” wrench to tighten the lock nut.
5. Replace the front guard.
[35]
CALIBER .30 CASE TAPER AND PLUG ‘ Adjustments

Procedure: To Replace.
(cont) 1. Remove the front guard.
2. Use a 114 " wrench to remove the hollow tool holder set screw on top
of the plug punch holder.
3. Remove the plug punch and replace with a new one.
4. Use a 11/4 " wrench to replace and tighten the hollow tool holder set
screw.
5. Replace the front guard.
[36]
CALIBER .30 CASE TAPER AND PLUG Adjustments
u
Ejecting Stem An ejecting stem is located at each of the forming stations. The stem
supports the case as the forming dies perform the tapering operation, and
after this operation, it holds the case down ﬁrmly on the carrier plate
as the forming dies withdraw. If the stroke of the ejecting stem is too long,
the stem will knock the primer pocket out of the case head; if the stroke of
the stem is too short, the carrier plate may be pulled up and chipped,
bent or broken. The ejecting stem has an adjusting nut by which it will
raise or lower the stem. The stroke of the ejecting stem can be regulated
by turning the stem holder.
‘f; S.


3/16" Allen Set
Screws
4.,
3/4" Stem Holder
n Die Holders
_,_'* at »:
W-* Index Dial


FRONT OF MACHINE SHOWING RAM
Tools: %" wrench, 5%" Allen wrench, ﬂywheel bar.
Procedure: 1. Remove the front guard.
2. Engage the clutch and use the ﬂywheel bar to turn the ﬂywheel until
the index dial moves to a position on the station.
3. Place a case under the ejecting stem.
4. Use the ﬂywheel bar to turn the ﬂywheel until the ram is at the end of
its downward stroke.
5. Use a 3/15" Allen wrench to turn the ejecting stem holder set screw on
the secondary ram in a counterclockwise direction.
6. Use a % " wrench to turn the stem holder on the ejecting stem clock-
wise until it pushes the bottom of the case ﬁrmly against the anvil
to compress the anvil spring as much as possible.
7. Turn the stem holder counterclockwise 1/4 turn.
8. Use a 346" wrench to tighten the ejecting stem holder set screw in the
secondary ram.
9. Use the ﬂywheel bar to turn the ﬂywheel until the ram is at the end of
its upward stroke. Disengage the clutch.
10. Remove the sample case and replace the guard.
I 37 I
CALIBER .30 CASE TAPER AND PLUG
Troubles and Corrections

Objective
Scored or
Scratched Outside
Walls
TROLIBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation
of this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection
of the component, together with constant observation of the machine as
it operates.
Visual inspection will reveal scratches on the outside walls of the case.
Scratches can also be detected by ﬁngernail inspection.
The causes are: The corrections are:
1. The sidewall of the body die is 1.
cracked.
Remove and replace the body
die with a new die. Unscrew
the cap screw beneath the die
and allow the die to fall out.
heres to the wall of the case.
. The body die or the shoulder 2. Replace with a new die and re-
die is chipped on the drawing turn the defective die to the
surface. Tool Servicing Department.
. The drawing surface of the die 3. Remove and polish the die with
is scratched and scratches the ﬁne emery cloth. Remove the
body of the case. die by unscrewing the cap screw
that holds it in place. If the die
is too badly scratched replace
with a new die and return the
scratched die to the Tool Serv-
icing Department.
. Excessive accumulation of brass 4. Remove the dies and polish,
on the shoulder and body dies. ﬁrst with emery cloth, then
with crocus cloth.
. Foreign matter. Dried soap ad- 5. Remove the dirty cases and
send to the Washing Depart-
ment to be rewashed. Remove
the dies and clean the foreign
matter from them. The die is
removed by ﬁrst removing the
cap screw beneath the die and
allowing the die to fall out of
the die holder.
[38]
CALIBER .30 CASE TAPER AND PLUG
Troubles and Corrections
Scratched Inside A visual inspection reveals that the inside walls of the case are scratched
or scored.
Walls
Marked or
Scratched Outside
Heads
The causes are:
1. The mouth expander is bent
and scores the inside of the
case.
. Excessive accumulation of brass
on the mouth expander.
. The surface of the mouth ex-
pander has become marred or
scratched.
The plugging punch has be-
come bent, scoring the inside of
the mouth.
. Excessive accumulation of brass
on the surface of the plugging
punch.
. Plugging punch is marred or
scratched.
The corrections are:
1.
Remove and replace the mouth
expander. Remove the nut from
the mouth expander and allow
the expander to drop in your
hand. Replace the mouth ex-
pander and the nut.
. Remove the mouth expander
and clean off the brass with ﬁne
emery cloth and crocus cloth.
Replace the mouth expander.
. Remove the mouth expander
and polish with emery cloth. If
the scratches are too deep, re-
place the mouth expander with
a new one.
. Remove and replace the plug-
ging punch. First remove the
screw at the top of the plugging
punch, then push the punch up
through the top of the punch
holder.
. Remove and polish the plug-
ging punch with emery cloth.
Finish polishing with crocus
cloth.
. Remove the plugging punch
and polish with emery cloth. If
the scratches are too deep, re-
place the plugging punch with
a new one.
Visual inspection discloses that the head of the case has become scratched,
dented or marred.
The causes are:
1.
Defective or damaged carrier
plate. The plate forces the case
head against the anvil with too
much pressure.
. The Allen screws on the dial
ring have become loose. The
case heads are scratched as
they pass over the Allen screws.
The corrections are:
1'
Remove the screw from the car-
rier plate and remove the car-
rier plate. Replace with a new
carrier plate and tighten the
screw.
. Remove the carrier plate and
turn the dials until the Allen
screws are exposed; then tight-
en the Allen screws.
[39]
CALIBER .30 CASE TAPER AND PLUG
Troubles and Corrections
Marked or
Scratched Outside
Heads (Cont.)
Marks on the
Inside Head of
the Case
Crooked Heads
Low Shoulder
_ 2. Ejecting stem is bent. 2.
3. Remove the body anvil and re-
place with a new one. The body
anvil is removed by loosening
the lock nut and unscrewing
the anvil. Replace.
3. Worn or broken body anvil lo-
cated in the bed of the machine.
Lower the body anvil; loosen
the lock nut and turn the anvil
counterclockwise, thus lower-
ing the anvil. Tighten the lock
nut.
4. Body anvil is adjusted too high. 4.
Visual inspection reveals that the primer pocket is being damaged and
that there are marks on the inside head of the case.
The cause is: The correction is:
1. Raise the ejecting stem. Loos-
en the lock nut on the ejecting
stem holder and turn the eject-
ing stem clockwise, thus raising
stem. Tighten the lock nut.
1. Ejecting stem is set too low and
strikes the inside of the case,
with too much force.
Gaging reveals that the body of the case is set at an angle to the head.
The causes are: The corrections are:
1. Remove the body anvil and re-
place with a new one. The body
anvil is removed by loosening
the lock nut and unscrewing
the anvil. Put in new anvil and
replace lock nut.
1. Worn or broken body anvil.
Remove and replace the eject-
ing stem. Remove the set screw
from the stem holder and allow
the stem to drop out. Put in
new stem and replace set screw.
Gaging reveals that the length of the case between the head and the
shoulder is too short.
The corrections are:
1. Raise the die. Loosen the die
cap and turn the adjusting screw
clockwise. Tighten the die cap.
The causes are:
1. The die is adjusted too low.
Raise the body anvil. Loosen
the lock nut and turn the anvil
clockwise. Tighten the lock nut.
2. Body anvil is adjusted too high. 2.
[40]
CALIBER .30 CASE TAPER AND PLUG
Troubles and Corrections

Split Neck
Wrinkled Necks
Buckled Necks
Mark Around
Case Above the
Extractor Groove
Visual inspection of the case reveals-that the neck of the case has split
or buckled.
The causes are: The corrections are:
1. The cases have been improperly
annealed. The mouth and neck
are too hard.
1. Have the inspector check the
cases.
2. Remove the defective cases and
check the source of supply.
2. The case mouth is dented or
bent.
Visual inspection reveals wrinkled necks on the ﬁnished case.
The causes are: The corrections are:
1. Reduce the amount of lubricant
by turning the lubricator valve
so that only one drop is fed to
ﬁve cases.
2. Have the cases checked by the
inspector.
1. There is too much lubricant at
the oiler station.
2. Improper annealing of the cases.
Visual inspection reveals that the necks of the cases are buckled.
The corrections are:
1. Fill the container with lubri-
cant and regulate the lubricator
valve.
The causes are:
1. Insufficient lubricant at the lu-
bricating station.
Remove, service and replace the
plugging punch. First remove
the screw at the top of the plug-
ging punch ; then push the punch
up through the top of the punch
holder. Replace the punch.
2. Oversize plugging punch. 2.
Visual inspection reveals that there is a ring around the case just above
the extractor groove.
The cause is: The correction is:
1. Remove the die and remove the
sharp edge with a ﬁne grade of
emery cloth. The die is re-
moved by ﬁrst removing the
cap nut that holds it in place
Replace the die and cap nu’r
1. A sharp edge at the mouth of
the body die.
[41]
CALIBER .30 CASE TAPER AND PLUG
Troubles and Corrections
Crooked Shoulder
Mark or Ring on
One Side of Case
Above Extractor
Groove
Large Mouth
Gaging discloses that the angle on the shoulder of the case is higher on
one side than on the other.
The causes are: The corrections are:
1. Replace the die with a new die.
Remove the die by ﬁrst remov-
1. The shoulder die has become
worn.
ing the cap nut that holds it in
place. Replace the die and the
cap nut.
2. The plugging punch is bent. 2. Remove the screw at the top of
the plugging punch; then push
the punch up through the top
of the punch holder. Put in a
new punch.
Visual inspection reveals that there is a ring half way around the case
just above the extractor groove.
The causes are: The corrections are:
1. Adjust the bumper studs so
that they are all at the same
level. To raise or lower the
bumper studs, loosen the lock
nuts and turn to right or left.
1. The bumper studs controlling
the depth of the ram are not all
at the same level.
Remove and replace the carrier
plate. First remove the screw
that holds the plate in place.
2. Carrier plate is bent and there- 2.
fore does not permit the case to
be held in an upright position.
Gaging discloses that the mouth of the case is too large in diameter.
The causes are: The corrections are:
1. Remove and replace the plug-
ging punch. First remove the
screw at the top of the plugging
punch, then push the punch up
through the top of the punch
holder.
Remove and replace the die.
Remove the cap nut on the die
and allow the die to drop out.
Replace the die by inserting it
into the die holder and tighten
the cap nut.
1. Plugging punch is too large.
2. Worn shoulder die. 2.
[42]
CALIBER .30 CASE TAPER AND PLUG
Troubles and Corrections

Small Mouth
Variation of
Shoulder Length
Smashed Cases
Buckled Case
Gaging discloses that the mouth of the case is too small.
The cause is:
1.
The plugging punch has be-
come worn and is too small.
The correction is .
1. Remove and replace the plug-
ging punch. First remove the
screw at the top of the plugging
punch, then push the punch up
through the top of the punch
holder.
Gaging reveals that shoulder is too short or too long.
The cause is:
1.
Broken shock spring. At times
the ram comes down too far and
at times it does not come down
far enough. Either condition
The correction is:
1. Remove and replace the shock
spring. The spring is removed
by ﬁrst removing the nuts on
the spring rod.
causes a variation of shoulder
length.
Visual inspection reveals that the cases have been smashed beneath the
ram.
The causes are: The corrections are:
1. Adjust the pawl stroke. Loosen
the lock nut on the pawl block
adjusting screw. Loosen the
cap screw on the pawl block.
Turn the pawl block adjusting
screw until the dial check is all
the way in the dial. Tighten
the lock nut and the cap screw.
1. The pawl that moves the index
dial does not stop at the proper
position beneath the dies.
Remove and replace the eject-
ing stem. Loosen the ejecting
stem lock nut and unscrew the
stem from the secondary ram.
Replace the assembly in re-
verse order.
2. The ejecting stem is crooked. 2.
Visual inspection reveals that the cases are buckled.
The causes are: The corrections are:
1. Remove and replace the plug-
ging punch. First remove the
screw at the top of the plugging
punch; then push the punch up
through the top of the punch
holder. Put in a new punch and
replace screw.
1. The plugging punch is oversized
or bent.
2. The mouth of the case is bent. 2. Remove the defective case and
check the source of supply.
I 43 I
CALIBER .30 CASE TAPER AND PLUG
Tool Servicing

TOOL SERVICING
Obiective Proper tool servicing is essential to maintain standard quality in the
tapering and plugging operation in the manufacture of a cartridge case.
Dies are costly and great care must be exercised in the servicing of these
tools. Adjusters will be concerned primarily with the removal of brass
and small scratches that appear on the working surfaces of the dies. They
must be careful when using an abrasive on any tool, not to alter materially
its dimensions.
Servicing of New
Dies
All tools that cannot be corrected by polishing must be returned to the
Tool Servicing Department.
1.
Dies, as received from the tool room, are normally ground to the
proper size and servicing is not necessary.
As a precaution, the die bore should be inspectedfor roughness and
polished if necessary. If the bore is rough, causing undue friction,
more metal may be pulled from the sidewall of the case than is neces-
sary.
A test run of cases should be made before any servicing is done on
the die. After the test run has been made, the cases should be care-
fully gaged and inspected.
If there are any irregularities in the die or the die is undersized, it
should be returned to the Tool Servicing Department for replacement.

OVER-ALL PICTURE OF SPEED LATHE
[44]
CALIBER .30 CASE TAPER AND PLUG Tool Servicing

Servicing of 1. Check the die visually to determine how badly it is scratched. If the
Brassed Up or die has a very deep scratch which cannot be removed by using a
Scratched Dies ﬁne emery cloth, it should be sent to the Tool Servicing Department.
2. If there is an excess accumulation of brass within the die, then the
die should be placed in a three-jaw chuck on a speed lathe. To re-
move the accumulation of brass, use a ﬁne emery cloth wrapped
around a lap stick. Use a lap stick made of brass, lead, ﬁber or wood
about the same diameter as the die hole.
3. After the accumulation of brass has been removed, polish the die
with ﬁne crocus cloth, using a lap stick as in the former procedure.
4. Wipe out the inside of the die with a cloth.
5. Remove the die from the chuck and check to see if all the brass has
been removed.
To service a scratched die, follow the same procedure as outlined in the
servicing of a brassed up die.
Hold the lap stick, with a piece of ﬁne emery cloth wrapped around it,
against the die. Give the stick a rapid in and out movement. Repeat
this operation until the scratch has been removed from the die. If it is
found necessary that any great amount of material has to be removed
from the die, stop the polishing procedure and return the die to the
Tool Servicing Department.
After the die has been removed from the chuck, examine very closely
to see whether or not the scratch has been removed from its inside surface.


CORRECT WAY WRONG WAY
I45]
CALIBER .30 CASE TAPER AND PLUG
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
MACHINE LUBRICATION
The efﬁciency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important‘ lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[46]
CALIBER .30 CASE TAPER AND PLUG
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.49‘?-"tP‘P°.N
Frequency of lubrication.
I 47 I
CALIBER .30 CASE TAPER AND PLUG
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9O.q.®,Ol!P“_¢*9l\Z>I-K
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
Screw down cups.
Compression cups.
Pressure guns and patented ﬁttings.
rl=~.°°.l\°t-*
Mechanical lubricators.
5. Grease packing.
A systematic control of all lu-brication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times——except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days. 6
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
[48]
CALIBER .30 CASE TAPER AND PLUG
Machine Lubrication

LUBRICATION CHART

Lubricant
Machine Part
No. of Fittings,
Grease Cups, etc.
Frequency of
Imbrication Hours

LIGHT GREASE
(Blue Gun)
Crankshaft bearings . . . . . .
Pitman bearings . . . . . . . .
Gibs .
Secondary ram cam
Secondary ram shaft and roller
Flywheel . . . . . . . . . . .
Hopper gear box
Hopper belt pullup
Dial driveshaft
I 0 o 0 I o
c o o c I u 0
G o I o 0 I
I I I u o n 0 o
Pawl rocker arm . . . . . . . .
I-—*l—*[\DI.\')l--*h')I—*I.\'J[\')NJ
OOOOOOOOOOOOOOOOOOOO
HEAVY OIL
(Yellow Oiler)
Gear reducer
Pitman assembly wrist pin wells . .
I o o c I o P I I
so
N9
(X)I—*
3
F‘

MEDIUM OIL
(Red Oiler)

Rocker arm follower . . . . . .
Safety clutch assembly . . . . .
Pawl cam . . . . . . . . . . .
Feed ﬁnger rocker arms
Feed ﬁnger roller
Dialstud. . . . .
Pawl bar .
Rocker arm assembly
Rocker arm roller .
Clutch lever assembly
Stripper rocker arm
Horizontal brake shift
Bumper studs . . . . . . . . . .
Stripper roller . . . . . . . . . .
Dialhead.............'......
Stripper plate . . . Feed ﬁnger assembly . . . . . . .
Pawl . . . . . . . . . . . . . .
Pawl bar guides Check plate and guide . . . . .
0 I o n 0
u O O G o u

[\')t—*I—*t—*[\DO0[\Dl\DI—*03t—*l—‘r-*t—‘t—*l\DC»9l—*N>t-*
ooooooooooooooooooooooooooooooooooooi--oo
8
F

[49]
CALIBER .30 CASE TAPER AND PLUG
Index
Adjustment, Body Anvils, 27
Brake, 33
Carrier Plate Replacement, 26
Conveyor Belt, 31
Die Holder, 28
Die Replacement, 29
Ejecting Stem, 37
Feed Finger, 34
Hopper Motor Belt, 30
Index Dial, 25
Motor Belt Tension, 32
Plug Punch, 35
Anti-friction Bearings, 46
Anvil, 6
Stud, 12
Body Anvils, Adjustment, 27
Brake, 3, 4
Adjustment, 33
Shoe,33
Spring, 33
Buckled Case, 43
Neck, 41
Cam, 4, 7
Roller Wheel, 5
Camshaft, 4
Cannelure Depth, 20
Carrier Plate Replacement Adjust-
ment, 26
Plates, 34
Case Kickoff, 3
Check Arm, 8
Clutch, 3, 4
Conveyor Belt, 15, 17
Belt Adjustment, 31
Crankshaft, 3, 7, 8, 18
Speed, 1
Crooked Heads, 40
Shoulder, 42
Detector, 15, 18
Punch Holder, 12
Punch Holder Assembly, 12
Dial Block, 6
Carrier Plates, 6
Head, 6, 7, 8, 18
Index Head, 15
Ring, 6
Rocker Arm, 3
Diameter at Bottom of Shoulder, 20
Diameter at Top of Shoulder, 20
Die Holder, 12
Holder Adjustment, 28
Holder Assembly, 12
Holder Cap, 12
Replacement Adjustment, 29
Dimensions, 20
Disposal, 16, 19
INDEX
Ejecting Stern, 5
Stem Adjustment, 37
Ejection, 16, 19
Feed Block, 3, 10
Finger, 3, 10, 15, 17
Finger Adjustment, 34
Motor, 1
Throat, 15, 17
Tube, 15, 17
Finish Forming Die, 16, 19
First Body Die, 13
Ejecting Stem, 14
Forming Die, 15, 18
Shoulder Die, 13
Floor Space, 1
Flow Chart, 17, 18, 19
Flywheel, 2, 4, 18
Friction, 46
Gage Care, 22
Gibs, 5
Grease, 47
Head Thickness, 20
Head to Shoulder Gage, 23
Height, 1
Hopper Motor Belt Adjustment, 30
Index Dial, 3, 6
Dial Adjustment, 25
Mechanism, 3
Indexing Mechanism, 7
Pawl, 8
Inside Diameter of Mouth, 20
Inside of Taper, 20
Large Mouth, 42
Length of Case, 20
Length of Neck, 20
Liberty Paddle Wheel Hopper, 3
Low Shoulder, 40
Lubricating Film, 46
Lubrication, 46
Chart, 49
Hints on, 48
Methods, 47
Machine Description, 1
Motor, 1
Manufacturer, 1
Mark around Case, 41
Mark on One Side of Case, 42
Marked Outside Heads, 39
Marks on Inside Head, 40
Methods of Getting Lubricant to
Bearing Surface, 48
Motor, 2
Belt Tension Adjustment, 32
Mouth Expander Punch, 13
Spreader, 15, 18
Oiling, 15, 18
Outside Diameter, 20
Diameter at Mouth, 20
Walls, 38
Over-all Length, 20
Overhead Hopper, 15, 17
Paddle Wheel, 31
Wheel Hopper, 15, 17
Pawl Arm, 8
Finger, 7
Plug Gage, 22
Punch, 11, 16, 19
Punch Adjustment, 35
Punch Holder, 12
Punch Holder Assembly, 12
Plugging Punch, 14
Pocket Depth, 20
Diameter, 20
Power, 2
Production, 1
Proﬁle Gage, 23
Ram, 3, 5, 10, 33
Ring Gage, 22
Ring on Side of Case, 42
Rocker Arm, 18
Scored Walls, 38
Scratched Inside Walls, 39
Outside Heads, 39
Second Body Die, 14
Ejecting Stem, 14
Forming Die, 16, 18
Shoulder Die, 13
Selecting Lubricant, 47
Servicing, 45
Servicing of New Die, 44
Small Mouth, 43
Smashed Case, 43
Split Neck, 41
Station 1—15, 18
2—15, 18
3-—15, 18
4-16, 18
5—16, 19
6—16, 19
Stripper, 11
Block, 11
Finger, 11
Stroke, 1
Tools, 1
Transmission, 2
Type of Feed, 1
Variation of Shoulder Length, 43
Visual Inspection, 22
V-type Belt, 2
Weight, 1
Wrinkled Neck, 41
[50]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Finish Trim


BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-4.-81, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAL CORRECTIONS—CAI.IBER .30 CASE FINISH TRIM
LOCATION ERROR CORRECTION
Page 3—Spec Motor Speed 145 Motor Speed 1145
Page 3— ii 1 Upper line shaft Lower line shaft
Page 18- ‘J 2 70% Copper and 30% Brass 70% Copper and 30% Zinc.
Page 12—- 12 “below the locknuts and below top spindle ' “below the locknuts and above the top
bearing” spindle bearing”
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tool Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
III

CALIBER .30 CASE FINISH TRIM MACHINE
IV
CALIBER .30 CASE FINISH TRIM
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Production
Spindle Speed
Tools
Floor Space
Height
Weight
CATALOGUE DATA
Fidelity Machine Co., Philadelphia, Pa.
Vertical, single spindle, trimming machine, belt
driven from motor.
1.5 h.p.; 3 phase; 60 cycle; 220/440 volts; 145
R.P.M.
Paddle wheel hopper mounted on machine. Belt
drive countershaft to hopper pulley.
120 per minute.
4000 R.P.M. Approx.
Piece No.
Cutter R-6
Cutter holder N-1
Pilot N-2
3 ft. x 5 ft.
5 ft. 11 in.
1,000 lbs.
CALIBER .30 CASE FINISH TRIM Machine Description
MACHINE DESCRIPTION
The Caliber .30 Finish Trim Machine trims the case to the speciﬁed
ﬁnished length.

Paddle - Hopper
Wheel "" Box
Hopper
—- Feed
Pulley "' Tube
Wheel
.5 Hopper
Line - Stand
Shafts
T‘ Switch
-2: “ Motor

OVER-ALL VIEW OF CALIBER .30 CASE FINISH TRIM MACHINE
Power and The Fidelity Vertical Spindle Case Finish Trim Machine, illustrated
Transmission above, is powered by a 1.5 h.p. motor. The motor is connected to the
machine by V-type and ﬂat-type leather belts through two line shafts.
The two line shafts are supported, one above the other, by two metal
brackets which are bolted to the concrete base at the back side of the
machine. The line shafts are so placed that their longitudinal axes run
parallel to the machine.
The motor is mounted on a metal plate which is bolted to the ﬂoor at the
rear of the machine. The motor is so placed that the motor pulley aligns
with the driven pulley on the lower line shaft.
The paddle wheel hopper is driven by a round leather belt connected to
the pulley on the upper line shaft. The upper line shaft is driven by means
of a round leather belt connected to a V-type pulley on the lower line shaft.
I2]
CALIBER .30 CASE FINISH TRIM
Machine Description

Power and
Transmission
(Cont.)
Liberty Paddle
Wheel Hopper
Feed Block
Transfer Slide
Gripping Jaws
Vertical Spindle
Assembly
Horizontal
Camshaft
The vertical spindle is driven by a round leather belt from the upper line
shaft, across an idler pulley to a V-type pulley on the vertical spindle.
The vertical camshaft is driven by a ﬂat type leather belt from the line
shaft pulley to the ﬂywheel attached to a cross-shaft. The cross-shaft
transmits the power through bevel gears to the vertical cam.
The cases are fed into the hopper box, through a chute from an overhead
source. The cases are picked up by a series of paddles which lift them to
the conveyor belt. The conveyor belt carries the cases to an opening where
they enter the feed throat head ﬁrst. The cases drop head ﬁrst through the
feed tube, assisted by a round leather disc.
The cases drop from the feed tube into a socket, located on top of the feed
block assembly. The cases are held in the feed socket until the transfer
slide jaws are in alignment with the feed socket. The cases drop from the
feed socket into the transfer slide and are carried to the gripping jaws.
The transfer slide rides on the machine bed, which acts as a bearing sur-
face. The transfer slide is held in alignment by a V-shaped gib plate,
bolted to the machine bed along the right side of the transfer slide. The
transfer slide transfers the cases from the feed socket to the gripping jaws
where the cases are trimmed. The transfer slide is actuated by a rocker
arm from a cam located on the bottom of the vertical camshaft. The
rocker arm is held in contact with the cam by a coil tension spring which is
attached from the rocker arm to the machine frame. This allows the
transfer slide to stop in case of a jam, while the spring absorbs the cam
action on the rocker arm.
The gripping jaws are guided in their back and forth motion by a bronze
bearing block which is held in position by the vertical camshaft. The grip-
ping jaws are so arranged that they encircle three sides of the bronze
block. The two opposite sides ﬁt snugly against the block, which acts as
the bearing surface in their travel. The gripping jaw arm forms a right
angle at the front of the bronze block and extends forward to the station-
ary jaw to hold the case for the trimming operation.
The vertical spindle assembly travels up and down in an adjustable dove-
tail gib. The lower end is machined to hold the cutting head. The vertical
spindle is actuated in its up and down stroke by an eccentric cam, which is
attached to the inner end of the cross-shaft. Through two bevel gears the
cross-shaft also operates the vertical camshaft. The eccentric cam is
enclosed by a constant cam follower collar. The spindle shaft is driven by
a round leather belt from the lower line shaft to the V-type pulley on the
spindle shaft.
The horizontal camshaft is held at the top of the vertical cam housing by
two babbitt bearings. A pulley wheel is attached to the right end of the
horizontal camshaft and is driven by a ﬂat leather belt from the lower
line shaft. A bevel gear is mounted on the center of the shaft which
meshes with a bevel gear on the upper end of the vertical camshaft. An
eccentric cam is attached to the left end of the horizontal camshaft and
actuates the vertical stroke of the spindle.
l3l
CALIBER .30 CASE FINISH TRIM
Machine Description

Vertical
Camshaft
The vertical camshaft is supported by and enclosed in a housing which is
bolted to the machine bed. The vertical camshaft is held in alignment and
rotates in two bearings. The upper bearing is a bronze bearing and the
lower one is a ﬁtted steel bearing. The lower part of the vertical camshaft
housing is cut away leaving the cam exposed for the operation of the
various machine parts.
CALIBER .30 CASE FINISH TRIM
Machine Description
Pulley Idler
Wheel Pulley
I ~\


LIBERTY PADDLE WHEEL HOPPER
Liberty Paddle
Wheel Hopper
Hopper Pulley Conveyor Feed Tube Hopper
Tube Box Wheel Belt Paddles Opening Box
\ I , I
INTERIOR OF PADDLE WHEEL HOPPER
The Liberty paddle wheel hopper is mounted on a metal stand, which is
bolted to the machine bed. The hopper is held, by the hopper stand,
directly above the vertical camshaft. The hopper paddle wheel is con-
nected to a hopper shaft, which extends through the back of the hopper
box. A bevel gear is attached to its outer end which meshes with the bevel
gear on the hopper cross-shaft. The cross-shaft is attached to the rear side
of the hopper box and extends out to one side to mount a jaw type clutch
and pulley wheel. The jaw type clutch is manually controlled for the
application of power from the motor, through a round leather belt to the
line shaft, from the line shaft through a second belt to the hopper pulley
wheel.
The cases are fed through a chute from an overhead source. The cases are
picked up by a series of paddles, which lift them to a conveyor belt. The
cases roll from the paddles, lengthwise, onto the conveyor belt. The belt
conveys them to the feed tube opening where they fall head ﬁrst into the
feed tube mouth. The feed tube mouth is so arranged, that if a case is
conveyed mouth ﬁrst to the feed tube, the mouth end will overshoot the
opening, allowing the case head to drop into the feed tube.
l5I
CALIBER .30 CASE FINISH TRIM Machine Description


l a
Transfer Slide '””"lt;””
Feed Tube
"I; _ 4 _ ’-‘ , _ . Feed Socket
Gripping Jaws ._
Feed Block
1/2" Adjusting
3/5" Lock Screw Screw
I/2" Adjusting
Screw “ 3/3” Lock Screw
FEED BLOCK ASSEMBLY
Feed Block The feed block provides the support which holds the feed socket in place.
The feed tube is connected to the feed socket. The cases are gravity fed
through the feed tube to the feed socket. When they drop into the feed
socket, the case head rests against the upper surface of the transfer slide,
until the slide comes back aligning the transfer slide jaw with the feed
socket. The feed block is bolted to the block base and is adjusted by means
of a set screw threaded in its forward edge.
[6]
CALIBER .30 CASE FINISH TRIM Machine Description
Stationary Jaw The stationary jaw is a rectangular metal block, whose face is machined
and Transfer Slide to receive the case from the feed socket and allow it to be carried by the
transfer slide to the gripping jaws below the vertical spindle. The sta-
tionary jaws are bolted to a three armed bracket which is in turn bolted
to the base block. The transfer slide is a rectangular block whose face is
machined to ﬁt the face of the stationary jaw plate, so that when the two
are placed together, they form a track through which the cases travel to
the gripping jaws. The transfer slide is held on top of the base block by a
V-type gib arrangement which allows it to travel back and forth from the
feed socket to the gripping jaws. The transfer slide is actuated in its back
and forth motion by means of a rocker arm and eccentric cam. The eccen-
tric cam is located on the lower end of the vertical camshaft. The rocker
arm is attached at its pivotal point to the machine bed. The cam end of
the rocker arm has a cam roller attached which is held in position by a
coil tension spring.
>l.bbIHh»~ :
Vertical -—-
Spindle
‘ -—- Transfer
Slide
3/3" Lock
Nut
-" Stationary
aw
1/2 " Adjusting
Screw

TRANSFER SLIDE AND STATIONARY JAW
I7]
CALIBER .30 CASE FINISH TRIM
Machine Description

Gripping .laws
The gripping jaws slide back and forth in an adjustable dovetailed gib
plate, which is machined in the base block. The jaws are operated in their
back and forth movement by two eccentric cams located on the bottom of
the vertical camshaft. The two eccentric cams are separated by a bronze
bearing block which is held in place by the vertical camshaft. The grip-
ping jaws are shaped to ﬁt around three sides of the bearing block, thus
guiding the gripping jaws in their back and forth stroke. A cam roller
rocker arm is attached to the right side of the gripping jaw arm and ex-
tends at right angles to the gripping jaw arm across the face of the upper
cam. A cam follower roller is attached to the mid-point of the arm against
which the upper cam rides actuating the forward stroke of the gripping jaws.
The cam follower arm extends forward beyond the vertical cam housing
and is held in position by a coil tension spring. The coil tension spring
provides the tension of the gripping jaw against the case. The backward
stroke of the gripping jaw is actuated by the lower cam on the vertical
camshaft which strikes against the cam roller located on the underneath
side of the gripping jaw bracket.


Transfer Slide \
Gripping Jaws .__
I/2' Adjusting
Screw
‘T Feed Tube
Feed Socket
Feed Block
— 1/2" Adjusting
Screw
"‘ 3/5" Lock Screw
Hvalti’ ’"
FEED BLOCK ASSEMBLY
-.-.._~i.i:..
I3]
CALIBER .30 CASE FINISH TRIM
Machine Description
Vertical Spindle
Assembly
The vertical spindle assembly travels in an adjustable dovetail gib. The
gib housing is bolted to the side of the hopper supporting stand. The
upper end of the vertical spindle assembly is cut out leaving a collar which
encircles the eccentric cam on the horizontal camshaft. An equalizer bar
is attached in a horizontal position across the top of the cross-shaft. The
equalizer bar extends forward to contact the vertical spindle shaft. A coil
compression spring is placed on top of the equalizer bar and held in place
by a stud. The stud is inserted through the spring and equalizer bar and
is threaded into the spindle shaft. This arrangement applies a constant
pressure to the spindle shaft thus restraining the shaft from ﬂoating in its
bearings. The spindle shaft is a vertically supported, tapered shaft. The
spindle rod is supported by, and rotates in, two bronze bearings. The lower
bearing is tapered to conform to the type of the shaft.


—- Eccentric Cam
—-_ Vertical Spindle
Assembly
VERTICAL SPINDLE ASSEMBLED ON MACHINE
[9]
CALIBER .30 CASE FINISH TRIM ' Machine Description

Horizontal The horizontal camshaft is supported by, and rotates in, two babbitt
Camshaft bearings which are mounted to the top of the vertical camshaft housing.
The horizontal camshaft is actuated from the horizontal camshaft through
two bevel gears attached to the upper end of the vertical camshaft and at
the center of the horizontal camshaft. A pulley wheel is attached to the
right end of the horizontal camshaft, and is driven through a ﬂat leather
belt from the lower lineshaft. An eccentric cam is attached to the left end
of the horizontal camshaft which actuates the vertical spindle assembly.
The bevel gears are covered by a three-piece housing for the protection
of the gears.


j\ ‘ .
i _ii.,'->1
I _ '
Pulley WheeI—- _ J" ‘ i A
Y ‘ - ‘Q ' .
T ’ l . ‘ $‘4- ' £3 .
Bevel Gears ' I _ .
I " I / 1 - , , Eccenlnc
. , Ki. ~ . ' F , _I : ' 3;; _._.f
I -P- ‘ ' Cum
E as; i I V ‘ Q
Camshaft 1 1
Bearings
HORIZONTAL CAMSHAFT AND ASSEMBLY
Vertical The vertical camshaft is enclosed in a metal housing. The shaft is sup-
Camshaft ported by and rotates in two bearings. The lower bearing is steel ﬁtted
while the upper bearing is made of bronze.
The camshaft is powered by the horizontal camshaft through the mating
bevel gears. The three eccentric cams are located on the lower end of the
camshaft. The housing side is cut away allowing entry of the various cam
follower arms to the cams.
I10]
CALIBER .30 CASE FINISH TRIM MOCIIIHG Description

H
;— sI§.'.’<'I’°'
\ Starting
Switch

OVER-ALL VIEW OF CALIBER .30 CASE FINISH TRIM MACHINE
Starting Switch The machine has neither clutch nor brake, so the power is controlled through
an electric push button type switch. The switch is mounted on the side
of the hopper stand within easy reach of the machine operator.
l11l
CALIBER .30 CASE FINISH TRIM Tool Holder Description
TOOL HOLDER DESCRIPTION
Spindle Assembly Lock Spanner Nut: The lock spanner nut is placed on the top
threaded end of the spindle above the adjustment spanner nut.
It locks the adjustment spanner nut.
Adjustment Spanner Nut: The adjustment spanner nut is
located on the threaded end of the spindle, below the lock span-
ner nut and the top spindle bearing. It is used to adjust the depth
of the spindle, and holds the spindle shaft in the bearing.
Spacer Washer: The spacer washer is positioned on the spin-
dle beneath the top spindle bearing and above the top race of
the ball bearing. It protects the top race from the pressure
applied in the spindle adjustment; it also acts as a spacer.
Ball Bearing Unit: The ball bearing unit is composed of a
top and bottom race and a bearing carrier. The ball bearing
unit provides the “free motion” of the spindle.
Adjustment Spanner Nut: The lower adjustment spanner
nut positions the ball bearing unit on the spindle. Its purpose
is to take up the end play on the spindle shaft and to hold the
shaft on true center.
Lock Spanner Nut: The lock spanner nut locks the adjusting
spanner nut.
Pulley: The pulley drives the spindle by means of a round
leather belt. It is held in a stationary position on the spindle by
a set screw.
Spindle: The spindle is a three dimensional shaft shaped as
illustrated in the photograph and cross-sectional drawing on this
page. The larger end is hollow to accommodate the collet. The
spindle holds the parts necessary for its vertical assembly in
the machine.
Collet: The collet is tubular with a ﬂanged end. It holds the
cutter holder up into the bottom of the spindle shaft.
Collet Sleeve: The collet sleeve holds the collet in the spindle.
Its hollow, partially threaded, interior is so constructed as to
cause pressure to be exerted on the collet mouth when it is
tightened on the hollow end of the spindle.

Cutter Holder: The cutter holder holds two cutting tools with
their cutting end projecting from the lower end of the cutter
holder. Each cutting tool is held in place by a washer and lock
nut. A pilot, or guide, is located in its bottom end.
[12]
CALIBER .30 CASE FINISH TRIM Tool Holder Description
Spindle Assembly
(Cont.)
Spanner Lock Nut Spclnnel‘ I-°¢I< Nut
Spanner Adj. Nut
Beaﬁng


Pulley Lock and Nut Washer
Spindle Shaft
Pilot
::'_'_'_'I::.:::_ I.[_'_.'_"_'_U I I
Spanner Washer
Bearing Tracer
Ball Bearing
Tool Holder


Spanner Adjusting
Nut
Bearing Tracer
Cutting Tools
[13]
CALIBER .30 CASE FINISH TRIM TOOI DGSCFIPIIOI1

TOOL DESCRIPTION
Tool Name: Cutter Holder
Piece N0.: N-1
Location: On end of spindle
Normal Life: Indeﬁnite
Cutter holder is made of tool steel, ground and polished.


Tool Name: Cutter
CUTTER HOLDER Piece N 0.: R-6
Location: In cutter holder on spindle
Normal Life: 17,914 pieces
Q Cutter is made of tool steel, hardened, ground and
. polished.
CUTTER
Tool Name: Pilot


Piece N0.: N-2
Location: In cutter holder on spindle
Normal Life: 50,000 pieces
PILOT Pilot is made of tool steel, ground and polished.
l14l
CALIBER .30 CASE FINISH TRIM
Process Sequence

Overhead Hopper
Paddle Wheel
Hopper
Conveyor Belt
Feed Throat
Feed Tube
Transfer Slide
Spindle and
Cutter Head
Eiecting and
Disposal
PROCESS SEQUENCE
The cases are fed by gravity from an overhead source into the overhead
hopper, then through a feed pipe down into the paddle wheel hopper.
The cases ﬂow down an incline into the bottom of the paddle wheel hop-
per, passing under the baffle plate to the paddle wheel. The paddle wheel
rotates clockwise and the paddles pick up the cases and convey them up
to the top of the hopper where they roll off onto the conveyor belt.
The cases are conveyed horizontally, in single ﬁle, to the adjustable feed
throat at the end of the conveyor belt.
A leather friction disc is located in the feed throat, behind the conveyor
belt pulley. The feed throat is partly cut away to accommodate the disc
which assists the cases through the feed throat into the mouth of the feed
tube. Because the head end of the case is the heavier end, the case goes
down the feed tube head ﬁrst.
The cases ﬂow by gravity through the brass feed tube, into the bushing,
where they stop in an upright position, and rest on top of the transfer slide.
The transfer slide moves back to receive the case. The case then drops
into the receiving grooves of the stationary jaw and transfer slide, resting
head down on the base block. The transfer slide moves in to convey the
case, in an upright position, to the cutting station. The case stops in the
trim slot located in the face of the stationary jaw, directly in line under
the vertical spindle and cutter head. The gripping jaw moves in, holding
the case ﬁrmly while the transfer slide moves back to its receiving posi-
tion. As the transfer slide moves backward, the case rests in the ejection
groove on the end of the slide.
The spindle moves down, the pilot of the cutter head enters the mouth of
the case, and the revolving cutters trim the case to the proper length.
As the spindle moves up, the gripping jaw moves back, releasing the case,
and the transfer slide starts to move in, conveying the next case into the
trim slot. The trimmed case is held in an upright position by the groove
in the end of the transfer slide and, as the slide moves in, is ejected into a
chute down to a conveyor under the machine. The scrap trimmings are
blown by air through a chute and down into a truck.
I15]
CALIBER .30 CASE FINISH TRIM
Process Sequence

FLOW CHART


Overhead Hopper
Cases are gravity fed from an overhead source, down
through a feed pipe to the paddle wheel hopper.


Power is furnished by 1 1%; h.p.
motor through ﬂat leather
belt to lower jackshaft.


Paddle Wheel Hopper
Cases ﬂow down an incline into bottom of paddle
wheel hopper, passing under baflie plate to paddle
wheel. Cases are picked up by paddles and carried to
top of hopper, where they roll onto a conveyor belt.


Paddle wheel is powered
through bevel gears, shaft,
pulley, round leather belt,
upper jack shaft round leather
belt to lower jackshaft.


Conveyor Belt
Conveys cases, single ﬁle, in a horizontal position, to
end of belt where they fall off, head end ﬁrst, into ad-
justable feed throat.


Powered through shaft pul-
ley round leather belt, upper
jackshaft round leather belt
to lower jackshaft.


Feed Throat
Cases are assisted through feed throat by revolving
leather friction disc and then drop into case feed tube.


Leather disc is powered from
pulley, round leather belt, to
upper jackshaf t, round
leather belt, to lower jack-
shaft.


Brass Feed Tube
Cases ﬂow by gravity through brass feed tube into a
bushing, where they stop in an upright position, rest-
ing on top of transfer slide.


Transfer Slide
Moves back to receive case. Case then drops into re-
ceiving grooves of stationary jaw and transfer slide,
resting head down on base block. Transfer slide
moves in conveying case to cutting station. Case
stops in trim slot in alignment under vertical spindle
and cutter head. Grip jaw moves in holding case
ﬁrmly, while transfer slide moves back to its receiv-
ing position to get another case.
I
Transfer slide is powered by
cam arm, cam, vertical cam-
shaft, bevel gears, horizontal
camshaft, pulley, flat leather
belt to lower jackshaft.


Grip jaw is actuated by com-
pound spring action through
cam arm, cam, vertical cam-
shaft, bevel gears, horizontal
camshaft, pulley, ﬂat leather
belt to lower jackshaft.


[16]
CALIBER .30 CASE FINISH TRIM Process Sequence

FLOW CHART (Cont.)
Spindle is powered by round
I — leather belt to lower jack-


Spindle and Gutter Head shaft‘
As the spindle moves down, the pilot of the cutter
head enters mouth of case and revolving cutter trims
the case to its proper length.

Cutter head is powered by
face cam, horizontal cam-


shaft, pulley, ﬂat leather belt
to lower jackshaft.


Ejecting and Disposal
As spindle moves up, grip jaw releases the case while
transfer slide moves in, ejecting trimmed case through
a chute onto a conveyor and then conveys another
case to the cutting station and repeats the above
operation.


CALIBER .30 CASE FINISH TRIM Product Description
PRODUCT DESCRIPTION
The component when received by the ﬁnish trim machine is in the form of
a case as shown in Fig. 1.
The case is made of brass (70% copper, 30% brass). The closed end of
the case is known as the head and the open end as the mouth.
The cases are received by the Finish Trim Department from the Washing
Department where they are washed and dried. The cases are delivered
to the Washing Department from the taper and plug machine.
The dimensions of the case are as follows:
Before ﬁnish trim operation
Over-all length 2.6519-2.6570
Inside diameter of
mouth .307 0—.3078
Outside diameter of mouth .3373
Length of case from case head to
bottom of shoulder 1.9500—1.9558
Diameter at the bottom of the
shoulder .4330-—.4385
Diameter at the top
of the shoulder .3393
After ﬁnish trim operation
Over-all length 2.47 93—2.4883
Inside diameter of
mouth .3070—.3078
Outside diameter of mouth .3373
Length of case from case head to
bottom of shoulder 1.9500—1.9558
Diameter at the bottom of the
shoulder .4330—.4385
Diameter at the top
of the shoulder .3393
After the ﬁnal trim operation (See Fig. 2), the cases are sent to the anneal-
ing machine for the mouth and neck anneal.

FIG. 1
BEFORE FINISH TRIM


FIG. 2
AFTER FINISH TRIM
[18]
CALIBER .30. CASE FINISH TRIM
Inspection
Visual
Gage Care
Gages
INSPECTION
At frequent intervals, after the trimming operation, a careful visual
inspection of the cases must be made. The cases should be inspected for
dents on the head and the body, also for inside and outside burrs on the
mouth, and for long and short cases. These defects indicate the necessity
of an immediate adjustment of the machine is necessary in order to cor-
rect the fault. Whenever defective cases are found, the lot from which
they come must be removed from the machine and properly identiﬁed, so
they will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use, or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool since heat causes expansion of
the metal and results in a temporary variation in the case size.
PLUG GAGE
(First Case Trim)
The length of the case is checked
with a notch plug gage which
indicates the standard maxi-
mum and minimum length.
This gage also checks the case
for inside burr.


SNAP LENGTH GAGE
(Second Case Trim)
The length of the case is checked
with a snap length gage which indi-
cates the standard maximum and
minimum length.


The above described inspection methods are those most commonly em-
ployed in the manufacture of Caliber .50 First and Second Case Trim.
However, other methods may be developed to maintain the manufactur-
ing standards.
[19]
CALIBER .30 CASE FINISH TRIM
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be clean and free from all
foreign objects at all times.
No adjustments are to be made on this machine while it is in motion or
until the handwheel has stopped.
Adjustments on or near the rotary cutter require extreme care to prevent
injury to the adjuster’s hands.
In order to insure proper adjustment of the machine and alignment of its
tools, always turn the machine over by hand before engaging clutch.
Safety guards must be in their proper place on the machine except when
repairs or inspections are being made. '
Inspect the machine periodically during the day’s run to determine
whether or not all connections and adjustments are secure.
I20]
CALIBER .30 CASE FINISH TRIM Adjustments
I
Feed Socket The feed socket receives the case from the feed tube. The case drops from
the feed socket into the hole in the stationary jaw and the transfer slide.
If the feed socket is not in line with the transfer slide and stationary jaw,
the cases will not drop into position to be carried to the cutter. The re-
ceiving block can be adjusted to the right or left and forward or backward
to move the feed socket to its proper position.
. - Q: P;
' ‘Uh
. "'v.“r_r-.. ‘ I


—-—- Feed Block
3/" Lock Screw A II * . . ‘ .- I , ; -_
8 i ’ \ 1/2" Adjusting Screw
1/2" Adjusting
Screw
\
3/3 " Lock Sctew
FEED SOCKET ASSEMBLY
Tools: %" wrench, %" wrench.
Procedure: 1. Open the ﬂywheel guard and turn the ﬂywheel until the transfer
slide is at its extreme backward position. Close the ﬂywheel guard.
2. Remove the feed tube by releasing the bayonet connection at the
feed throat and lifting the tube from the feed socket.
3. Place a test case in the feed socket, mouth up.
(To adjust the feed socket to the left or right)
4. Use a % " wrench to loosen the lock screw on the right side of the feed
block.
5. Use a %” wrench to turn the adjusting screw at the right of the feed
block until the case in the feed socket falls easily into the hole in the
transfer slide and the stationary jaw.
[21]
CALIBER .30 CASE FINISH TRIM
Adjustments
Procedure:
(Cont.)
10.
Tighten the lock screw on the right end of the receiving block.
(To adjust the feed socket forward or backward)
Use a %" wrench to loosen the lock screw on top of the receiving
block.
Use a V2 ” wrench to turn the adjusting screw in front of the receiving
block until the case falls easily into the hole in the transfer slide and
the stationary jaw.
Tighten the lock screw on top of the receiving block.
Replace the feed tube.
[22]
CALIBER .30 CASE FINISH TRIM
Adjustments
Transfer Slide The transfer slide conveys the case from the receiving station to the cut-
ting station. It is necessary that the concave portion of the transfer slide
be in line with the concave portion of the stationary jaw to form the re-
ceiving station for the case.


Tools:
Procedure:
—" Transfer Slide
-— Spring
-- Pin
_ 11/16” Retaining Nut
‘ '>-'' Connecting Link
TRANSFER SLIDE ASSEMBLY
1/2" wrench, 1%," wrench.
1.
2.
11.
Remove the spring from the transfer slide rocker arm by unhooking
it from the pin on the connecting link.
Open the ﬂywheel guard and turn the ﬂywheel until the rocker arm
is at its extreme backward position. Close the ﬂywheel guard.
Remove the feed tube by releasing the bayonet connection at the feed
throat and lifting it from the feed socket.
Use a Kg” wrench to loosen the pin on the connecting link.
Use an 1%” wrench to loosen the retaining nut on the connecting link.
. Pivot the connecting link to move the concave portion of the transfer
slide in line with the concave portion of the stationary jaw.
Hold the connecting link in position and tighten the connecting link
retaining nut.
Tighten the pivot pin on the connecting link.
. Replace the spring on the pivot pin.
10.
To replace the feed tube, ﬁrst, insert the feed tube into the feed
socket; then fasten it onto the feed throat.
Operate the machine and observe the action of the transfer slide.
l 23 I
CALIBER .30 CASE FINISH TRIM Adjustments

Stationary Jaw The case is carried along the stationary jaw from the receiving station to
the cutting station. The stationary jaw must be adjusted to hold the case
directly beneath the pilot on the tool holder for the trimming operation.
.,'-~_
I
a
l
L
4-
A
0
I
A
A
0
-0
A


3/8" ,'.ocI< Nut._____ Stationary Jaw __
1/2 " Adjusting
TRANSFER SLIDE AND STATIONARY JAW
Tools: %" wrench, 1/2" wrench.
Procedure: 1. Place a test case in the feed tube. Open the ﬂywheel guard and turn
the ﬂywheel until the pilot on the tool holder is directly above the
mouth of the case. Close the ﬂywheel guard.
I 2. Use a % ” wrench to loosen the lock screw on the adjustable gib behind
the transfer slide.
3. Loosen the lock screw on the stationary jaw with a % " wrench.
4. Use a %" wrench to turn the stationary jaw adjusting screw to the
right or left whichever is necessary to align the mouth of the case with
the pilot on the tool holder.
5. Tighten the lock screw on the stationary jaw.
6. Press the adjustable gib against the transfer slide and tighten the lock
screw on the gib.
7. Open the ﬂywheel guard and turn the ﬂywheel until the test case is
ejected; at the same time observe whether or not the pilot enters the
mouth of the case. Close the ﬂywheel guard.
[24]
CALIBER .30 CASE FINISH TRIM
Adjustments
Gripping Jaw
(Bumper Screw)
The gripping jaw is forced against the case by cam and spring action. The
spring pressure is adjusted by adjusting the bumper screw against the
movable arm connected to the gripping jaw assembly.

Tools:
Procedure:
CLOSE-UP SHOWING BUMPER SCREW
1%" wrench, %” steel rod.
1.
Remove the transfer slide spring by releasing it from the pivot pin on
the connecting link.
Open the ﬂywheel guard and turn the ﬂywheel until the gripping jaw
is at its extreme backward position. Close the guard.
Use a 11%” wrench to loosen the lock nut on the bumper screw.
Use a %” steel rod to turn the bumper screw against the movable arm
until there is a slight tension on the spring.
Replace the spring on the pivot pin.
[25]
CALIBER .30 CASE FINISH TRIM
Adiustments
Gripping Jaw
Adjusting Screw
Gripping Jaw
Tools:
Procedure:
The gripping jaw holds the case ﬁrmly in position at the cutting station.
When there is a case at the cutting station and the gripping jaw is all the
way forward, there should be about %" clearance between the bumper
screw and the movable arm connected to the gripping jaw assembly. The
clearance at this point is determined by adjustment of the gripping jaw.
I
1. 1-’
';'
Retaining Nut --—- - .


VIEW SHOWING GRIPPING JAW
3 3" wrench, screwdriver.
1.
Release the transfer slide spring from the pivot pin on the connecting
link.
Place a test case at the cutting station. Open the ﬂywheel guard and
turn the ﬂywheel until the gripping jaw is at its forward position.
Observe the clearance between the movable arm and the bumper
screw; there should be a clearance of %;” at this point.
Use a %" wrench to loosen the retaining nut on the gripping jaw.
Use a screwdriver to turn the adjusting screw until the desired clear-
ance exists between the bumper screw and the movable arm.
Tighten the retaining nut against the gripping jaw.
Remove the test case and replace the spring on the pivot pin.
I 26‘ I
CALIBER .30 CASE FINISH TRIM
Adjustments
Spindle Shaft
The spindle shaft rotates the cutters which trim the case. It is mounted
on two bronze bushings. The bottom bushing is tapered and the shaft can
be raised to eliminate any play caused by wear of the bushings. Trimmed
cases of varying lengths indicate a loose spindle shaft. I
Lock Spanner Nut
i
Adjusting Spanner __~ I
Nut . I
Spanner Nuts -___
5
Tools:
Procedure: 1.
2.
3.
5'9‘


Belt
CLOSE-UP OF SPINDLE ASSEMBLY
Screwdriver, two spanner wrenches.
Use a screwdriver to loosen the guard screws and remove the guard.
Remove the belt from the spindle pulley.
Use a spanner wrench to loosen the spanner nuts directly above the
spindle pulley.
Use a spanner wrench to loosen the spanner lock nut on top of the
spindle shaft.
Turn the spanner adjusting nut directly above the top- spindle shaft
bracket until the spindle ﬁts snugly into the tapered bushing.
Hold the adjusting nut in place and tighten the lock nut.
Tighten the spanner nuts above the pulley. (The upper spanner nut
should be tightened against the thrust bearing until the racer ﬁts
snugly against the bearing. The lower nut should be tightened against
the upper one).
Check the adjustment by rotating the spindle by hand. (The spindle
shaft should not have any up or down play, but should rotate easily).
Replace the belt on the spindle pulley.
Replace the guard and tighten the guard screws.
I27]
CALIBER .30 CASE FINISH TRIM Adjustments
Spindle Cutter The cutter trims the case at the mouth to the correct length. If the
trimmed case is too short or too long, the spindle assembly can be raised
or lowered.

Spanner Nut
Clamp Screw
/
VERTICAL SPINDLE ASSEMBLED ON MACHINE
Tools: Screwdriver, spanner wrench.
Procedure: 1. Operate the machine and check the length of the case.
2. Use a screwdriver to loosen the screw on the clamp that holds the spin-
dle adjusting screw.
3. Use a spanner wrench to turn the spindle adjusting screw thereby
raising or lowering the spindle assembly. To shorten the trimmed
cases, turn the adjusting screw counterclockwise and lower the spindle
assembly. To increase the length of the ﬁnished case, turn the ad-
justing screw clockwise and raise the spindle assembly.
4. Tighten the clamp screw.
5. Operate the machine and check the length of the trimmed case. Read-
.lust if necessary.
[28]
CALIBER .30 CASE FINISH TRIM ' Adiustments
Spindle Assembly A spring located above the equalizing bar on a rod connected to the spin-
Tension dle assembly holds a tension on the spindle assembly. Variation in the
trimmed cases may be caused by the springs being too loose. The tension
can be increased by turning the nut above the spring.


- I ...¢.'A44vawee-.¢__,,§._t i
'\
(y i
SPINDLE ASSEMBLY TENSION SPRING
Tool: V ” wrench.
Procedure: 1. Open the ﬂywheel guard and turn the ﬂywheel until the spindle is at
its lowest position. Close the ﬂywheel guard.
2. Use a '/8” wrench to loosen the lock nut on top of the spring rod.
3. Use a %" wrench to turn the adjusting nut until there is about V8”
clearance between the spring washer and the equalizing bar.
[29]
CALIBER .30 CASE FINISH TRIM Adjustments
Hopper The conveyor belt carries the cases from the paddle wheel to the feed
Conveyor Belt throat. If the belt becomes loose, a knurled pulley can be adjusted to
increase the tension of the belt.
Tool: "/16” wrench.
Procedure: 1. Use a V16” wrench to loosen the capscrew on the idler pulley bracket.
2. Raise the idler pulley bracket until the conveyor belt is taut.
3. Hold the bracket in position and tighten the nut on the bracket.
Conveyor Idler Cap Adjusting Nut Idler
Belt Pulley Screw Bracket Located Behind Bracket Pulley
| t H l / I}
L‘


HOPPER CONVEYOR BELT AND IDLER PULLEY VERTICAL SPINDLE AND BELT DRIVE
Spindle Shaft The spindle shaft is driven by a round belt. The tension of the belt is ad-
Belt justed by raising the idler pulley.
Tool: 7/3" wrench.
Procedure: 1. Use a 7/8 " wrench to loosen the nut on the idler pulley.
2. Raise the idler pulley until the belt is taut.
3. Hold the idler pulley in position and tighten the nut.
[30]
CALIBER .30 CASE FINISH TRIM
Troubles and Corrections

Objective
Scratches on the
Inside Mouth
of Case
Burred Mouth
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation
of this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection
of the component, together with constant observation of the machine
as it operates.~
Visual inspection reveals that the inside mouth of the case has become
scratched or marred.
The causes are: The corrections are:
1. Excessive accumulation of brass 1. Remove the pilot and polish off
. Foreign matter.
on the surface of the pilot.
The mouth of the case at the
cutting station is not aligned
with the pilot.
. Oversize pilot. The pilot is too
large and will cause a skinned
mouth on the case.
There is for-
eign matter such as dirt, chips
and scrap around the pilot and
cutting surfaces.
the brass accumulation with
ﬁne emery cloth.
. To align the case with the pilot,
adjust the stationary jaw by
loosening the capscrew and
turning the stationary jaw ad-
justing screw.
. Remove the oversize pilot and
replace with a new pilot. Re-
turn the oversize pilot to the
Tool Servicing Department.
. Remove the pilot and clean
away all foreign matter.
Visual inspection reveals that the mouth of the case has become burred or
has a ragged fragment of brass adhering to the outer edge.
The causes are:
1. The cutter is not seated or
adjusted properly.
2. The edge of the cutter has be-
come dull.
The corrections are:
1. Loosen the clamp screw on the
cutter and allow the cutter to
seat on the pilot. Tighten the
clamp screw, locking cutter se-
curely in place.
. Remove the dull cutter from
the holder and replace with a
sharp cutter. Return the dull
cutter to the Tool Servicing
Department to be resharpened.
[31]
CALIBER .30 CASE FINISH TRIM
Troubles and Corrections
Uneven Case
Length
Irregular Mouth
Gaging discloses that the cases are either too long or too short to meet
speciﬁcations.
The causes are:
1.
Foreign matter. There is dirt
or scrap under the cutting sta-
tion which causes the case to
rise.
. Spindle out of adjustment. This
is caused by play in the spindle
shaft.
. Improper air pressure. Too
much air pressure will force the
case upward.
The gripping jaw gibs become
loose and cause the case to rise
at the cutting station.
The corrections are:
1. Clean the foreign matter from
the cutting station insert.
2. Adjust the spindle by tighten-
ing the spanner nuts on the top
of the spindle shaft, drawing
the spindle shaft farther up
into the tapered bushing.
. Decrease the air pressure by
turning the air valve, so that
the case will seat ﬁrmly on the
base block.
. Call the Maintenance Depart-
ment to tighten the gibs.
Visual inspection reveals that the mouth of the case is irregular, it has
ragged edges or a wavy mouth.
The causes are:
1.
Spindle out of adjustment. This
is caused by play in the spindle
shaft.
. Foreign matter. There is dirt,
scrap and oil in the cutting sta-
tion.
. The edge of the cutter has be-
come dull.
. The gripping jaw is out of ad-
justment and does not hold case
in the cutting station securely.
The corrections are:
1. Adjust the spindle by tighten-
ing the spanner nuts on the top
of the spindle shaft, drawing
the spindle shaft farther up
into the tapered bushing.
. Remove all foreign matter from
the cutting station.
. Remove the dull cutter and re-
place with a sharp cutter. Re-
turn the dull cutter to the Tool
Servicing Department to be re-
sharpened.
. Advance the gripping jaw so
that it will grip the case more
ﬁrmly. Loosen the lock screw,
turn the adjusting screw to ad-
vance the gripping jaw. Tight-
en the lock screw ﬁrmly.
CALIBER .30 CASE FINISH TRIM
Troubles and Corrections

Incomplete Trim Visual inspection discloses that the case is not completely trimmed, either
leaving a ring of brass or having dents around the mouth of the case.
and Dents on
Mouth
Mouth of Case
Mashed
Improper Feed
of Cases from
Hopper or Feed
Tube or Machine
The causes are:
1.
A broken spindle drive belt will
cause spindle to stop rotating.
The thrust bearings in the spin-
dle loosen up and cause the
spindle to freeze and stop ro-
tating.
. Loose spindle belt will cause
irregular spindle motion.
. The gripping jaw does not hold
the case ﬁrmly for the cutting
operation.
The corrections are:
1.
2.
Replace with a new belt.
Loosen the spanner nuts on top
of the spindle, free spindle from
tapered bushing, lubricate the
bushing and adjust the spindle
shaft so the spindle will rotate
freely. Tighten the spanner
nuts.
. Tighten the spindle belt idler
pulley.
. Loosen the lock screw and turn
the adjusting screw bringing
the gripping jaw forward so
that it will grip the case more
ﬁrmly. Tighten the lock screw
ﬁrmly holding the gripping jaw.
Visual inspection reveals that the mouth of the case has become mashed
by the pilot striking it improperly.
The causes are:
1.
The transfer slide is out of ad-
justment and fails to bring the
case in alignment with the pilot.
The cutter tool holder is slip-
ping in the collet.
The corrections are:
1. Adjust the transfer slide by
loosening the nut on the con-
necting link and change posi-
tion of transfer slide to align it
with the stationary jaw.
. To prevent cutter tool holder
from slipping, tighten the span-
ner nut which holds the tool
holder in the collet.
Visual inspection discloses that the cases are not properly feeding through
hopper or feed tube to the machine. This will result in loss of production.
The causes are:
1.
Hopper overloaded with cases.
Foreign matter. There is dirt
and chips in the feed tube.
Conveyor belt is loose and does
not convey cases properly into
the feed tube.
The corrections are:
1.
Remove excess supply of cases
from hopper.
. Remove feed tube and clean.
. Tighten the belt by adjusting
the knurled idler pulley.
[33]
CALIBER .30 CASE FINISH TRIM
Troubles and Corrections
l

Improper Feeding
of Cases through
Machine
Visual inspection discloses that the cases are not properly feeding under
the spindle and cutter.
The corrections are:
1. Align the transfer slide and the
The causes are:
1. Stationary jaw and transfer
slide out of alignment.
. Defective cases or lack of cases
in the feed tube will cause jam-
ming or bouncing at the trans-
fer slide.
. Cases with thick heads will
stick in the insert station.
stationary jaw by loosening
bolts on connecting link and
changing position of the trans-
fer slide.
. Clear cause of jam and ﬁll the
feed tube with cases. Check
the hopper for the proper ﬂow
or cases.
. Remove defective case and
check source of supply. Call
the inspector.
CALIBER .30 CASE FINISH TRIM TOOI Servicing
TOOL SERVICING
Curruvo E-06¢‘


CH/P (‘wave
DRAWING SHOWING ANGLES TO WHICH TOOL IS SHARPENED
Cutter 1. The Caliber .30 Case Finish Trim uses a lathe tool cutter bit about @115"
square and V8 ” long. There is a front clearance of about 6°, a chip curve
and a cutting edge that is tapered about 6°.
2. When the cutter becomes dull, it will not completely trim the cases.
3. Whenever the cutting edge becomes dull, it must be replaced with a
new or reconditioned one.
i ! MIR”
. ' ‘
- I ‘
“ II .
IY I 1
IT 1
I l
1..
.->.. /0
' I
I‘ . fatal‘-IAY »”T"5l " '
VIEW SHOWING APPROVED METHOD or GRINDING CUTTER

I 35 I
CALIBER .30 CASE FINISH TRIM
Tool Servicing
Reconditioning
Cutter
1.
Reconditioning of cutters is to take place in the tool shop. When a
cutter is turned in to the tool shop for reconditioning, it is reground
according to the speciﬁcation and the direction indicated on the blue
print for that cutter.
Each grinder will remove about .002" and leave a new cutting edge.
Under normal conditions this tool can be reconditioned ten or ﬁfteen
times.
The cutter can be ground on a surface grinder. The grinding wheel
should be a crystolon vitriﬁed type, grain 120, grade P., structure 8,
which is a soft grinding wheel. Surface speed of surface grinder is
ﬁxed at between 2750 F.P.M. and 3000 F.P.M. which is suﬂicient speed
for this type of work. If the grinding wheel feed exceeds .0003", the
metal will be distorted due to its hardness.
r *‘ -
U \
VIEW SHOWING WRONG METHOD OF GRINDING CUTTER

I36] ‘.
CALIBER .30 CASE FINISH TRIM
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefﬁciency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[37]
CALIBER .30 CASE FINISH TRIM
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.‘49‘.°‘!F‘.°°.l\'>
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
7q.°°$"t'>‘.¢*-"PD
Frequency of lubrication.
I 38 l
CALIBER .30 CASE FINISH TRIM
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°.‘q9‘P‘!P“.°°.N
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I39]
CALIBER .30 CASE FINISH TRIM
Machine Lubrication

LUBRICATION CHART

Lubricant
Machine Part
N 0. of Fittings,
Grease Cups, etc.
Frequency of
Lubrication H ours

LIGHT GREASE
(Blue Gun)
Driveshaft
Q Q Q I a 0 Q Q 0 0

LIGHT OIL
(Brown Oiler)

J ackshaft for hopper drive
Hopper gear housing and bearing
Idler pulley on conveyor belt
Conveyor belt pulley . . . . . .
Horizontal jackshaft assembly
Vertical jackshaft . . .
Cutting head cam assembly . . .
Gibs on transverse gripper bar
Gripper bar rocker arm . . . . .
Clutch pulley . . . . . . . . .
Spindle pulley bearings . . . . .
Cam rollers . . . . . . . . . .
Head assembly vertical gib plates
Feed ﬁnger gib and guide plates .

l\')[\'.)0Ql\')I—-‘I--*l\D[\'J|\'JO'>I-‘I-*00I\'J
OOOOOOOOOOOOOOOOOOOOOOOOOOOO
I40]
CALIBER .30 CASE FINISH TRIM
Index
Adjustment, Feed Socket, 21
Gripping Jaw, 26
Gripping Jaw, Bumper Screw, 25
Hopper Conveyor Belt, 30
Spanner Nut, 12
Spindle Assembly Tension, 29
Spindle Cutter, 28
Spindle Shaft, 27
Spindle Shaft Belt, 30
Stationary Jaw, 24
Transfer Slide, 23
Anti-friction Bearings, 37
Ball Bearing Unit, 12
Burred Mouth, 31
Camshaft, 3
Horizontal, 3, 10
Vertical, 4, 5, 8, 10
Collet, 12
Sleeve, 12
Conveyor Belt, 3, 15, 16
Cross Shaft, 5, 9
Cutter, 14, 35
Head, 15, 17
Holder, 12, 14
Dents on Mouth, 33
Diameter at Bottom of Shoulder, 18
Diameter at Top of Shoulder, 18
Disposal, 15, 17
Ejecting, 15, 17
Feed Block, 3, 6
Socket, 3, 6
Socket Adjustment, 21
Throat, 15, 16
Tube, 3, 6, 15, 16, 21
Tube Mouth, 5
INDEX
Floor Space, 1
Flow Chart, 16, 17
Friction, 37
Gage Care, 19
Grease, 38
Gripping Jaw Adjustment, 26
Jaw, Bumper Screw,
Adjustment, 25
Jaws, 3, 8
Height, 1
Hopper Conveyor Belt
Adjustment, 30
Idler Pulley, 2
Improper Feed of Cases, 33, 34
Incomplete Trim on Mouth, 33
Inside Diameter of Mouth, 18
Irregular Mouth, 32
Length of Case from Case Head to
Bottom of Shoulder, 18
Liberty Paddle Wheel Hopper, 3, 5
Line Shaft, 2, 3
Lock Spanner Nut, 12
Lubricating Film, 37
Lubrication, 37
Chart, 40
Hints on, 39
Methods, 38
Machine Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 39
Motor, 2
Mouth of Case Mashed, 33
Outside Diameter of Mouth, 18
Over-all Length, 18
Overhead Hopper, 15, 16
Paddle Wheel Hopper, 2, 15, 16
Pilot, 14
Plug Gage, 19
Power, 2, 16
Production, 1
Pulley, 12
Reconditioning Cutter, 36
Rocker Arm, 3, 7
Scratches on Inside Mouth of Case, 31
Selecting a Lubricant, 38
Snap Length Gage, 19
Spacer Washer, 12
Spindle, 12, 15, 17
Assembly, 12, 13
Assembly Tension Adjustment, 29
Cutter Adjustment, 28
Shaft, 3, 9
Shaft Adjustment, 27
Shaft Belt Adjustment, 30
Speed, 1
Starting Switch, 11
Stationary Jaw, 7
Jaw Adjustment, 24
Tools, 1
Transfer Slide, 3, 7, 15, 16, 21
Slide Adjustment, 23
Transmission, 2
Type of Feed, 1
Uneven Case Length, 32
V-belt, 2
Vertical Spindle Assembly, 3, 9
Visual Inspection, 19
Washing Department, 18
Weight, 1
[41]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Inspection
Machine
BY
Training Department

Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481. Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917 , C30, Title 1, Sec. 1; 40 Stat. 217 . Act of March 28,
1940 ; Public No. 443, 7 6th Congress, 3rd Session).
II
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . 2
Process Sequence . . . . . . . . . . . . . . . . . . 9
Product Description . . . . . . . . . . . . . . . . 11
Adjustments . . . . . . . . . . . . . . . . . . . . 12
Troubles and Corrections . . . . . . . . . . . . . . 17
Lubrication . . . . . . . . . . . . . . . . . . . . 19
Index . . . . . . . . . . . 23
III

CALIBER .30 FIDELITY CASE INSPECTION MACHINE
IV
CALIBER .30 CASE INSPECTION MACHINE
Catalogue Data

Manufacturer
Machine
Description
Machine Motor
Type of Feed
Feed Motor
Production
Height
Weight
Floor Space
CATALOGUE DATA
Fidelity Machine Co., Philadelphia, Pa.
Fidelity Horizontal Twin Spiral Conveyor Ma-
chine. Single V belt drive, motor to driveshaft,
drive shaft through spur gears to conveyor shaft.
M h.p.; single phase; 60 cycle; 115—230 volts;
1140 R.P.M.
Liberty Paddle Wheel hopper.
% h.p.; single phase; 60 cycle; 115-230 volts;
1140 R.P.M.
Average 45 per minute.
6 ft.
1000 lbs.
5 ft. x 4 ft.
CALIBER .30 CASE INSPECTION MACHINE Machine Description

MACHINE DESCRIPTION
The Caliber .30 Case Inspection Machine rotates the case in a nearly
vertical position along a horizontally placed screw conveyor permitting
an operator to visually inspect each case.

Hopper Pulley Hopper Box
Wheel
Paddle Wheel
Housing
Clutch Lever
CALIBER .30 CASE INSPECTION MACHINE
Power and The Fidelity Inspection Machine, illustrated above, is powered by a
Transmission % h.p. motor through a V-type belt connecting the motor to the drive-
shaft. The machine is mounted on a metal stanchion which is bolted to
the ﬂoor. The hopper is held directly above the machine bed on a support-
ing stand which is part of the machine frame. The motor is mounted on a
stand at the rear of the machine frame. Power is supplied from the
motor through a V-type belt to the driveshaft. The power is supplied
from the driveshaft pulleys through round leather belts to the hopper and
the spiral conveyor screws.
[2]
CALIBER .30 CASE INSPECTION MACHINE Machine Description

_ Pulley
Wheel
__ Conveyor
—- Belt

SIDE VIEW OF PADDLE WHEEL HOPPER
Paddle Wheel The cases are fed into the hopper box, through a chute from an overhead
Hopper source. The cases are picked up by a series of paddles which lift them
to the conveyor belt. The conveyor belt carries the cases to an opening
where they pass from the conveyor belt into the feed throat. The cases
enter the feed throat, head ﬁrst, and drop by gravity through the feed
tube to the worm conveyor shafts.
Paddle
Wheel
§:|r; veyor
Paddles
Hopper
Box

INTERIOR VIEW OF PADDLE WHEEL HOPPER
[3]
CALIBER .30 CASE INSPECTION MACHINE
Machine Description


Defective
Case Gate
Feed Gate ——
Feed Tube
“" Gate Shoulder
VIEW OF THE CASE GATE
The defective case gate is located in the feed tube just above the feed tube
mouth. As the cases descend through the feed tube to the spiral conveyor
shafts, they enter the defective case gate. The gate is equipped with a
spring ﬁnger which stops any cases that may have bent mouths which
would bind the case in the feed gate. The spring ﬁnger is mounted on the
movable section of the case gate. The defective case gate housing con-
tains a movable portion of the feed tube which may be swung out to
remove a faulty or jammed case. As the gate moves out, the cases in the
upper portion of the feed tube are held in place by the shoulder of the gate.
When the faulty case has been removed, the gate is swung back into
position, allowing the cases to continue to ﬂow through the feed tube.
‘ Spring Finger
_§q\—


CLOSE-UP or THE c/xss GATE
I 4 l

CALIBER .30 CASE INSPECTION MACHINE
Machine Description
Pulley Wheel
Driveshaft
Feed Tube
FRONT VIEW SHOWING DRIVESHAFT
The driveshaft is held by, and rotates in, two ﬁtted bearings. The shaft
is held in a horizontal position between the hopper supporting shaft and a
machined arm which extends from the supporting shaft. The cross-shaft
is located below the hopper and just above the machine bed. The drive-
shaft contains the main drive pulley, the hopper pulley and the pulley
wheel which drives the spiral conveyor shafts.

[5]
CALIBER .30 CASE INSPECTION MACHINE Machine Description
Pulley __ , i - " '_ --—Dog CIIIQCII


-—- Clutch Lever
Pulley Wheel
N.
REAR VIEW SHOWING DRIVESHAFT LOCATION
Clutch The driveshaft is equipped with a dog clutch which is manually operated
by a clutch lever. The clutch is mounted on the left end of the driveshaft
and controls power to the spiral conveyor shafts. The clutch lever extends
downward to the left end of the machine bed. When the clutch is engaged,
the spiral conveyor is actuated carrying the case across to the feed chute
leading to the conveyor belt.
I6l
CALIBER .30 CASE INSPECTION MACHINE Machine Description

\
— Dog Clutch
" Clutch Lever

Pulley Wheel -— I I I ;
~l r 4 ’
VIEW SHOWING CLUTCH ASSEMBLY
Spiral Conveyor The two spiral conveyor shafts hold the cases in a nearly vertical position
Shafts and carry them across the machine bed. Two mirrors are arranged, one
above the case mouth, and the other below the case head, an arrangement
which permits the operator to inspect the interior of the case and the case
head, visually. The conveyor screws are driven by a set of interlocking
spur gears at the left end of the machine. Power is transmitted from the
driveshaft pulley to a pulley wheel mounted on a cross-shaft at the rear of
the gear box. The right end of the cross-shaft has a spur gear attached
which meshes with two other spur gears, one of which is attached to the
left end of the conveyor screws. As the cases reach the end of the conveyor
shaft, they are counted by a recording meter and dropped into the chute
leading to the conveyor belt.
[7]
CALIBER .30 CASE INSPECTION MACHINE Machine Description


/ Counter
P II ‘’
viléi -;
Case
-—- Mouth
Mirror
Feed _,
Tube
- Long
‘ '_ Case
Upper Indicator
Conveyor "
Shah
Lower _, , _ . . __ . _
C°'"SshY<;' . - . . - ~. - '.-; - . A
at __ _, ._ ' .> _ ., _ H _ _
.~ ‘ Case
‘ ' Head
Mirror
FRONT VIEW OF THE MACHINE
Mirror
Showmg
’ Mouths
of Cases
Long
- Case
Indicator
Cases
Moving
l\hong _-
the , , ‘
Conveyor * .» . ... D V ' L_,» ;;
Sham " . I ,.m - ' " ‘ r‘ C-—I:';‘"li " Mirror
‘ __ Showing
Heads
of Cases
VIEW SHOWING CASES ON THE CONVEYOR SHAFTS
[8]
CALIBER .30 CASE INSPECTION MACHINE
Process Sequence

Overhead
Hopper
Liberty Paddle
Wheel Hopper
Feed Tube
Spiral Conveyor
Shafts
Inspection
Mirrors
Case Inspection
and Disposal
PROCESS SEQUENCE
The cases are gravity fed from a truck or conveyor into the overhead
hopper, and drop through a feed pipe which has a control gate, into the
Liberty paddle wheel hopper.
The cases are picked up by the paddles on the rotating paddle wheel and
dropped onto a conveyor belt. The conveyor belt carries the cases to the
feed throat. Because of the construction of the feed throat, and because
the head of the case has more weight than the mouth, the cases drop
“mouth up” through the feed throat. The cases are assisted in their travel
through the feed throat by a leather disc mounted on the inside face of
the conveyor belt pulley.
After the cases pass through the feed throat, they fall by gravity through
a feed tube mounted from the lower end of the feed throat to a casting
above the spiral conveyor shafts.
The cases fall onto the spiral conveyor shafts which are mechanically
rotated and which carry the cases in view of the operator. The heads of
the cases rest on a feed track, and as they are conveyed by the spiral
shafts, they rotate thus making it possible for the operator to inspect the
entire walls of the cases for scratches or dents.
Mounted above and below the spiral shafts are inspection mirrors. The
mirrors are mounted at an angle which makes it possible for the operator
to inspect the mouth and the primer pocket for defects.
Defective cases are removed by the operator from the spiral conveyor
shafts and are placed, according to the defect, into various compartments
in front of the machine. Cases that are too long are stopped by a detector
arm mounted above the spiral conveyor shafts and the cases are removed
by the operator. The good cases are allowed to travel the length of the
conveyor shafts, past a counter which records the number of cases, and
then drop into a tube, and are carried by gravity to a container.
\
CALIBER .30 CASE INSPECTION MACHINE
Process Sequence

Overhead Case Hopper


Feed Pipe


Paddle Wheel Hopper


FLOW CHART


Feed Tube

Spiral Conveyor Shaft

Good Cases


Defective Cases


Container
Container
[10]
CALIBER .30 CASE INSPECTION MACHINE Product Description
PRODUCT DESCRIPTION
The caliber .30 case, when delivered to the case visual inspection
machine from the mouth and neck anneal, is a semi-ﬁnished case as
shown in Figure 1.
Mouth: The open end of the case is known as the mouth.
Neck: The neck is that portion of the case between the mouth and
shoulder.
Shoulder: The shoulder is the tapered portion of the case adjacent
to the neck.
Body: The major portion of the case is called the body. It extends
from the extractor groove to the shoulder and tapers slightly all the
way from head to shoulder. The thickness of the body wall de-
creases gradually from head to the neck.
Web Thickness: The web thickness is the distance from the inside
bottom of the case to the primer pocket.
I
Extractor Groove: The extractor groove is a groove cut around the
circumference of the head portion of the case. Its purpose is to
permit the ejecting mechanism to grasp the head of the case and to
eject it from the gun chamber.
At this inspection machine the cases are checked by the operator for
the following: buckles in the cases, dents, bent mouths, rings on the
outside of the case near the head, split cases, thin heads, identiﬁca-
tion on the head, over-all length and foreign material in the primer
pocket.
\\\\\\\\\\\\\\\X\\ \\ \ \\\ \ \ \ \\\

\ L\ \ \ \ \ \ \\ \\ \

/
FIGURE 1
CROSS-SECTIONAL
DRAWING OF CALIBER

.30 CASE
CALIBER .30 CASE INSPECTION MACHINE
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production, a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect
the machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged
is not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be encoun-
tered, therefore certain adjustments may be required that have not been
described in this section. A thorough analysis of the trouble will indicate
what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be clean and free from all
foreign objects at all times.
No adjustments are to be made on this machine while it is in motion.
In order to insure proper adjustment of the machine and alignment of its
tools, always turn the machine over by hand before engaging clutch.
Safety guards must be in their proper place on the machine except when
repairs or inspections are being made. '
Inspect the machine periodically during the day’s run to determine
whether or not all connections and adjustments are secure.
CALIBER .30 CASE INsPECTIoN MACHINE Adjustments
Feed Plate The feed plate is a small plate which extends over the left end of the spiral
shafts. The purpose of this feed plate is to assist the cases in starting
their travel correctly along the spiral shafts. The feed plate can be raised
or lowered which will reduce or increase the space between the plate and
the spiral conveyor shafts. If the plate is raised too high, insufﬁcient
clearance will be allowed between the spiral conveyor shafts and the plate
to accommodate the case. If the plate is lowered too far, there will be too
much clearance which will tend to allow the case to tip and become
jammed between the plate and the conveyor shafts.


Defective Case
Gate -‘_“'
Conveyor Shafts
VIEW OF THE FEED ASSEMBLY
Tool: Screwdriver.
Procedure: 1. Use a screwdriver to loosen the feed plate.
2. Slide the plate into the position you think will develop smoothness in
action of the case travel.
Note: Be sure the spiral shafts are in alignment. Then to determine
the proper position of the feed plate, make an adjustment, operate the
machine and see if smoothness of case travel has developed. If
smoothness of case travel is not developed, readjust.
3. Use a screwdriver to tighten the feed plate.
I 13 I
CALIBER .30 CASE INSPECTION MACHINE
Adjustments
Lower
Spiral _
Shaft
Long Case
Detector
ll
I .
t
The long case detector is the arm which extends over the top spiral con-
veyor shaft. Its purpose is to reject long cases. If the cases which are too
long pass the detector arm and are not rejected, the detector arm should
be lowered until it rejects the long cases.
‘ L.‘
" Ak


A . I ' ‘


VIEW OF THE SPIRAL SHAFT AND LONG CASE DETECTOR
Tool:
Procedure:
Screwdriver.
1. Place a case of the correct length on the spiral conveyor shafts.
2. Use a screwdriver to loosen the long case detector arm.
3. Lower the detector arm until it clears the case approximately .001.
4. Hold the detector in position and tighten with a screwdriver.
I14]
CALIBER .30 CASE INSPECTION MACHINE Adjustments


Upper Spiral The upper spiral conveyor shaft is one of the two shafts that convey cases
Conveyor Shaft across the machine for visual inspection. This spiral conveyor shaft must
be so adjusted in relationship to the bottom spiral that the cases rest upon
the conveyor shafts in a position perpendicular to the track.


VIEW OF THE GEARS WITH
GUARD REMOVED
%o_we|r
/ Sliilii
VIEW OF SPIRAL SHAFT GEARS WITH GUARD
IN PLACE
Tools: V8" Allen wrench, screwdriver.
Procedure: 1. Use a screwdriver to remove the guard on the timing gears.
2. Use a 1/8” Allen wrench to loosen the Allen set screw on the gear of the
top spiral conveyor shaft.
3. Place a case on the spiral conveyor shafts.
4. Hold the gear stationary and turn the top spiral conveyor shaft until
the case is held perpendicular to the track on which they ride.
5. Use a 1g” wrench to tighten the Allen set screw.
6. Use a screwdriver to replace the guard over the timing gear.
I 15 l
CALIBER .30 CASE INSPECTION MACHINE Adjustments

Idler Pulley The idler pulley is the adjustable belt tension regulator. Its purpose is to
press against the belt ﬁrmly enough to take out any slack in the hopper
conveyor belt. If the hopper conveyor belt is not conveying the cases to
the feed tube throat smoothly, a readjustment of the idler wheel will have
to be made. The idler wheel can be pressed more ﬁrmly against the belt
until it is taut.
1/2" Stud
Pulley
Feed Idler
Throat Pulley
Co v or
BelT ey
Feed
Tube

VIEW OF THE PADDLE WHEEL HOPPER
Tool: V2" wrench.
Procedure: 1. Use a %” wrench to loosen the idler wheel stud.
2. Push the idler against the belt until it is taut.
Note: If the belt cannot be made taut, it will have to be replaced.
3. Use a V2” wrench to tighten the idler wheel stud.
I16]
CALIBER .30 CASE INSPECTION MACHINE
Troubles and Corrections

Objective
Cases Not
Feeding to the
Conveyor Shafts
Long Cases
Not Detected
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as
it operates.
Visual inspection reveals that the cases are not being fed to the spiral
conveyor shafts.
The cause is: The correction is:
1. Tighten the hopper conveyor
belt. Loosen the nut on the
knurled idler pulley and push
the idler pulley against the
conveyor belt until the belt is
taut. Tighten the nut on the
idler pulley.
1. The hopper conveyor belt is
loose. It fails to convey the
cases to the feed tube.
Gaging reveals that the long case detector does not stop the ﬂow of long
cases.
The cause is: The correction is:
1. Adjust the detector to stop the
ﬂow of long cases. Place a case
of correct length beneath the
detector arm. Loosen the nut
on the detector arm and lower
the arm until the case just
clears the bottom side of the
arm. Tighten the nut.
1. The long case detector is not
properly adjusted. It allows
the long cases to pass along the
worm conveyor gears.
CALIBER 30 CASE INSPECTION MACHINE Troubles and Corrections

Cases Jamming at Visual inspection reveals that the cases are jamming at the feed plate.
the Feed Plate ,.
I he causes are:
1. The feed plate is not adjusted
The corrections are:
1. Adjust the feed plate so that
so that the cases start a proper
travel along the spiral conveyor
shafts. The cases turn and
jam between the feed tube and
the spiral gears.
. The upper spiral shaft is not
adjusted to hold the case per-
pendicular to the feed track.
2.
the cases drop smoothly down
onto the feed track. Loosen
the screw on the feed plate and
raise or lower it to the proper
position. The proper position
can be determined only by
changing the position of the
plate and trying it out until
the position of the plate is
found where the cases will be
carried properly along the feed
track.
Adjust the upper spiral shaft.
Remove the guard from the
gears at the end of the shaft.
Place a case against the spiral
shafts. Loosen the set screw in
the upper spiral shaft gear.
Turn the spiral shaft until the
case is perpendicular to the feed
track. Tighten the Allen screw
on the gear and replace the
guard.
CALIBER .30 CASE INSPECTION MACHINE
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction hearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[19]
CALIBER .30 CASE INSPECTION MACHINE
Machine Lubrication
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.‘q.°‘.¢"tl>.°°.l\'>
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.\lS3°$"t‘>‘.°°'.l\'>
Frequency of lubrication.
[20 l
CALIBER .30 CASE INSPECTION MACHINE
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°.‘q.°°$"tl>‘.°°.l\'>
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I21]
CALIBER .30 CASE INSPECTION MACHINE Machine Lubrication
LUBRICATION CHART


. . N 0. of Fittings, Frequency of
Lubricant Machme Pa” Grease Cups, etc. Lubrication Hours
Main Driveshaft . . . . . . . . 2 24
Driveshaft Pulley . . . . . . . . 1 24
Dog Clutch . . . . . . . . . 2 24
Clutch Lever Pivot. . 1 1 Wk.
Conveyor Screw Driveshaft . . . . 2 24
Conveyor Screw Driveshaft Gears . 1 24
LIGHT OIL Conveyor Screw Bearings . 4 8
(Brown Oiler) Counter . . . . . . . . 1 1 wk.
Hopper Driveshaft . . . 1 8
Hopper Driveshaft Clutch 1 8
Hopper Paddlewheel Shaft . . . . 1 8
Hopper Conveyor Belt Idler Pulleys 2 8
Large Case Head Ejector . . 4 1 wk.
Aligning Guide 2 1 wk.

CALIBER .30 CASE INSPECTION MACHINE
Index
Adjustment, Feed Plate, 13
Idler Pulley, 16
Long Case Detector, 14
Upper Spiral Conveyor Shaft, 15
Anti-friction Bearings, 19
Body, 11
Case Inspection, 9
Cases Jamming at the Feed Plate, 18
Not Feeding to the Conveyor
Shafts, 17
Clutch, 6
Lever, 6
Conveyor Belt, 3, 6, 7
Shaft, 3, 5, 8
Shafts, 6
Cross-shaft, 7
Defective Case Gate, 4
Disposal, 9
Driveshaft, 2, 5
Extractor Groove, 11
INDEX
Feed Motor, 1
Plate Adjustment, 13
Tube, 4, 9
Floor Space, 1
Flow Chart, 10
Friction, 19
Grease, 20
Height, 1
Hints on Lubrication, 21
Idler Pulley Adjustment, 16
Inspection Mirrors, 9
Introducing Lubricating Film Re-
duced Friction, 19
Liberty Paddle Wheel Hopper, 9
Long Case Detector Adjustment, 14
Case Not Detected, 17
Lubrication, 19
Chart, 22
Methods, 20
Machine Description, 1
Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 21
Mouth, 11
Neck, 11
Overhead Hopper, 9
Paddle Wheel Hopper, 3
Production, 1
Power, 2
Selecting a Lubricant For a Given
Bearing, 20
Shoulder, 11
Spiral Conveyor Shaft, 9
Conveyor Shafts, 7
Spur Gear, 7
Transmission, 2
Type of Feed, 1
Upper Spiral Conveyor Shaft,
Adjustment, 15
Web Thickness, 11
Weight, 1
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Case Mouth and
~ Neck Anneal


BY
Training Department
Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Specifications have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
TABLE OF CONTENTS
Page
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reason for the Anneal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Adjustments . . . . . . . . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Trouble and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
III

CALIBER .30 CASE MOUTH AND NECK ANNEAL MACHINE
IV
CALIBER .30 CASE MOUTH AND NECK ANNEAL Catalogue Data

CATALOGUE DATA
Manufacturer Modern Bond Corp., Wilmington, Del.
Machine Horizontal twin screw conveyor type annealing
Description machine, equipped with gas burners.
Machine Motor 1/4 h.p.; single phase; 60 cycle; 110 volts; 4.2 amps.;
1725 R.P.M.; ratio 16 to 1; 108 R.P.M. Belt
drive from motor.
Type of Feed Pedestal type paddle wheel hopper. Belt driven
from machine motor.
Production 130 per minute.
Conveyor Speed 130 R.P.M.
Tools None.
Height 5 ft. 5 in.
Weight 900 lbs.
Floor Space ' 3% ft. x 4 ft.
CALIBER .30 CASE MOUTH AND NECK ANNEAL Reason for Annealing

REASON FOR ANNEALINC
Any operation that cold works brass to any great extent makes the grain
size smaller and brass harder. Prior to the mouth and neck anneal the
case has been hardened over its entire length by the taper and plug opera-
tion. To facilitate the insertion of the bullet and the crimping of the case
mouth, and to eliminate danger of splitting the mouth during these opera-
tions, or the danger of season cracking during storage, it is necessary to
anneal the mouth and neck of the case. During this anneal the ﬂames are
directed upon only the mouth and neck and should not affect the hardness
in the shoulder. If the case mouth is over-annealed so that the metal
becomes too soft, the pull required to extract the bullet from the case will
be below the speciﬁcations for the Caliber .30 pull test.
[2]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Machine Description
Power and
Transmission

MACHINE DESCRIPTION
The Caliber .30 Case Mouth and Neck Annealing Machine heats the
mouth and neck of the case to soften the metal in that portion.
Gm Burner
Common
Horizontal Pipe
Conveyor
Screw
. \ ' fy -
. ~' L
’
\
\
OVERALL VIEW OF THE CALIBER .30 CASE
MOUTH AND NECK ANNEAL MACHINE
The Modern Bond Twin Screw, Mouth and Neck Annealing Machine,
illustrated above, is powered by a B4 h.p. heavy duty geared head motor,
through a V-type leather belt connecting the motor to the drive pulley.
The motor is mounted on the left end of the machine bed and can be moved
back and forth to tighten or loosen the motor belts. The motor is equipped
with a double surface drive pulley which also serves to drive the paddle
wheel hopper. The drive pulley is connected to the hopper pulley by a V-
type belt. The machine drive pulley is keyed to the lower conveyor shaft
[3]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Machine Description

Power and
Transmission (Cont.)
Machine Frame
Gas Burners
Conveyor Screws
Paddle Wheel
Hopper
and drives the upper conveyor shaft through meshing spur gears. Each
spur gear is attached to the left end of the conveyor shafts.
The frame work of the case mouth and neck annealing machine consists of
a cast-iron table, swing-mounted on the same pedestal column which sup-
ports the hopper. The table is supported about 2% ft. from the ﬂoor.
Supported above the table of the machine are ten gas burners rigidly
mounted to a common horizontal pipe which distributes the gas to the
burners. The conduit pipe is supported at each end by telescoping rods.
The height of the burners is controlled by this adjustment.
Mounted to the table of the machine are two conveyor screws. These
conveyor screws extend almost the full length of the machine. They are
parallel and are situated directly in front of the gas burners.
The case mouth and neck anneal machine is equipped with a paddle wheel
hopper. This hopper is supported above the machine by a cast-iron
pedestal on the left end of the machine.
CALIBER .30 CASE MOUTH AND NECK ANNEAL Machine Description
Hopper
Feed Tube


Hopper
Pedestal \
PADDLE WHEEL HOPPER
Paddle Wheel The cases are fed into the hopper box through a chute from an overhead
Hopper source. The cases are picked up by a series of paddles which lift them to
the conveyor belt. The conveyor belt carries the cases to an opening
where they pass from the conveyor belt into the feed throat. The paddle
wheel is driven by a horizontal cross-shaft at the front of the hopper box.
A pinion gear is attached to the right end of the cross-shaft which meshes
with the ring gear attached to the outer end of the paddle wheel shaft. A
pulley wheel is attached to the left end of the cross-shaft which is con-
nected to the driveshaft by a round leather belt. The hopper pulley wheel
is equipped with a dog clutch which is manually operated by a lever at the
end of the cross-shaft. The paddles on the paddle wheel lift the cases to
the conveyor belt which carries them to the feed throat. The cases enter
the feed throat head ﬁrst and drop by gravity through the feed tube to
the feed finger. ‘
I5]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Machine Description

Gas Burners
Conveyor
Screw
VIEW SHOWING GAS BURNERS
There is one row of 10 gas burners which direct their ﬂame toward a point
just above the conveyor screw. The purpose of these burners is to anneal
the mouth and neck of the case. These gas burners are of the generator
type. They are rigidly mounted and cannot be spaced differently with
relation to each other. However, their common angle from the horizontal
plane can be adjusted. The ﬁrst two burners and the last two burners are
equipped with thumb valves. The six in between have no control valves
beyond the common valve which controls all ten burners. The holding
plate through which these burners are fastened to the bed of the machine
can be moved in such a manner that the gas burners can be positioned
closer to, or farther from, the conveyor screws.
[6]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Machine Description
Counter _._


-T ’ Conveyor
Screw
Case
D Guide
Track
VIEW SHOWING CONVEYOR SCREW
Conveyor Screws The conveyor screws are the two horizontal spiral shafts, parallel to each
other. These conveyor screws turn in opposite directions causing the cases
to revolve on their axes as they are being conveyed past the gas burners.
I7]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Process Sequence
Overhead
Hopper
Case Paddle
Wheel Hopper
Conveyor Belt
Feed Finger
Gas Burners


PROCESS SEQUENCE
The cases are fed by gravity from a truck or conveyor into an overhead
hopper and ﬂow down through a pipe into a paddle wheel hopper.
The cases ﬂow down the incline of the paddle wheel hopper to the paddle
wheel by gravity. The paddle wheel rotates, picks up the cases and con-
veys them up to the edge of the hopper, where they roll onto the conveyor
belt in a horizontal position.
The conveyor belt carries the cases, single ﬁle, in a horizontal position to
the end of the belt where they fall head ﬁrst into the adjustable feed
throat. -
The cases fall by gravity through the feed tube into the feed block where
they are held in position by a spring tensioned ball stop. From this posi-
tion the cases are knocked out of the feed block against a ﬁxed stop by a
cam actuated feed ﬁnger which is timed by the cam to place a case in each
groove of the conveyor screw to be conveyed through the gas ﬂames.
After being knocked onto the screw conveyor by the feed ﬁnger, the cases
are conveyed in a continuous line before a series of ten gas burners. The
position of these burners and the size of their ﬂames are such that only the
necks and mouths of the cases are annealed. From the conveyor, the cases
pass a counter, then fall into a discharge chute and onto a conveyor belt.


FLOW CHART
Cases
l
Overhead
Hopper
I
Feed Pipe
l
Paddle Wheel Conveyor Belt Feed Throat ' Ten Gas Burners
Hopper ]
Feed Tube
l
\ Feed Block -— Feed Finger Conveyor Screw


l
Discharge Tube

l
Conveyor Belt


[8]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Product Description
PRODUCT DESCRIPTION
When the component arrives at the Caliber .30 mouth and neck annealing
machine, it is a completely formed case. It is made of cartridge brass,
70% copper and 30% zinc. The closed end of the case is called the head
and the open end is the mouth. The case comes to the mouth and neck
anneal machine from the pickle, wash and dry operation.
After the annealing operation during which the case is heated in the region
of the mouth and neck, the annealed portion of the case gives evidence
of the anneal by a slightly darker, duller color as contrasted to the some-
what lighter appearance of the body.
The dimensions of the case before the annealing operation are as follows:
Over-all length 2.4793 — 2.4883
Inside diameter of mouth .3070 — .3078
Outside diameter of mouth .3373
Length of case from case head to
bottom of shoulder 1.9500 - 1.9558
Diameter at the bottom of the shoulder .4330 — .4385
Diameter at the top of the shoulder .3393
There is no appreciable change in the dimensions of the case after the
mouth and neck anneal.
After the annealing operation the cases are sent to the Visual Inspection
Department.
T“ 1‘! F


‘Ell!
~.-5* -at? - '
%.‘;‘§%._’~i§‘i‘*“s:<saw.»'§sﬁs’*§»'it.‘*?:r:‘.‘~‘~'- ~' >"-P‘/' ' _.a':~ﬂ_m. £25 In
FIG. 1 FIG. 2
BEFORE MOUTH AND NECK AFTER MOUTH AND NECK
ANNEALING OPERATION ANNEALING OPERATION
I9]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Inspection

INSPECTION
The annealed cases are tested and inspected by the Metallurgical Depart-
ment. Every ﬁfteen minutes the inspector selects a sample annealed case
from the conveyor screw and makes a Rockwell test on it. The Rockwell
hardness tester is a machine which determines the hardness of the metal.
A representative sample is a case taken from the center of a full row of
cases as it leaves the conveyor screw.


‘St Region of Oxidation
Rockwell Readings

ROCKWELL HARDNESS SKETCH SHOWING ROCKWELL READING SPECIFICATIONS
TESTER
A variable factor which may inﬂuence the mouth and neck anneal is the
working temperature of the annealing machine. Gas pressure is controlled
by a hand valve in the gas line. The positions of the burners also markedly
affect the anneal. When cartridge cases are subjected to an uneven dis-
tribution of heat, the result is an uneven distribution of hard and soft
metal; that is, the metal is softened in irregular patches. The position of
the burner is regulated by the machine adjuster when he is advised that
certain portions of the case fail to meet speciﬁcations in regard to case
hardness. A continuous check on the annealed cases must be carried on
by the Finish Laboratory.
. [10]
CALIBER .30 CASE MOUTH AND NECK ANNEAL I Adjustments

ADJUSTMENTS
Objective To maintain satisfactory operation of this annealing machine both the
product and the machine should be inspected at frequent intervals.
This section of the manual with its illustrations, photographs and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged
is not necessarily the preferred sequence. It is impossible to predict all
the machine troubles that will be encountered; therefore certain adjust-
ments may be required that have not been described in this section.
Thorough analysis of the troubles will indicate what corrective measures
must be taken other than those included in this manual. Adjustments
and repairs requiring special equipment and knowledge should be referred
to the Maintenance Department.
The machine and surrounding ﬂoor space must be free from all foreign
matter at all times.
Do not make any adjustments while the machine is in motion. Examine
the machine periodically to determine whether all connections and adjust-
ments are secure.
Check the ﬁttings to see that they are being oiled and greased properly
by the lubrication engineer.
Make certain that the air currents around the machine are as nearly
normal as it is possible to keep them.
[11]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Adjustments
Drive Pulley The drive pulley belt should be taut in order to produce the best results
Belt Tension in the transmission of power. The motor mount may be shifted so that
the belt tension is sufﬁcient.
Hopper Motor
Pedestal
9/16" Bolt
Bed of
Machine T‘

VIEW SHOWING MOTOR MOUNT
Tool: 9/15 " wrench.
Procedure: 1. Use a 9/16” wrench to loosen the two bolts holding the motor mount to
the machine bed.
2. Slide the motor mount backward until the belt tension is taut.
3. Use a %" wrench to tighten the bolts which secure the motor mount.
[12]
CALIBER .20 cAsE MOUTH AND NECK ANNEAL Adjustments
___—.__s._______
Case Ball The case ball spring stop is the mechanism which prevents the case from
Spring Stop falling out onto the conveyor screws from the feed tube. This ball spring
stop holds the case in the feed tube for the feed ﬁnger to push it onto the
conveyor screws. The ball spring stop can be adjusted to hold the cases
more ﬁrmly in the feed tube so that the action of the feed ﬁnger against
the case is more positive. This adjustment is made by means of a set
screw which may be tightened or loosened.
Feed
Tube
Set Screw
osf Ball 6
' as
Burner
Machine
Bed

VIEW SHOWING FEED TUBE AND BALL SPRING STOP
Tool: 1/2” wrench.
Procedure: 1. Use a 1/2" wrench to turn the set screw of the ball spring stop until the
ball spring exerts enough pressure against the case in the feed tube to
hold it there until the feed ﬁnger will eject it.
[13]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Adjustments

Idler Pulley The idler pulley rides against the outer surface of the conveyor belt to
maintain the proper belt tension. The hopper conveyor belt should be
taut in order to give a maximum amount of efficiency. If the belt is not
taut, the cap screw that holds the idler pulley bracket should be loosened
and the idler pulley should be pressed more ﬁrmly against the conveyor
belt to make it taut.
Puddle
_ Idler
Pulley


Feed Tube
VIEW SHOWING IDLER PULLEY
Tool: "/l6” wrench.
Procedure: 1. Use a "/16” wrench to loosen the cap screw on the idler wheel support.
2. Raise the idler wheel support until the proper belt tension is obtained.
3. Use a "/16” wrench to secure the cap screw.
[14]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Adjustments
Gas Burners


Gas
Burners
Ml‘
Tools:
Procedure:
The gas burners are the jets by means of which proper shape is given to
the gas ﬂame, and a comparative steadiness of burning is assured. The
distance between the burners and the conveyor screws, the height and the
angle of the burners can be adjusted. These gas burners must be adjusted
to direct their ﬂame on proper section of the mouth and neck of the case in
order to meet the speciﬁed Rockwell test. The adjuster might have to
make all three adjustments before the annealed case will meet the speci-
ﬁcations of a properly mouth and neck annealed case.
6" screwdriver, 1/4" wrench, 11/16
1.
2.
l
- Feed Tube
Conveyor
‘_ Screw


VIEW SHOWING GAS BURNERS
’ ” wrench, 965" wrench.
Adjustment for distance between burners and conveyor screw
Use a 9/16” wrench to loosen the two bolts on the gas burner’s holding
plate.
Move the holding plate forward until the.correct distance from the
burners is obtained.
Note: The correct position may be found through a trial and error
adjustment.
Tighten the bolts to secure the holding plate to the machine bed.
Height Adjustment
Use a %" wrench to loosen the set screws holding the gas burners in
a vertical position.
Raise the burners to the correct height.
Note: Correct height is that at which annealing takes place on the
mouth and neck to the extent that the line of discoloration measured
on the inside of split cases will be 14” below the shoulder.
Use a 1/4" wrench to tighten the set screws to secure the burners
remaining at this height.
[15]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Adjustments
Guide Track The case guide track anvil is a small adjustable steel plate against which
Anvil the cases drop when they fall in front of the feed ﬁnger. The purpose of
this anvil is to hold the head of the case in such a position that the case
will start its travel properly along the conveyor screw. If the cases do not
start their travel properly, they may fall down in the guide track. To
correct this, the anvil must be raised or lowered.
_ F..d M.


Gas .
Burner \ __ Conveyor
Case ' Screw
VIEW SHOWING CASE GUIDE TRACK HOLDING-SCREW
Tools: 5/16" Allen wrench, 3/i3/2” Allen wrench.
Procedure: 1. Use a 5/16” Allen wrench to loosen the holding screws on the case
guide track.
2. Remove the case guide track.
3. Use a .3/3/2 " Allen wrench to loosen the set screw on the guide track anvil.
4. Move the anvil in to the proper position.
Note: The correct position may be found through a trial and error
method of adjustment.
5. Use a 3/32” Allen wrench to tighten the set screw on the guide track
anvﬂ.
6. Replace the guide track.
7. Use a 5/,6” Allen wrench to tighten the holding screws on the case
guide track.
[16]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Adjustments
~
Procedure: Angle Adjustment
(Cont.)
1. Use a 1%” wrench to loosen the nuts securing common horizontal
pipe of the burners to the uprights.
2. Change the angle of the burners until a correct (185°) angle is obtained.
3. Use a 11/16” wrench to tighten the end nuts to secure the common
horizontal pipe of the burners to the uprights.


I Conveyor Screw
1/4" Set Screw __.
VIEW SHOWING GAS BURNER ADJUSTMENTS
I17]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Troubles and Corrections

Objective
Uneven flow
of cases to
screw conveyor
Cases fall over
Jam in
feed tube
TROUBLES AND CORRECTIONS
The adjuster will encounter troubles and defects in the operation of this
machine. It is impossible to anticipate all the problems that may confront
an adjuster, but the production troubles that most commonly occur, their
causes and corrections are listed below.
There is an uneven ﬂow of cases to the screw conveyor, leaving gaps in the
row of cases as they pass the gas ﬂames.
The causes are: The corrections are:
The cases pile up at the hopper
outlet. They should be loosened
with a poker. The hopper gate
may need to be opened wider.
1. The lower hopper is jammed. 1.
Wipe off any surplus oil and
tighten the belt if necessary.
If the belt is too smooth, rough-
en it with coarse emery cloth.
Place the feed tube in line with
the feed block.
2. The conveyor belt is slipping. 2.
3. The feed tube throat is out of 3.
alignment with the feed block.
Some of the cases fall over on the track instead of passing the ﬂames in
an upright position.
The corrections are:
1. Adjust the feed ﬁnger to push
the case farther in against the
conveyor screws.
The causes are:
1. The case heads are not entering
the channel and therefore are
not holding the case close
enough to the lower conveyor
screw. -
2. Clean off the track to keep the
depth and width of the track
channel uniform.
2. There is a build-up of foreign
matter on the track.
A jam occurs in the feed tube or at the feed block.
The cause is: The correction is:
1. Keep scrap cases out of the
hopper. A case not ﬁnish
trimmed is too long to pass
the feed block.
1. A defective case or a case
which has not received a ﬁnish
trim, has entered the feed tube.
[18]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Troubles and Corrections

Rockwell The inspector reports that the Rockwell test shows that the cases are of
tests vary irregular hardness.
The causes are: The corrections are:
1. There is an irregular gas pres- 1. Observe the size of the gas
sure. ﬂames often and if the gas
pressure is irregular, adjust the
gas valve.
2. There are strong air currents. 2. Use a wind break if necessary
to prevent the heat from being
diverted by draft.
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite_tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[20]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Machine Lubrication
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Constant or intermittent operation.
2
3
4
5. Cleanliness of surroundings.
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
f°9°P‘t“?°P°
Frequency of lubrication.
I 21 l
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Machine Lubrication
Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
. Bottle oiler.
. Ring oiler.
. Plain oil cups.
2
3
4
5. Drop feed cups.
6. Wick feed cups.
7. Mechanical, force feed, central lubricating system.
8. Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I22]
CALIBER .30 CASE MOUTH AND NECK ANNEAL Machine Lubrication
LUBRICATION CHART


. . N 0. of Fittings, Frequency of
I/ubmcam Machine Part Grease Cups, etc. Imbrication Hours
HEAVY GREASE Feeder shafts . . . . . . . . . . 2 24
(Green Gun)
Motor reduction gear . . . . . . Res. 1 wk.
Idler gear on hopper . . . . . . . 1 24
Clutch lever on hopper . . . . . . 2 24
OIL Driveshaft on hopper . . . . . . 1 24
° Paddle wheel . . . . . . . . . . 2 24
Counter . . . . . . . . . . . . 1 8
Drive gear bearings . . . . . . . 1 8


I23]
CALIBER .30 CASE MOUTH AND NECK ANNEAL
Index
Adjustment, Case Ball Spring Stop, 13
Drive Pulley Belt Tension, 12
For Distance Between Burners and
Conveyor Screw, 15
Gas Burners, 15
Guide Track Anvil, 16
Idler Pulley, 14
Angle Adjustment, 17
Anti-friction Bearings, 20
Caliber .30 Pull Test, 2
Case Ball Spring Stop Adjustment, 13
Paddle Wheel Hopper, 8
Cases Fall Over, 18
Conveyor, 3
Belt, 8
Screw, 4, 6, 7
Screws, 4, 6, 7
Speed, 1
Cross-Shaft, 5
Diameter at the Bottom of the Shoul-
der, 9
at the Top of the Shoulder, 9
Drive Pulley Belt Tension Adjust-
ment, 12
Feed Finger, 5, 8
Finish Laboratory, 10
Floor Space, 1
Flow Chart, 8
INDEX
Friction, 20
Gas Burner Adjustment, 17
Burners, 4, 6, 8
Burners Adjustment, 15
Pressure, 10
Grease, 21
Guide Track Anvil Adjustment, 16
Height, 1
Adjustment, 15
Hints on Lubrication, 22
Hopper Box, 5
Idler Pulley Adjustment, 14
Inside Diameter of Mouth, 9
Introducing Lubricating Film Reduces
Friction, 20
Jam in Feed Tube, 18
Length of Case from Case Head to
Bottom of Shoulder, 9
Lubrication, 20
Chart, 23
Methods, 21
Machine Description, 1
Frame, 4
Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 22
Motor, 3
Motor Belts, 3
Mouth and Neck Anneal Machine, 3
and Neck Annealing Operation, 9
Objective of Troubles and Correc-
tions, 18
Outside Diameter of Mouth, 9
Over-all Length, 9
Overhead Hopper, 8
Paddle Wheel Hopper, 4, 5
Wheel Shaft, 5
Pinion Gear, 5
Power, 3, 4
Production, 1
Rockwell Hardness Tester, 10
Reading Speciﬁcations, 10
Test, 10
Tests Vary, 19
Selecting a Lubricant for a Given
Bearing, 21
Taper and Plug Operation, 2
Tools, 1,
Transmission, 3, 4
Type of Feed, 1
Uneven Flow of Cases to Screw Con-
veyor, 18
V-type Belt, 3
Weight, 1
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Primer Insert Machine
BY
Training Department

Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
-_.
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.” ’ '
(June 5, 1917 , C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 7 6th Congress, 3rd Session).
II
MANUAL CORRECTlONS—CALlBER .30 PRIMER INSERT
LOCATION ERROR CORRECTION
Page 3-1 5 Transfer bar carries 27 cases. Transfer bar carries 26 cases.
Page 4-1 3 Transfer bar carries 27 cases. Transfer bar carries 26 cases.
Page 1,—'l 3 Five detector stations. Four detector stations.
Page 6-Fig Case supporting stem. Slug chute.
Page 1 1 —ll 1
“Thru bevel gears and a round leather “Thru bevel gears and a round leather
pulley” belt"
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . 44
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . 78
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
III

CALIBER .30 PRIMER INSERT MACHINE
IV
CALIBER .30 PRIMER INSERT
Catalogue Data
Manufacturer
Machine
Description
Machine Motor
Type of Feed
Production
Speed of crank
Stroke
Height
Weight
Floor Space
Tools
CATALOGUE DATA
Henry and Wright Manufacturing Company,
Hartford, Connecticut

Straight line horizontal bed and crankshaft press.
Vertical action, gear drive from motor to crank-
shaft.
Totally enclosed; fan cooled; 3 h.p.; 3 phase; 60
cycles; 220/440 volt; 5.81-2.91 amp.;1735 R.P.M.
Pedestal type paddle wheel hopper mounted on
machine. Belt-driven from machine. Primers feed
by a gravity slide hopper mounted on machine.
85 per minute
85 R.P.M.
3 in.
7 ft. ‘
2,000 lbs.
11 ft. x 5 ft.
Piece No.
No case detector
Detector punch P-2
Burring pocket
Piece No.
No primer detector
Detector punch P-11
Seating and crimping
Burring punch P-I Seating and crimp-
Stem—Mouth ing punch P-13
spreader P-60 Holder P-47
Venting Anvil P-14
Venting or ﬂash hole Stem P-15
punch P-76 Mouth varnish
Die P-5 Cup body P-16
Stern P-6 Cup P-17
Holder P-43 Plunger P-18
No ﬂash hole detector Cup spring (1x‘3Qx
Detector punch P-7 .042) AB-3
Primer insert
Inserting pun ch P-9
Plunger spring
( "/§x%jx.022) AB-4
Stem P-10 Split nut P-48
Primer shellac
Pin P-1 9
I1]
CALIBER .30 PRIMER INSERT
Machine Description

Primer
Housing
Drying Traclc
Power and
Transmission
MACHINE DESCRIPTION
The purpose of the Henry and Wright Primer Insert machine is to pierce
a ﬂash hole in the bottom of the primer pocket through the web thickness
of the case. The machine then burrs the shoulder of the primer pocket,
after which it inserts and seats the primer in the case pocket and crimps
the primer into place. As a ﬁnal operation, the machine moisture-proofs
the primer and the inside of the case mouth.

CALIBER .30 PRIMER INSERT MACHINE
The Henry and Wright Primer Insert machine, illustrated above, is
powered by a 3 h.p. motor through a series of spur gears to the crank-
shaft. The motor is mounted solidly on the machine base at the right
end of the machine. Power to the motor is controlled by a toggle switch.
The power from the motor to the crankshaft is controlled through a
friction type clutch. The brake and clutch are mounted on the horizontal
countershaft in the machine gear box. The clutch is manually controlled
by a starting lever. The clutch and brake are synchronous in action; that
is, when the clutch is disengaged, the brake is applied and vice versa. The
crankshaft consists of ﬁve eccentric cams and a barrel cam which operate
the various rams and machine parts. The crankshaft also has a spur gear
attached to the right end within the gear housing which meshes with
another spur gear to drive the crankshaft.
The machine is equipped with a mechanical detector system which
automatically stops the machine when the detector punches indicate
trouble. The power is transmitted from the crankshaft through the
eccentric cam and connecting rods to the three machine cams.
I2]
CALIBER. so PRIMER INSERT
Machine Description

Paddle Wheel
Hopper
Ra ms
Crankshaft
Brake and Clutch
Transfer Bar
Primer Feed Belt -
Latch Blocks
The cases are fed into the hopper box, through a chute from an overhead
source. The cases are picked up by a series of paddles which lift them to
the conveyor belt. The conveyor belt carries the cases to an opening
where they pass from the conveyor belt into the feed throat. The cases
drop head ﬁrst through the feed tube to the feed block.
The upper ram is supported and actuated by four connected rods. The
four rods travel in a ﬁtted bearing through the machine bed. The con-
necting rods are attached at the four corners of the upper ram and are
actuated through the lower ram from the eccentric cams on the crank-
shaft. The lower surface of the upper ram is machined to hold the various
machine punches. The lower ram is also connected to, and actuated by,
, the eccentric cams on the crankshaft. The upper surface of the stem ram
is machined to hold the case supporting stems. The two rams are ac-
tuated in a vertical reciprocating motion.
The crankshaft is held in a horizontal position near the bottom of the
machine base within the housing. The crankshaft consists of an eccentric
cam attached to the left end of the crankshaft outside the machine
housing. This cam actuates the shellac and varnish station. The eccentric
cams and barrel cam actuating the machine parts are attached to the
crankshaft within the machine housing. The crankshaft extends through
the right end of the machine housing and a spur gear is attached on the
crankshaft within the gear housing. This spur gear meshes with another
spur gear to drive the crankshaft.
The machine brake and clutch are mounted on the horizontal counter-
shaft within the gear box. The clutch is manually engaged through a
hand starting lever, which is located at the front of the machine gear box.
The brake and clutch operate synchronously. When the clutch is engaged,
the brake is released and vice versa. The machine is equipped with a
detector system which automatically disengages the clutch when the
detecting system indicates trouble.
The transfer bar is held in a horizontal position on the machine bed by
two sliding gibs. The transfer bar is arranged to position the cases be-
tween the working tools of the upper and lower rams. The transfer bar
consists of a transfer bar block and a series of transfer rails which are
attached to the transfer bar block. The rails overlap the forward edge of
the transfer bar block and are notched to grasp the case as it is moved
from station to station. The transfer bar carries twenty-seven cases
simultaneously through the machine bed.
The primer feed belt is an endless spring steel belt which extends along
the front of the machine bed. The primer belt conveys the primer from
the primer hopper to the turnover ﬁnger which positions it for insertion
into the primer pocket of the case. The primer belt travels over four ﬂat
type pulleys, two at each end of the machine. The primers are fed onto
the primer belt from the primer hopper which is located at the right end
of the machine.
The latch blocks are rectangular metal blocks, whose base is slightly
wider than the top edge. The blocks are bolted to the machine bed
[3]
CALIBER. 30 PRIMER INSERT
Machine Description
Latch Blocks
(Cont.)
Stripper Plates
Stations
directly in front of the transfer bar. Latch plates are attached to the
upper surface of the latch block which acts as a case guide rail. The latch
plates overlap the edge of the latch block. Each latch block is equipped
with latch ﬁngers. The curved portion of the latch ﬁnger extends out into
the case and holds each case steady for the station operation and also holds
the cases in place as the transfer bar moves. At the rear, the transfer bar
is partially covered by a case guide rail which extends over the transfer
bar toward the inner surface of the latch plates thus forming the track
through which the case moves.
The machine bed is equipped with a series of holes through which the
stems on the lower ram enter the case as the operations are performed by
the tools in the upper ram. The holes in the machine bed are large enough
in diameter for the stem to pass through,‘ but too small for the case to
drop through. The stem holes therefore act as case strippers for the
stems. There are only six tools on the upper ram which require strippers,
these are Burring Tool, Flash Hole Detectors, Flash Hole, Primer, Insert-
ing, and Crimping Stations. The stripper at the ﬂash hole station is a ﬂat
metal arm which is attached to the rear case guide rail and extends out over
the head of the case. The forward end is machined in a semi-circular shape
which allows the punch to pass through to contact the case head. As the
punch rises, it brings the case with it; the case head strikes the lower sur-
face of the stripper, stripping the case from the punch. The stripper at the
crimping station is a narrow metal bar which contacts one edge of the case
head as the crimping punch descends to crimp the primer into the pocket.
As the punch rises, the stripperkeeps the case seated in the transfer bar.
The machine contains ten stations, eight of which are equipped with
punches and detector punches which complete the operations of burring
the case, piercing the ﬂash hole, inserting the primer, and crimping the
primer in place; it also performs ﬁve detecting operations as the cases
pass through the machine. As a ﬁnal operation, the primer and case
mouth are water-proofed by the application of shellac and varnish, re-
spectively. The punches and detector punches are aligned in the upper
ram so that each of eight tools performs an individual operation on each
case. The cases pass through the ten stations carriedby the transfer bar.
The transfer bar handles twenty-six cases on every movement it makes.
CALIBER .30 PRIMER INSERT
Machine Description

Paddle Wheel Clutch Conveyor Clutch
Housing Assembly Belt Lever
/ /
I j /
Belt
Guard
Idler
Pulley
OVER-ALL VIEW OF PADDLE WHEEL HOPPER
Paddle Wheel
Hopper


Feed
Tube
Stanchion
INTERIOR VIEW OF HOPPER
The cases are picked up from the bottom of the hopper by the paddles
of the paddle wheel which raises them to the level of the conveyor belt.
The paddle wheel is mounted on the inner end of a horizontal stud shaft
which is actuated through spur gears mounted to a cross-shaft at the
rear of the hopper. The cross-shaft extends beyond the edges of the hopper
and has a large pulley wheel attached to the right end which is driven by
a V-Type belt from the primer feed belt jackshaft. A smaller pulley
wheel is mounted to the left end of the cross-shaft which drives the con-
veyor belt. The conveyor belt is an endless fabric belt which carries the
cases from the paddle wheel to the feed tube mouth. The conveyor belt is
equipped with a small idler pulley held on a bracket at the left side of the
hopper. The hopper cross-shaft is equipped with a manually operated
key type clutch which allows the hopper to be independently stopped.
The clutch is located on the conveyor pulley shaft at the left rear of the
hopper. Thenentire hopper assembly is supported on a circular metal
stanchion which is bolted to the right end of the machine bed.
[5]
CALIBER .30 PRIMER INSERT Machine Description

Upper
Ram
ilaih " I 5 “ Hole
D I Te - " “ ' _. ,. I Detector
e e‘; or ' ' . . r Station
Statlon -_ _ . H ,


Primer Hole
Insert -
Station station
Inverted ‘ "f\
Primer ,5
Detector Sh d
Station ‘ ort an
‘ \ No Case
C . . Detector
nmpmg
Station
VIEW SHOWING UPPER RAM AND THE VARIOUS STATIONS
Rams The upper ram is machined to hold the working punches. The lower ram is
machined to hold the supporting stems. The bottom ram is connected to
the upper ram by connecting rods and is actuated from two eccentric
cams on the crankshaft in the following manner.
The upper ram is actuated through, and guided by, four connecting rods,
one attached to each corner of the upper ram. The connecting rods extend
through the machine, and through the corners of the stem ram to the
driving ram. The connecting rods are bolted solidly to the driving ram
and extend through two bearing blocks located in the machine bed. The
driving ram is actuated by, and connected to, the eccentric operating cam
by two short connecting rods.
The stem ram is guided by, and rides on, the four connecting rods which
actuate the upper ram. Power is supplied to the stem ram through a
connecting rod at each end of the ram. The connecting rods are attached
to two other eccentric cams which actuate the stem ram. This arrange-
ment transmits a vertical reciprocating motion to the punch and stem
rams.
"\-


Case . _.
Supporting — ' ’ ‘,._ I .\‘
Stem _ 7 Q’ * ‘H H A :'...f
1 2- “r F K“
.~ 4 ' V_ y, \ j
a_ _ _
_ '°’ “"‘.__.__- _...|II-es."-1'-Fl“
LOWER RAM AND CASE SUPPORTING STEMS
I 6 I
CALIBER .30 PRIMER INSERT .
Machine Description
Space Finger
Cam
Latch Block
Primer Spacing
Finger


Feed Tube
Feed Block
P ~
1/ Case Track
Latch Plates
VIEW SHOWING FEED BLOCK ASSEMBLY
Feed Block The feed block is located at the right end of the machine bed below the
right end of the upper ram. The feed block is attached to, and supported
by, a metal stand directly above the holding ﬁnger in the transfer bar.
The feed tube opens into the feed block from the rear of the block and
feeds the cases singly onto the case lip of the feed block. Two metal wire
ﬁngers are attached to a ﬁnger block which is held to the left side of the
feed block by a wrist pin arrangement which allows a free action of the
ﬁnger block. The two ﬁngers extend from the block into the feed block
directly above the case lip. The upper ﬁnger closes the feed tube mouth
as one case enters the lip. At the same moment the case on the feed lip
is struck by the lower ﬁnger which knocks it into the feed chute. The
pin turns the case head up as it drops into the transfer bar. The ﬁnger
block is held in a forward position by spring tension and is forced back
allowing the case to enter from the feed tube by a wedge cam arm attached
directly above the ﬁnger block to the upper ram. Thus the feed block
mechanism is actuated on every stroke of the ram.
[7]
CALIBER .30 PRIMER INSERT
Machine Description

Connecting
Rod -_
Crankshaft


VIEW OF CRANKSHAFT ASSEMBLY
The crankshaft comprises four eccentric cam wheels which actuate the
three rams of the machine. These cams are circular metal wheels, at-
tached to the crankshaft at an off center position, which describe an ir-
regular motion as the crankshaft revolves. Through this motion the rams
are actuated in a reciprocating motion allowing the upper ram and the
lower stem ram to meet at the machine bed where the various operations
are performed on the cases. The crankshaft is driven by a large bevel gear
attached to the right end inside the gear housing. The shellac and varnish
cam wheel is attached to the left end of the crankshaft-which extends
through the machine housing directly below the shellac and varnish sta-
tions. The crankshaft is supported by, and rotates in, three ﬁtted bearings.
I8]
CALIBER .30 PRIMER INSERT Machine Description
Throw-Out
Shaft
Counter-
shaft
Brake
Shoe
Brake
Adjusting
Spﬁng

BRAKE AND CLUTCH MECHANISM
Brake and Clutch The brake and clutch are mounted on the horizontal countershaft con-
tained within the gear housing. The clutch and brake are mounted and
connected to operate in conjunction with each other. When the detector
system of the machine indicates trouble at one of the various detector
stations, the clutch throw-out arm is released by the detector shaft. The
clutch throw-out arm springs forward, engaging the dog clutch at its lower
end. The dog clutch is mounted on a cross-shaft which revolves to actuate
the mechanism which disengages the clutch and applies the brake. The
brake and clutch mechanism are so arranged that when the machine is
automatically stopped, the top ram will always stop at the top position.
When the machine is started again, the clutch throw-out arm must be
manually reset behind the detector shaft.
I9l
CALIBER .30 PRIMER INSERT Machine Description

Burring ' No Case
Station _ ' A , ‘ Detector
, .5 . . .;~' ; . » Punch
-—- Detector
Shaft
Stripper
Finger \-


Transfer
Central- > _ A _, ' _ / Bar
_mng-— ~ 1 - j . ' Location
Fmger . " -- ‘ ' .1 - ' ‘ ' I ' ‘
Latch
Plate
_ Latch
Block
r' 1 _,~_g.~r,,ﬂ4:"t, I _
s , '
Y.‘ ;.
__.~~-..>:_',.-: .
SECTIONAL VIEW OF DETECTOR AND BURRING PUNCH STATIONS
Transfer Bar The transfer bar is held in a horizontal position on the machine bed and
slides from right to left on two blocks. This right to left motion is actu-
ated by a rocker arm from a barrel cam on the crankshaft. The rocker arm
extends from the barrel cam through the machine bed and is attached to
the transfer bar by a wrist pin arrangement which allows a free swing of
the arm. The arm is supported at its pivotal point within the machine
bed by a horizontal cross-shaft.
The movement of the transfer bar follows the path of a rectangle and it is
actuated in its in and out stroke by an eccentric cam which is located on
the crankshaft. A connecting link, attached to a horizontal cross-shaft
and connected through strap links to the transfer bar, works off of a rocker
arm which in turn contacts the eccentric cam. The horizontal rocker arm,
extending through the rear of the machine frame, is supported at its pivotal
point by a wrist pin arrangement which allows freedom of movement when
the rocker arm is actuated by the eccentric cam. The ﬂat metal connecting
link is attached to the outer end of the rocker arm by a stud which allows
the connecting link to swing freely. The upper end of the connecting link
is attached to the center point of the horizontal cross-shaft which is held
in position along the rear edge of the machine bed by two ﬁtted bearings.
The cross-shaft is connected to the transfer bar by two strap links con-
nected to the transfer bar operating blocks. A tubular shaft is held in po-
sition between the two connecting links which contains a heavy coil spring
that holds the transfer bar at its forward stroke until it is actuated by the
eccentric cam. The connecting blocks are attached to the transfer bar by
a square bronze block which ﬁts into a slotted section of the transfer bar
and acts as a bearing surface when the transfer bar is drawn back by the
eccentric cam and brought to the left or right by the barrel cam.
[10]
CALIBER .30 PRIMER INSERT Machine Description

Primer
Feed Belt
Primer
Belt
Adjusting
Pulley

VIEW OF PRIMER FEED BELT PULLEYS
Primer Feed Belt The primer feed belt is an endless steel belt which travels across the front
of the machine bed, directly in front of the ease track. The belt travels
on four pulleys, two located at each end of the machine. The pulley wheel
mounted at the right end of the machine provides the motive power which
drives the belt over the three idler pulleys. The driven pulley is mounted
on a horizontal shaft and driven through bevel gears and a round leather
pulley from the countershaft within the gear box. The tension of the belt
can be adjusted by moving the idler pulley at the left end of the machine.
The primers pass from the primer feed hopper onto the primer belt at the
right end of the machine. /The primers are spaced evenly along the primer
belt by a spacing ﬁnger which is mounted on the belt guard at the right.
At the front of the case track, the primer belt is partially covered by metal
plates which form the guides through which the primers travel on their
way to the inserting station. The spacer ﬁngers are actuated by a tapered
punch which is located in the upper ram. By this arrangement the primers
are fed onto the section of the primer belt which leads to the inserting sta-
tion on every down stroke of the upper ram.
I11i
CALIBER .30 PRIMER INSERT
Machine Description


Crimping Tool
Holder
Crimping Stripper _ Connecting
Rod
Latch Plate
Latch Block
Latch Block
Stud
Latch Blocks

VIEW OF LATCH BLOCK
The latch blocks are rectangular metal blocks, whose bases are slightly
wider than the upper edges. The blocks are bolted to the machine bed
along the front edge of the transfer bar. Each block is provided with
adjustable latch ﬁngers which extend from the inner surface of the block
into the case track and support the cases at each station. Latch plates
are attached to the upper surface of the latch blocks and act as a case guide
rail. From the rear of the machine the transfer bar is partially covered
by the rear case guide rail, which extends over the transfer bar leaving only
the notched sections exposed, thus forming the track through which the
cases move. The latch blocks are held in correct alignment on the bed of
the machine by dowel pins, thus keeping the blocks in proper alignment
at all times. The latch ﬁngers may be adjusted from left to right, or in
and out, as is necessary to position the cases directly below the punch.
[12]
CALIBER .30 PRIMER INSERT Machine Description

Machine
Bed

VIEW SHOWING STRIPPER PLATES
Stripper Plates The stems in the lower ram enter through the machine bed through a
series of holes to support the cases as the tools of the upper ram perform
the various operations on each case. The holes through which the lower
stems enter are large enough in diameter to allow a free passage of the
stern, but are too small in diameter to allow the case to drop through.
Thus the holes of the machine bed act as stripper plates as the stems are
withdrawn after each operation. The upper surface of the rear case guide
rail is provided with six strippers which strip the cases from the punches
in the upper ram after each operation. These upper strippers are adjust-
able and the outer ends are recessed in a half moon shape to allow the
punches to enter through them to contact the case heads.
[13]
CALIBER .30 PRIMER INSERT
Machine Description
Turnover Finger
Mechanism

VIEW OF TURNOVER FINGER MECHANISM
The turnover ﬁnger assembly is supported in a horizontal position between
the primer belt and the case track by a bracket at the insert station. The
bracket is a U-shaped affair which is bolted to the machine bed. The
turnover ﬁnger assembly consisting of a pair of ﬁngers and a barrel
clutch, is held in the bracket by male adjusting screws which may be
adjusted allowing the barrel clutch to rotate freely. The turnover ﬁnger
mechanism consists of a spur gear and metal block held together on the
cross-shaft. The metal block contains the turnover ﬁngers by which the
primers are picked up from the primer feed belt and carried in a half
circle to a position directly above the case pocket and beneath the in-
serting punch. The turnover ﬁngers are actuated by a gear shaft which
meshes with the teeth of the spur gear to move the ﬁngers from the primer
belt to the case head.
The spur gear is mounted between two adjustable rings which are sep-
arated by ﬁber washers forming a friction clutch which partially absorbs
the shock of the ram movement. The gear rack is mounted with a slip ﬁt
in the lower ram. The gear rack is provided with a spacer block operated
by cam action.
As the lower ram travels upward, the spacer block is held beneath the
lower ram surface and a collar on the gear rack. When the ram reaches
its top stroke, a cam removes the spacer block from beneath the gear
rack collar allowing the gear rack to slide downward into the ram. As
the lower ram starts on its downward stroke, the gear rack again slides
upward thus allowing the ﬁngers to remain over the case head as the
[14]
CALIBER .30 PRIMER INSERT Machine Description

Turnover Finger punch in the upper ram moves away. At the same time the lower ram,
Mechanism moving down, releases the spacer block from against the cam, allowing it
(Cont.) to insert itself again between the ram surface and the gear rack collar.
This arrangement allows the turnover ﬁngers to stop momentarily at
each end of their half circular stroke.
As the ﬁngers are brought down against the primer belt, the primer push-
in ﬁngers insert a primer into the ﬁngers of the turnover mechanism. The
push-in ﬁngers are actuated from a face cam attached to the lower ram.
A rocker arm attached at its pivotal point within the machine bed trans-
mits the cam action to the push-in ﬁngers.
[15]
CALIBER .30 PRIMER INSERT
Machine Description

Station I,
Short or No Case
Detector
The no case detector punch is held in the upper ram
and may be adjusted up or dowh in the punch tool
holder. The lower end of the punch is machined
leaving a ﬁat circular head which contacts the head
of the case on every down stroke of the ram. The
upper end of the punch is externally threaded about
1/2 of its total length. When “no case” is shown in
the transfer bar, the detector ﬁnger is allowed to
strike the stop dog, releasing the latch and auto-
matically stopping the machine. If a short case is
the cause of the stop, the case may be lifted out by
the operator, examined and replaced with a good
case. If no case is the cause of the stop, the operator
will place a case into the empty space and continue
operations.
[16]
CALIBER .30 PRIMER INSERT
Machine Description
Station 2,
Burring Station

The burring tool is held in an adjustable tool holder in
the upper ram and may be raised or lowered to a posi-
tion where it will properly burr the case pocket for the
insertion of the primer. The case, having been checked
at station 1, moves to this station passing under a
stripper. The stripper is held in place by a cap screw
and is set high enough to allow the case to pass under
easily. It is provided with a hole large enough to
allow the burring punch to pass up and down easily
and small enough to prevent the case head from being
pulled up. The hole in the lower stripper block is large
enough that the case cannot fall through. The lower
stripper block is located in the bottom of the case
track and is held down by the guide rails.
At this station on the down stroke of the machine, a
burr is put in the pocket of the case so that a primer
may be started into the case easily. The burring punch
is held in the machine by the punch holder. The
burring punch holder is assembled in the upper ram.
The punch holder is screwed into the ram and may be
adjusted up or down. It is. locked into position with a
lock nut. The burring punch is allowed to ﬂoat in the
punch holder to insure a free lining in the case pocket
and an even all-around burr. The ﬂoating punch may
be adjusted by moving the set screw and lock nut in the
top of the punch holder which moves the plunger up or
down on top of the burring punch until a proper adjust-
ment of .005 to .010 clearance between the plunger and
punch is obtained. Too much pressure on the case
head which causes a ring may result in the case’s crack-
ing. Careful adjustment must be made to avoid this
possibility.
The burring stem is held in the lower ram in an ad-
justable tool holder. The stem may be adjusted by
means of the tool holder to support the case as the
burring tool contacts the case head. The tool holders
are held in place by tool holder blocks which are
bolted to the ram by four cap screws.
[17]
CALIBER .30 PRIMER INSERT
Machine Description
_————____9__—___——_—-__-——————
Station 3,
Flash Hole Punch
.__.---—\_’


The ﬂash hole punch is held in an adjustable tool
holder in the upper ram. The ﬂash hole stem and die
assembly are held in the stem holder on the lower ram
and supports the case as the piercing operation is
completed. The case having been burred at station 2,
moves to this station where the ﬂash hole is pierced.
The case, as it travels from station 2 by means of the
transfer bar, passes under a stripper and is held in place
by a centering ﬁnger and a latch ﬁnger. On the up
stroke of the lower ram, the piercing die located in the
top of the stem enters the case and at the ﬁnish of the
up stroke of the lower ram, the case head is seated mouth
down on the piercing die.
A hole known as the ﬂash hole is pierced in the bottom
of the primer pocket through the case head. The
piercing punch must enter the die at least 1% of an
inch. It is necessary that the piercing punch and
piercing die be in proper alignment. The stripper at
station 3 holds the case down while the punch comes
out on the downward stroke of the lower ram. The bot-
tom stripper is located in the bottom of the case track
and holds the case up while the bottom stem and die are
drawn out on the downward stroke of the ram.
A centering ﬁnger at this station is used to hold the
case directly under the punch to prevent the ﬂash hole
from being pierced out of center in the case head. The
centering ﬁnger is located in a seat in the bottom of the
stripper block. The die stems have a hole all the way
through to allow the plug or scrap metal that comes
from the piercing operation to fall out. Piercing dies
are pressed in the end of the piercing stems. The plug
is dropped through the stem, through the stem holder,
and through the bottom ram into a funnel shaped brass
pipe which is bent to allow the plugs to fall in a con-
tainer outside the machine.
[13]
CALIBER .30 PRIMER INSERT
Machine Description

Stations 4 and 5,
Flash Hole
Detectors

STATION 4
FLASH HOLE DETECTOR
STATION 5
FLASH HOLE DETECTOR
The case having been pierced at station 3 moves to the station where it is
checked for ﬂash hole, and moves to station 5. Stations 4 and 5 are
identical, having the same adjustments and serving the same purpose.
The ﬂash hole detector punches are cylindrical steel shafts tapered to a
ﬁne point at their lower ends. The upper ends are threaded for insertion
into tool holders that may be adjusted up or down by loosening or tighten-
ing the punches in the tool holders. The tool holders are assembled by a
sliding ﬁt in the upper ram. Each tool holder shaft is connected to -a
horizontal cross-shaft on the upper surface of the ram. The cross-shafts
are held by, and rotate each in, two individual bearing blocks. A detector
ﬁnger is attached to the outer end of each cross-shaft which extends in a
downward position beyond the surface of the ram to contact the detector
dogs when the detector punches indicate cases having no ﬂash holes.
Through this arrangement the machine is automatically stopped and the
operator may remove the faulty cases.
[19]
CALIBER .30 PRIMER INSERT
Machine Description

Station 6,
Primer Insert

The cases having been checked for ﬂash holes at
stations 4 and 5, are brought to station 6 by the
transfer bar where the primer is inserted into the
primer pocket. The inserting tool is held in an ad-
justable tool holder in the upper ram by the hexa-
gonal headed cap nut. The tool is cylindrical in
shape tapering at its lower end to the diameter of
the primer pocket. The working end is slightly con-
cave to ﬁt the head of the primer. The inserting
punch may be raised or lowered to seat the primer
to its correct depth for this particular station by ad-
justing the tool holder up or down in the upper ram.
The bottom stem, which supports the case as the
primer is inserted, is located in the bottom ram held
in an adjustable tool holder. The tool holder is
bolted to the lower ram by four cap screws. The bot-
tom stripper is a hole in the bottom of the case track
large enough for the stem to enter freely, but too
small for the case mouth to drop through, and acts as
a bottom stripper.
[20]
CALIBER .30 PRIMER INSERT
Machine Description

Station 7,
Inverted or
No Primer Detector
M .. ., ~ » _ ....,~ ~..*...~.~.wt..~...-~ »\-...-.‘_.-_,~.-.1.‘ . . . . -_.


The case, having had the primer inserted at station
6, moves to this station where it is checked for no
primer or inverted primer. The case is held in posi-
tion by the transfer bar and the latch ﬁngers. The
case is supported by the extractor groove around the
case head which ﬁts into two supporting rails, one
located on each side of the guide rail. The supporting
surfaces of the guide rails slightly raise the case,
lifting the mouth from the bottom of the case track
as the primer detector punch contacts the case. The
supporting rails are held in a slot in the rail clamps
by three small screws and when these become worn,
they must be replaced.
Detector Punch
The detector punch screws into the bottom of the
detector spindle and is locked into position by a
lock nut. The lower end of the punch is tapered to a
point for entrance into the primer pocket in the
event that the primer has been left out. Cases hav-
ing a primer inserted at the proper height are de-
tected by the punch which comes down in the ram,
and touches the primer lightly on its top. The
detector punch touches the primer before the down
stroke is completed and at the ﬁnish of the down
stroke, the punch lifts the detector ﬁnger.
Detector Finger
The detector ﬁnger is located in the slot in the top
of the detector shaft and swings in a stationary
bracket located on top of the ram. This ﬁnger is in a
ﬁxed position approximately off center three to one.
When the punch lifts the detector ﬁnger, the free
end of the ﬁnger drops, holding the escapement
ﬁnger. The detector punch is connected to the de-
tector ﬁnger by a pin arrangement which allows
freedom of action.
I21]
CALIBER .30 PRIMER INSERT
Machine Description

Escapement Finger
Detection
Reset Shaft
Ejector Shaft
The escapement ﬁnger is a T-shaped bar located in the slot in the top of
the ram. The escapement ﬁnger is controlled by a coil tension spring
extending from the spring post on the escapement ﬁnger to a spring post
on the upper surface of the ram. The escapement ﬁnger is held in a back-
ward position by the tension of the coil spring. The forward stroke is
actuated by a wedge cam on the escapement door shaft.
When no primer or an inverted primer is detected, the punch comes
down and on the up-stroke, the escapement ﬁnger is pulled by the coil
spring under the release clamp, located on the case ejector shaft. This
compresses the escapement door spring, opening the door in the case
track at station 8, allowing the case to drop through the tube into a con-
tainer on the outside of the machine. On the next down stroke, as another
primer is detected, the case having, no primer is discharged at the next
station On this down stroke if a good primer is indicated, the reset pin
in a T-shaped escapement ﬁnger is held back by the detector ﬁnger, and
the escapement door is closed by the compression coil spring located and
held in the side of the machine by a screw plug. The good cases then move
past the escapement door to the next station.
The case reset ejector shaft is located in the hole in the top of the machine
bed. It is held stationary by a nut on the end of the shaft.
An arm is pinned on the ejector shaft and holds a stop pin with the detec-
tor shaft in the same position at the beginning of each down stroke.
Friction pins are located in the bottom of the detector shaft bushing.
Three holes are drilled in line approximately %" apart in the detector
shaft bushing. Brass pins of equal length are inserted in the two outside
holes and the friction shaft is screwed in the center hole. A washer slips
over the shaft and rests on the brass pins. A coil spring is slipped on the
shaft behind the washer. A nut and washer are screwed on the friction
shaft, applying pressure on the spring, the washer and the friction pins,
and hold the shaft in the position determined by the detector pin at the
down stroke and the shaft reset pin at the up-stroke.
[22]
CALIBER .30 PRIMER INSERT Machine Description


Dt t P I: .
R:sceFPinunc \
/ Stationary Shaft


Escapement
Door Block


Detector Punch _ Q’ R ,\\
Q-I
~“ .. If
“"'*f’\ ‘III
Latch Plates 6" '
Escﬂpement Door \
. 0,9 ,/

IT:-I0‘
\/
\'


/ “@ ' I /
Friction Pin V
Adjustment II!

Escapement Door
Operating Shaft
[23]
CALIBER .30 PRIMER INSERT
Machine Description

Station 9, Seating
and Crimping

The case having a primer properly inserted, passes
station 8 to this station where the primer is further
seated and crimped. The case is held in position by a
latch ﬁnger located in the latch block directly in line
with the crimping punch. On the up stroke of the
lower ram the bottom stem enters the case and sup-
ports it while the tool in the upper ram performs the
crimping operation. The crimping punch is made in
two pieces, the crimper and the crimper holder. The
crimper is held in the holder by a set screw that may
be replaced as often as necessary. The crimper holder
is counter-bored to slip over the case head, centering
it while the primer is seated and crimped. The
crimping punch holder is located in the top of the
ram and is adjustable up and down. It is locked in
position by a lock nut. The crimping holder is held
in the crimping punch holder by a lock nut. The
crimper pin is adjustable up and down by a plunger
set screw and locked in correct adjustment by a
lock nut.
The cases are held down by a stripper located in the
stripper block. The stripper block is bolted to the
rear of the case track immediately below the crimp-
ing tool and can be adjusted by sliding it in or out
in a dovetailed slot in the stripper block. The stripper
is locked in position by a screw and clamp.
A slot is cut in the cimper holder on the rear surface
so that on the up and down stroke of the ram the
crimper holder will not strike the stripper.
The lower stem is ﬁtted with a heavy coil spring
which controls pressure against the stem when the
case is lifted and the crimping tool performs the
crimping operation. This pressure is very important
and may be adjusted by means of the coil tension
spring adjustment until the correct pressure is ob-
tained.
The stem holder shaft is assembled in the lower ram.
The shaft slips through the coil spring, and through
the pressure block, and is locked in place by a lock
and jam nut. A dog point set screw through the
pressure block rests in the key way out in the bottom
of the shaft holding it in place while the lock nuts
are adjusted.
I24]
CALIBER .30 PRIMER INSERT
Machine Description


Primer Belt —-"
Salety Block _
Station 8, Case
Ejector Station
Opening Finger
_ Stationary Shait
. Primer Stop Plate
ESCAPEMENT DOOR ASSEMBLY
The cases, having been checked for no primer or an inverted primer at
station 7, are moved by the transfer bar to this station where the defective
cases are ejected. This station has neither bottom stem nor top punch
since the only purpose here is to eject the cases that are unsatisfactory.
The station consists of an escapement block which is held in place on the
machine bed by three screws and two dowel pins in each gib. The gibs
are screwed tightly to the bed. Enough clearance is left between the gibs
and the escapement block to allow the block to slide freely. The escape-
ment block has a shoulder machined on the front of the block which
forms part of the case guide track when the escapement block is in a
closed position. The escapement block is opened by the case ejector
shaft. The case ejector shaft lifts the opening ﬁnger and pushes the
escapement block back, compressing a coil spring and plunger located
in the side of the machine and held in by a screw plug.
The opening ﬁnger is held in a bracket by a wrist pin arrangement which
allows a free swing of the ﬁnger. The bracket is held in place under the
machine bed by cap screws. The escapement block has a boss on the bot-
[25]
CALIBER .30 PRIMER INSERT
Machine Description

Opening Finger
(Cont.)
Holding Finger
tom of the block that rests in a square hole in the top of the machine bed.
When a bad case is detected as it passes to this station, the opening ﬁnger
pushes on the boss opening the escapement block. The spring and plunger
rest on the front of the boss, keeping the escapement block closed at all
other times. A slot is machined in the escapement block shoulder for
the holding ﬁnger.
The holding ﬁnger is held in a horizontal position extending into the case
track above the escapement door opening. A pin through the holding
ﬁnger holds it in place. A compression spring pushes the ﬁnger holding
the case against the anvil, while the transfer bar moves back to advance
the next case.
[26]
CALIBER .30 PRIMER INSERT
Machine Description

Curve
Shaped -_
Cam
Cam
Roller
Vertical
Slide
Shellac
Container
Station ID, Shellac
and Varnish
Curve Shaped
Cam and Cam
Roller
Vertical Slide
Horizontal
Slide
Horizontal
Slide
TOP VIEW OF VARNISH AND SHELLAC STATIONS
The shellac and varnish station assembly is mounted on a special housing
which is bolted to the left end of the machine bed. The varnishing and
shellacking mechanism consists of the following parts, all of which are
actuated from an eccentric cam wheel through an adjustable connecting
rod. The cam wheel is attached to the left end of the crankshaft.
The plate cam is bolted on the unit casting and is adjustable from front
to back. The screw holes in the cam are elongated to allow the cam to be
moved to the desired position. The cam roller is located in the top of the
vertical slide and is held in place on the slide by a cam roller stud.
The vertical slide is located in a dovetailed seat machined in the top of
the horizontal slide. The dovetailed seat is slightly wider than necessary
for the insertion of a bronze gib. The gib is approximately V16 of an inch
thick and 4 inches long and is held in place by counter-sunk holes for
adjusting screws. The cam roller on the slide is held on a cam track by a
coil compression spring located in the slot at the back of the vertical slide.
The horizontal slide is located in a dovetailed slot approximately 4 inches
below the upper edge of the unit casting. This slide moves back and
forth, carrying the shellac tool from the shellac reservoir to the primer
pocket in the case head, in a dipping motion. The shellac tool dips into
the shellac reservoir, then descends to the top of the case head. This mo-
tion is controlled by the plate. At the end of the forward stroke, the
horizontal slide strikes a stop screw located in the unit casting in line
with the slide. The shellacking pin may be adjusted in position over the
primer pocket by the stop screw.
[27]
CALIBER .30 PRIMER INSERT
Machine Description

Horizontal Slide
Spring and Con-
necting Rod
“L” Shaped Arm
Connecting Link
Lower Cross Arm
Bottom Tool Slide \
and Adjusting
Screw
The horizontal slide connecting rod connects the slide to an L-shaped
arm. The rod slips into the slot cut in the L-shaped arm and is held in
place by a stud lock nut. The small end of a shaft slips through the hole
in the push block on the horizontal slide. A coil compression spring
keeps the slide pushed forward on the connecting rod. A lock nut holds
the push block on the shaft. At the ﬁnish of the forward stroke, the con-
necting rod lock nut should extend approximately %; of an inch beyond
the block. This adjustment is to insure that the horizontal slide goes clear
to the stop screw, and is not held back by the lock nut.
The L-shaped arm connects the horizontal slide connecting shaft to the
eccentric connecting shaft and the eccentric connecting rod, and is held in
place and rocks on a stud which is screwed into the unit casting. The
eccentric is located on the outer end of the crankshaft by a screw, the
point of the screw being set in a hole in the shaft. The connecting rod
screws into the eccentric bearing strap on the lower end, and into an
adapter. The adapter is held in place by a stud through an L-shaped
arm and nut.
The connecting link, made of ﬂat steel, is held in place by the upper end
by a stud which also runs through the adapter, the L-shaped arm and
the link. It is held in place at the bottom by a stud through the short
end of the lower cross arm.
The lower cross arm is held in place in a unit casting by a stud. This
stud also acts as a pivot pin for the lower cross arm. The long end of the
cross arm is connected to the bottom of the horizontal by an adjusting
screw.
The tool slide is a dovetailed bar to which the varnishing tool is attached '
at the lower end. A slot is cut in the lower end in the slide for the ad-
justing screw. The slide is approximately 9 inches long, and is located in
a casting bolted on the bottom of the machine bed. The casting contains
a machined slot in which the slide travels up and down. A steel bracket
is bent to shape, supporting the varnishing tool and is screwed to the top of
the slide. The bracket is bent to allow the varnishing tool to be held up-
right on the tool slide.
[28]
CALIBER .30 PRIMER INSERT Machine Description

Varnish Reservoir
Connecting Link
Varnish Tool Slide
Connecting Rod
Lower Cross Arm

Varnish Tool Ad-
’ justing Screw
LOWER VIEW OF VARNISH STATION
[29]
CALIBER .30 PRIMER INSERT
Tool Holder Description

TOOL HOLDER DESCRIPTION
Crimping Punch
Holder Assembly

Retaining Studand Lock Nut: The retaining stud is externally
threaded from below the head to the lower end of the stud. A %"
hexagon head is machined on the upper end of the stud. The stud
is equipped with a 15/16” lock nut which locks against the upper end
of the tool holder.
Crimping Assembly Tool Holder: This cylindrical tool holder is
hollow to permit insertion of the space rod and crimping tool. Below
the hexagonal machined head the holder is externally threaded,
approximately V; its length for insertion into the ram. The lower
end of the tool holder is threaded to receive a clamp nut.
Tool Holder Lock Nut: The tool holder lock nut is internally
threaded and has a narrow hexagon head machined in its upper end.
The lock nut is used to lock the tool holder securely in the upper
ram.
Space Rod: The space rod is cylindrical and small enough in
diameter to enter through the tool holder. It is used as a spacer
between the tool and the retaining stud.
Crimping Punch Holder: The crimping punch holder is a metal
shaft, the lower end of which is equipped with a hollowed cylinder
for insertion of the crimping tool. The hollowed section is split
longitudinally to allow the stripper to pass through the holder. A
small Allen head lock screw is used to secure the crimping tool in
place.
Crimping Tool: The cylindrical metal crimping tool is slightly
concave on the lower end and has a ﬂat machined portion at approxi-
mately the center on the side of the tool. The set screw in the tool
holder contacts the ﬂat surface to lock the tool securely in the tool
holder.
Cap Nut: The hexagonal headed cap nut is internally threaded for
application to the lower end of the tool holder. The lower end of the
cap nut is partially enclosed leaving a circular opening for the inser-
tion of the crimping tool holder.
[30]
CALIBER .30 PRIMER INSERT Tool Holder Description
Inserting Punch Retaining Stud and Lock Nut: The retaining stud is externally
Holder Assembly threaded from below the head to the lower end of the stud. A
7/8” hexagon head is machined on the upper end of the stud. The
stud is equipped with a 15/16" lock nut which locks against the upper
end of the tool holder.
Inserting Assembly Tool Holder: The cylindrical inserting tool
holder is hollow to permit insertion of the space rod and inserting
tool. Below the hexagonal machined head the holder is externally
threaded approximately 1/; its length for insertion into the ram.
The lower end of the tool holder is threaded to receive a cap nut.
Tool Holder Lock Nut: The tool holder lock nut is internally
threaded and has a narrow hexagon head machined in its upper end.
The lock nut is used to lock the tool holder securely in the upper ram.
Space Rod: The space rod is a cylindrical metal rod small enough
in diameter to enter through the tool holder. It is used as a spacer
between the tool and the retaining stud.
Inserting Tool: The inserting tool is a cylindrical metal rod
tapered at its lower end to a diameter approximately the size of the
primer and primer pocket.
Cap Nut: The cap nut is hexagon in shape internally threaded for
application to the lower end of the tool holder. The lower end of the
cap nut is partially enclosed leaving a circular opening for the in-
1 sertion of the inserting tool.

I31]
CALIBER .30 PRIMER INSERT Tool Holder Description

Retaining Stud and Lock Nut: The retaining stud is externally
threaded from below the head to the lower end of the stud. A %”
hexagon head is machined on the upper end of the stud. The stud
is equipped with a 1*"/1/6” lock nut which locks against the upper end
of the tool holder.
Burring Punch
Holder Assembly


_ R
Burring Tool Holder: The cylindrical burring tool holder is
hollow to permit insertion of the space rod and burring tool. Below
the hexagonal machined head, the holder is externally threaded
approximately %; its length for insertion into the ram. The lower
end of the tool holder is threaded to receive a clamp nut.
Tool Holder Lock Nut: The tool holder lock nut is internally
threaded and has a narrow hexagon head machined at its upper end.
The lock nut is used to lock the tool holder securely in the upper ram.
Space Rod: The space rod is a cylindrical metal rod small enough
in diameter to enter through the tool holder. It is used as a spacer
between the tool and retaining stud.
Burring Tool: The burring tool is cylindrical and machined to
three diameters; it is held in the lower end of the tool holder by a
cap nut. The burring tool produces a small chamfered radius
around the edge of the primer pocket.
Cap Nut: The hexagonal headed cap nut is internally threaded for
application to the lower end of the tool holder. The lower end of the
cap nut is partially enclosed leaving a circular opening for the inser-
tion of the burring tool.
[32]
CALIBER .30 PRIMER INSERT Tool Holder Description
Flash Hole Punch Retaining Stud and Lock Nut: The retaining stud is externally
Assembly threaded from below the head to the lower end of the stud. A 7/8”
. hexagon head is machined on the upper end of the stud. The stud
' is equipped with a 15/16” lock nut which locks against the upper end
of the tool holder.
Flash Hole Punch Assembly Tool Holder: The cylindrical
I ﬂash hole punch is hollow to permit insertion of the space rod and
ﬂash hole punch. Below the hexagonal machined head the holder is
externally threaded, approximately half its length for insertion into
the ram. The lower end of the ﬂash hole punch is threaded to re-
ceive a cap nut.
Tool Holder Lock Nut: The tool holder lock nut is internally
threaded and has a narrow hexagon head machined at its upper end.
The lock nut is used to lock the tool holder securely in the upper ram.


Space Rod: The space rod is a cylindrical metal rod small enough
in diameter to enter through the tool holder. It is used as a spacer
between the tool and the retaining stud.
.
Flash Hole Punch: The ﬂash hole punch is a cylindrical steel rod
which has a ﬁat machined portion near its upper end which the
locking stud contacts to lock the ﬂash hole punch securely in place.
The lower end of the punch is machined to two smaller diameters
forming the correct diameter of the working end.
Flash Hole Punch Holder: The ﬂash hole punch holder is a metal
shaft, the lower end of which is equipped with a hollowed cylinder
for insertion in the ﬂash hole punch. A small Allen head lock screw
is threaded through the side of the punch holder to lock the punch
securely in place.
Cap Nut: A hexagonal headed cap nut is internally threaded for
I ‘ / application to the lower end of the tool holder. The lower end of
"i the cap nut is partially enclosed leaving a circular opening for the
insertion of the ﬂash hole punch holder.
[33]
CALIBER so PRIMER INSERT Tool Holder Description

Shellac Tool: The cylindrical shellac tool is equipped
with a horizontal pin near the upper end. The pin
supports the shellac tool in the tool holder. The lower
1 end of the shellac tool is shouldered and tapered to a
Shellac Tool
Holder Assembly


pair of small ﬁngers which are machined on the end of
the tool.
Shellac Tool Holder: The shellac tool holder is
_ bolted to the lower end of the dovetailed tool slide.
The shellac tool arm is held at right angles to the tool
I .4 ' ' slide and is ﬁtted with 3. vertical cylinder into which the
t "' ' shellac tool ﬁts.
/ Coil Spring: The coil spring is inserted in a slot in
the rear surface of the dovetailed slide which forces the
cam roller mounted on the upper end of the tool slide
against the cam which actuates the dipping motion
of the tool holder.
::~.~.::n
Inverted Prim‘er Coil Spring: A small coil spring is used to hold the
Tool Holder outer end of the detector ﬁnger at its lowest position.
Assembly The coil spring is inserted in the slotted end of the de-
tector-shaft beneath the end of the detector ﬁnger.


Detector Finger Pin: The detector ﬁnger pin is
ﬁtted with a small collar pin and is used to hold the
detector ﬁnger in the slotted end of the detector shaft.
Detector Finger: The detector ﬁnger is a metal shaft
having one end bent at an approximate 30° angle. A
small hole is drilled through the shaft for the insertion
of the pin to hold it securely in the upper end of the
detector shaft.
Detector Shaft: The cylindrical detector shaft is
inserted through the upper ram and is fastened to the
detector ﬁnger. The upper end of the shaft is slotted
and has a circular hole drilled horizontally through the
slotted sections for the insertion of the pin to hold the
detector ﬁnger in place. The lower end of the detector
shaft is hollowed and internally threaded for the in-
sertion of the detector punch.
Detector Punch: The cylindrical punch is threaded
% its length from the upper end. A hexagon nut is
used to lock the detector punch into the detector shaft.
The lower end of the detector shaft is tapered to a
point to enter into the pockets of the cases in the event
a primer has not been inserted at the inserting station.
[34]
CALIBER .30 PRIMER INSERT Tool Holder Description

"No-Case" Tool
Holder Assembly
Bearing Block, Cross-Shaft and Detector Finger:
The cross-shaft is held in place by two rectangular
bearing blocks on the upper surface of the ram. The
cylindrical cross-shaft is equipped with a connecting
ﬁnger between the bearing blocks for attachment to the
~: ‘ detector plunger. The detector ﬁnger is a rectangular
""" metal shaft attached to the rear end of the cross-shaft.
It is held solidly to the cross-shaft by a key.


Coil Spring: A small coil spring ﬁts beneath the con-
necting ﬁnger and holds the detector ﬁnger cross-shaft
- at its back position unless actuated by the detector
' punch.
.' g Detector Shaft: The cylindrical detector shaft is
‘ pl: __ I 3 inserted through a bored hole in the upper ram and its
: ' -. .. ‘ V T upper end is attached by means of a slot and pin to the
t cross-shaft. The detector shaft is able to slide up and
I *i7;ﬁ"p£,‘ "‘ down through the ram. The lower end is hollow and
l ‘ :4. ' internally threaded for the insertion of the detector
' "i" tool holder. The lower end of the detector shaft is
' also externally threaded for the application of a hexa-
gon nut.
- r_ Coil Spring: The detector shaft employs the use of a
l coil spring to hold the shaft in its lower position in the
l ram. The coil spring ﬁts over the detector shaft and
- __.n7 ,,'; 1 rests against the underneath surface of the ram. The
i ' spring is held in place by the hexagon nut.
Hexagon Nut: The hexagon nut is internally threaded
L ‘H I
" i for application to the threaded portion of the detector
3- "‘ shaft to hold the coil spring in place.
-. _ 7.5 Detector Punch: The cylindrical detector punch is
. threaded V2 the distance from the upper end. The
lower end is equipped with a circular shoulder which
;' conforms to the diameter of the case head. A hexagon
"5 nut is threaded onto the detector punch to lock it
securely in place in the detector shaft.
‘[35]
CALIBER .30 PRIMER INSERT Tool Holder Description

Bearing Block, Cross-Shaft and Detector Finger:
The cross-shaft is held in place by two rectangular
bearing blocks on the upper surface of the ram. The
cylindrical cross-shaft is equipped with a connecting
ﬁnger between the bearing blocks for attachment to
the detector plunger. The detector ﬁnger is a rec-
tangular metal shaft attached to the rear end of the
( M12 ., ‘ cross-shaft. It is held solidly to the cross-shaft by a
L ‘ key.
Coil Spring: A small coil spring ﬁts beneath the
connecting ﬁnger and holds the detector ﬁnger cross-
shaft at its back position unless actuated by the detec-
tor punch.
Detector Flash
Hole Punch Holder
Assembly


Detector Shaft: The cylindrical detector shaft is
inserted through a bored hole in the upper ram and its
upper end is attached by means of a slot and pin to the
cross-shaft. The detector shaft is able to slide up and
down through the ram. The lower end is hollow and
internally threaded for the insertion of the detector
tool holder. The lower end of the detector shaft is
also externally threaded for the application of a hexa-
gon nut.
Coil Spring: The detector shaft employs the use of a
coil spring to hold the shaft in its lower position in the
ram. The coil spring ﬁts over the detector shaft and
rests against the underneath surface of the ram. The
spring is held in place by the hexagon nut.


IIlIIll\
.i__---——‘r4 Hexagon Nut: The hexagon nut is internally threaded
for application to the threaded portion of the detector
shaft to hold the coil spring in place.
Detector Punch Hexagon Nut: The hexagon headed
detector punch nut is internally threaded for applica-
tion to the detector punch. It is used to lock the punch
\ in place in the detector shaft.
- \
Detector Punch: The cylindrical detector punch is
externally threaded %; its length from the upper ram
for insertion into the internal threads of the detector
shaft. The lower end of the punch is shouldered and
hollowed for the insertion of the detector pin.
‘
Lock Collar: The circular lock collar is equipped
with a set screw which is threaded through the sides.
The collar is used to lock the detector pin in the detec-
tor punch.
Detector Pin: The cylindrical detector pin is small
enough in diameter to enter the ﬂash hole of the case.
It is locked in the detector punch by the lock collar.
[36]
CALIBER .30 PRIMER INSERT Tool Holder Description
Varnish Tool
Holder Assembly
Varnishing Pin: The cylindrical varnishing pin has
a dome-shaped head machined on the lower end. The
upper end is slotted for the entrance of the assembly
key. The varnishing pin is inserted into the hollow
varnishing shaft which is contained as a unit in the
varnishing tool holder.

Split Nuts: Two half nuts are used to hold the
varnishing shaft and pin securely in the varnish tool
holder. The split lock nuts have a hexagon head ma-
chined on the upper end and are threaded on the lower
end. They are clamped around the varnish shaft and
threaded into the upper end of the varnish tool holder.
Varnish Shaft: The varnish shaft has a circular
head on the upper end and is slotted through the
lower end. It is hollowed for the insertion of the
varnishing pin.
Coil Springs: Two coil springs are used in the tool
assembly. The larger of the two is inserted into the
tool holder. The smaller one is inserted into the
varnish shaft.
Varnish Tool Holder: The varnish tool holder is
hollowed for the insertion of the various component
parts of the tool assembly. The tool holder is threaded
at the lower end for attachment to the tool holder arm.
A hexagon headed, internally threaded nut secures the
tool holder in place. The tool holder is slotted through
the sides for the insertion of a metal key which holds
the assembly in place.
Varnish Tool Slide: The varnish tool slide is a rec-
tangular metal plate which supports the varnish tool
arm. The varnish tool arm is bolted to the upper end
of the tool slide.
[37]
CALIBER .30 PRIMER INSERT
Tool Description

TOOL DESCRIPTION
DETECTOR PUNCH


BURRING PUNCH


PUNCH
DIE
Tool Name: Detector Punch——Short case or no case.
Piece No.: P-2
Location: Held vertically in upper ram
Normal Life: 850,000 pieces
This punch is made of drill rod, hardened and ground.
Tool Name: Burring Punch
Piece No.: P-1
Location: Held vertically in upper ram
Normal Life: 600,000 pieces
This punch is designed from tool steel, hardened,
ground and polished.
Tool Name: Stem-Mouth Spreader
Piece No.: P-60
Location: Held vertically in lower ram
Normal Life: 1,250,000 pieces
This stem is constructed from tool steel, hardened and
ground.
Tool Name: Punch—Venting (ﬂash hole)
Piece No.: P-76
Location: Held vertically in upper ram
Normal Life: 20,000 pieces
This punch is made of needle wire, hardened and
ground.
Tool Name: Die—Venting (ﬂash hole)
Piece No.: P-5
Location: On tip of P-6 stem; held vertically in
lower ram
Normal Life: 75,000 pieces
The venting die is made of tool steel, hardened, ground
and polished.
[33]
CALIBER .30 PRIMER INSERT
Tool Description

STEM—\/ENTING
DETECTOR PUNCH-NO VENT


PUNCH—PRIMER INSERT
.. _ - M)
STEM—PRlMER INSERT
1,
DETECTOR PUNCH—lNVERTED


PUNCH—SEATlNG AND
CRIMPING
Tool Name: Stem—Venting (ﬂash hole)
Piece No.: P-6
Location: Held vertically in lower ram
Normal Life: 225,000 pieces
This stem is constructed from tool steel, hardened and
ground.
Tool Name: Detector Punch—No vent (ﬂash hole)
Piece No.: P-7
Location: Held vertically in upper ram
Normal Life: 50,000 pieces
There are two of these detector punches, located at
stations 4 and 5. They are made of needle wire.
Tool Name: Punch—Primer Insert
Piece No.: P-9
Location: Held vertically in upper ram
Normal Life: 850,000 pieces
This punch is designed from tool steel, hardened, ground
and polished.
Tool Name: Stem—Prirner Insert
Piece N 0.: P-10
Location: Held vertically in lower ram
Normal Life: 1,000,000 pieces
This stem is made of tool steel, hardened, ground and
polished.
Tool Name: Detector Punch—Inverted or no primer
Piece No.: P-11
Location: Held vertically in upper ram
Normal Life: 1,250,000 pieces
This detector punch is constructed from tool steel
and hardened.
Tool Name: Punch—Seating and Crimping
Piece No.: P-13
Location: Held vertically in upper ram
Normal Life: 50,000 pieces
This punch is made of tool steel, hardened and ground.
[39]
CALIBER .30 PRIMER INSERT
Tool Description

—nr~2-Y0.-‘Ms .
bu-¢_a\
STEM-SEATING AND
CRIMPING


TOOL—MOUTH VAR NISH
:g',;&'.\_,|l.-U ‘
0- r:
Ll
PIN-SHELLAC
Tool Name: Stem——Seating and Crimping
Piece No.: P-15
Location: Held vertically in lower ram
Normal Life: 250,000 pieces
This stem is made of tool steel, hardened and ground.
Tool Name: Tool-rMouth Varnish
Piece No.: Cup body P-16, Cup P-17, Plunger
P-18
Location: Held vertically in bottom slide tool
holder
Normal Life: 1,000,000 pieces
This tool is made from tool steel, hardened and ground.
~
Tool Name: Pin—Shellac
Piece No.: P-19
Location: Held vertically in bottom slide tool
holder
Normal Life: 1,250,000 pieces
This pin is made from tool steel, hardened and ground.
[40]
CALIBER .30 PRIMER INSERT
Process Sequence

Overhead Hopper
Paddle Wheel
Hopper
Feed Throat and
Feed Tube
Positioning
Mechanism
Receiving Block
and Transfer Bar
Station I,
Detector
Station 2,
Burring
Station 3,
Piercing
Punch
Station 4,
Detector
Station 5,
Detector
PROCESS SEQUENCE
The cases are fed from a truck or conveyor into an overhead liberty-type
hopper and ﬂow down through a feed pipe to the paddle wheel hopper.
The cases ﬂow down the incline of the paddle wheel hopper, under the
baffle plate to the paddle wheel. The paddle wheel rotates clockwise,
picks up the cases and conveys them up to the edge of the hopper where
they roll off onto the conveyor belt.
The cases fall head ﬁrst into the feed throat and are assisted through by a
leather friction disc. From the feed throat, the cases ﬂow through the
brass feed tube to the positioning mechanism.
The cases enter the feed lip from the feed tube and lie at a slight angle
with the case head at the lower end. Actuated from the upper ram, the
upper ﬁnger on the ﬁnger block holds the succeeding cases in the feed tube
as the lower ﬁnger knocks the case on the feed lip into the feed chute. A
positioning pin in the feed chute momentarily holds the head of the case,
allowing the case to drop into the feed chute, mouth ﬁrst. A second pin
on the opposite side of the feed chute keeps the case mouth from striking
the outer edge of the feed chute.
The case rests mouth down in the receiving block and guide rails, and is
held in position by the latch ﬁnger. The transfer bar moves in and con-
veys the cases, one station at a time, through each of the ten work
stations as follows:
At this station the detector punch moves down. If there is no case or a
short case in the station, the machine will stop.
At this station a stem enters the case mouth from underneath and spreads
the mouth. It then raises the case 1/16 inch. The burring punch moves
down, chamfering the edge of the primer pocket. The case is stripped from
the stem and punch by strippers located below and above the case.
At this station a hollow stem and die enter the mouth of the case from
underneath raising it V8 inch. The piercing punch moves down, piercing
the ﬂash hole through the web of the case. The case is stripped from the
stem and punch by strippers located below and above the case. The scrap
passes through the hollow stem into a tube and down to a pan outside of
the machine.
At this station the detector moves down and enters the ﬂash hole. If the
hole is defective or a hole has not been pierced, the machine will stop.
At this station the same action occurs as at station 4. In the event the
detector fails to detect the absence of a ﬂash hole at the fourth station,
this station will detect it and stop the machine.
[41]
CALIBER .30 PRIMER INSERT
Process Sequence
Station 6,
Primer Insert
Station 7,
Detector
Station 8,
Escapement
Door
Station 9,
Crimping and
Seaﬁng
Station IO,
Shellac and
Varnish
Drying Track and
Disposal
The primers are transferred from a brass plate into the hopper, anvil up,
by hand. The brass plate holds 500 primers at a time. The primers ﬂow
by gravity down the hopper incline, and through an opening in the bot-
tom onto a metal feed conveyor belt in front of the agitator. The agitator
moves in a forward and backward motion to prevent congestion and
aligns the primers in a single ﬁle. The primers ride along the belt and
stop against the spacer bar. The spacer bar, actuated by a cam, allows
one primer at a time, properly spaced and timed with each downstroke of
the ram to travel along the metal conveyor belt, where the primer stops
against the stop plate in front of the push-in ﬁnger. The push-in ﬁnger
forces the primer into the primer turnover ﬁngers. As the stem enters
the case from the mouth, raising the case 1/16 inch, the primer turnover
mechanism inverts the primer and places it in alignment with the primer
pocket and inserting tool. The inserting tool presses the primer into the
primer pocket in the case.
At this station the detector moves down to detect whether there is a
primer in the pocket or if the primer is inverted. If these defects are
found, the escapement door at station 8 will open. If no defects are
found, the escapement door will remain closed.
At this station a case with an inverted primer or a case with no primer,
will fall through the escapement door and discharge tube. If no defects
are found, the case passes to the next station.
At this station the stem enters the mouth from underneath and raises
the case 1/16 inch, as the crimping punch moves down to seat and crimp
the primer. The primer is seated from .001 to .007 below the face of the
case.
At this station the case is moisture-proofed. The shellac pin moves down
allowing a drop of shellac to run around the rim of the primer. The
varnish tool enters the mouth of the case, leaving a coat of varnish inside
of the neck of the case.
The transfer bar forces the cases in close single ﬁle through a 2%-ft.
drying rack, where they drop off at the end into the inspection trough.
ill:-ISNI tIElWItId 08' EIHEIFIVD
eouenbeg SS9.'JO.ld
Cases
4?
Overhead
Source
T
Overhead
Hopper
I
Paddle Wheel
Hopper
I
Conveyor
Belt
4
Feed Primers
Throat I
I Hand
Feed Feed
Tube L
_ _I _ Primer Primer
Pos1t1on1ng H _ Feed
Mechanism Opper Belt
A I
Receiving Turnover
Block Fingers
I I
Transfer Transfer Transfer Transfer Transfer J Transfer Transfer Transfer Transfer Transfer
Bar T Bar T Bar T Bar Bar Bar T Bar 7 Bar T Bar T Bar
I J I I I I‘ I I I I I
_ Flash Flash ' Flash Primer Inverted FCrimping Shellac _
Detect _‘ Burrmg _ Hole Q Hole Hole H Insert _ Primer _ and H and _ _ Drying
Station Station Station Detect Detect Station Detect Seating Varnish Track
Stallion St3lli011 Statiorg Station Station
T J
Escapement Container
Door


IEIVHD N\O'l:I

I817]
CALIBER .30 PRIMER INSERT Product Description

PRODUCT DESCRIPTION
The case, when received by the primer insert machine, is in the form of a
semi-ﬁnished case as shown in\Fig. 1. The pocket has-been placed in the
head of the case and the extractor groove cut to the desired speciﬁcations.
The primer pocket dimensions should be as follows:
Pocket depth .125—.129
' Pocket diameter .2093—.2098
The primer is a completely assembled unit when received by the Primer
Insert Department, Fig 2. The primer cup dimensions should be as
follows:
Over-all height .127—.131
Primer diameter 2105-2112

The purpose of the Henry & Wright Primer Insert Machine is to pierce a
ﬂash hole in the bottom of the primer pocket through the web thickness
of the case. The machine then burrs the shoulder of the primer pocket,
after which it inserts and seats the primer in the pocket and crimps the
primer into the case. As a ﬁnal operation, the machine varnishes the case
mouth and shellacs the primer pocket as a protection against moisture.

Station 1 is known as a detector station. This station detects for short or
no cases in the transfer bar. In the event of no case or a short case, the
machine will automatically stop and the operator will remove the faulty
case or cases from the transfer bar.
Station 2 is known as the burring station which removes any burrs from
the shoulder of the primer pocket and chamfers the shoulder edge of the
pocket to facilitate the insertion of the primer. See Fig. 3.

Station 3 is known as the ﬂash hole punch station. At this station the
ﬂash hole is pierced through the bottom of the primer pocket through the
web thickness of the case. See Fig. 4. The transfer bar passes the cases
through two ﬂash hole detector stations which check for the presence of a
cleanly cut ﬂash hole. The ﬂash hole detectors are located at the fourth
and ﬁfth station.
Station 6 is known as the primer inserting station. The primer is in-
serted in the case pocket at this station. See Fig. 5. The primer is
picked up from the primer feed belt and transferred to a position directly
above the case pocket where the inserting punch contacts and forces it
into the primer pocket approximately % of its over-all height.


Station 7 is known as the inverted primer detector station which detects
a primer that‘ has been inserted into the case pocket in an inverted posi-
tion or has been left out entirely. See Fig. 6. The following station is the
escapement door station through which the faulty case will be ejected
as the machine continues to run.
[44l
CALIBER .30 PRIMER INSERT
Product Description


FIG. 6

Station 8 is known as the escapement door station which the cases pass
through if the primer has been correctly inserted. From this station the
cases pass to station 9 where the primer is seated and crimped. Note:
the primer should be seated below the case head from .001 to .007 to
pass inspection. See Fig. 7.
Station 10 is known as the shellac and varnish station. As the case
leaves the crimping station, it is counted as it passes the counter clock
and is transferred by the transfer bar through several positions to the
shellac and varnish station. Here the case mouth is varnished and the
primer is shellacked as a protection against moisture. -See Fig. 8.
ﬁx Y"


FIG. 7 FIG. 8
I45]
CALIBER .30 PRIMER INSERT
Inspection
Visual
Gage Care
Gages
INSPECTION
The cases are received at the primer insert machine from the Inspection
Department in containers and are placed into a paddle wheel hopper
which automatically feeds them to the machine. The cases pass through
the hopper feed tube and drop singly into the transfer bar.
The primer insert machine passes the cases through a series of ten opera-
tions in which a radius is placed around the top of primer pocket, the ﬂash
hole is pierced, ﬂash hole detected, primer inserted, primer seated and
crimped, primer shellacked and the mouth and neck of the case are var-
nished to water-proof the component. After the cases have passed through
the ten stations, they are inspected for primer seating depth with a dial
indicator gage. They are also visually inspected to make sure that every
case has a ﬂash hole, shellac around the primer and varnish in the mouth
and neck. If any one of these is lacking, there must be an immediate ad-
justment of the machine to correct the fault. Whenever defective cases are
found, the lot from which they come must be removed and properly identi-
ﬁed so that the bad lot will not be mixed with good cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their damage when not in use. The most accurate
checks are made when the cases are cool since heat causes expansion
of the metal and results in a temporary variation in the case size.
FLUSH PIN GAGE
The depth of the case pocket is determined by a
ﬂush pin type gage, illustrated at the left. The
center pin may be adjusted to a predetermined
Ln length. The speciﬁed pocket depth is from .125
to .129.


DIAL INDICATOR GAGE
The primer seating depth is gaged at fre-
quent intervals with a dial indicator gage.
This manual gaging provides a check on the
accuracy of the machine. The primer is ‘
seated in the case pocket from .001 to .007 '
below the case head.
l46l
CALIBER .30 PRIMER INSERT Inspection

Gages (com) CANNELURE DEPTH
GAGE
The extractor groove is gaged with a cannelure
depth gage which should be used if the cases are
binding in the stripper plates. The extractor
groove speciﬁcations are as follows: .403—.407


SNAP GAGE
The head thickness of the
case is checked by a snap
gage. If the primers are
being seated to various
depths and the crimping “I -*~‘ .
adjustment has not been
changed, the case head
thickness should be
checked. Specifications
are as follows: .048—.049
TWIN RING GAGE
The case head diameter is checked
with a twin ring gage. If the cases
are binding in the case track and no
change has been made in the position
of the latch plates or latch blocks,
the head diameter should be checked
before making any adjustment on the
machine. The speciﬁcations are as
follows: .467—.471


DOUBLE PLUG GAGE
The diameter of the primer
pocket is determined with a
double plug gage. Speciﬁcations
are as follows: .2098—.()(l5
The foregoing inspection methods are those most commonly employed
in the manufacture of Caliber .30 cases. Other methods may be de-
veloped, however, to maintain the manufacturing standards.
[47]
CALIBER .30 PRIMER INSERT
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory operation of the primer insert machine, both
the product and the machine must be inspected at frequent intervals
during operation. The components, both primer and case, must be peri-
odically inspected to determine whether or not they meet speciﬁcations
when they come to the primer insert machine. The primed cases should
be inspected frequently as they come from the machine to determine
when an adjustment is necessary.
This section of the manual, with its illustrations, photographs and
procedures, contains the necessary information relative to the adjust-
ments normally required. The order in which these adjustments are
arranged is not necessarily the preferred sequence. It is impossible to
predict all the machine troubles that will be encountered; therefore cer-
tain adjustments may be required that have not been described in this
section. Thorough analysis of the troubles will indicate what corrective
measures must be taken other than those included in this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be free from all foreign
matter at all times.
Before making an adjustment, the clutch must be disengaged, and the
motor and power turned off.
In order to insure proper adjustment of the machine and the alignment
of its tools, always engage the clutch intermittently, permitting only one
complete cycle of the machine to be made at a time before placing the
machine into production operation.
When the adjustments have been completed, make sure that there are
no tools or rags on any of the moving parts of the machine or where they
may fall onto any of the machinery in motion. See that there are no
loose primers lying in the feed track. See that the machine guards are in
proper repair and closed at all times except when inspections or repairs
are being made.
CALIBER .30 PRIMER INSERT
Adjustments
-_—_~_—_=—_
Primer Insert Punch The primer insert punch is the tool which inserts the primer into the
Primer Insert Punch
,\
VIEW OF TOOL HOLDERS AND RAM
TOOIS:
Procedure:
primer pocket of the case. The punch is located at station 6. If the
insert punch does not push the primer into the pocket until the head of
the primer is 1/16” or less above the case head, the punch must be lowered.
The punch holder is threaded into the ram and by loosening the lock nut,
it can be turned in or out until the proper position is reached.
1 1 1/ 1
Punch LJER
Holder N,uI
Ram
Primer
Insert
Punch
ENLARGED VIEW OF
PRIMER INSERT PUNCH

111/ﬁ;" wrench, 11/4" wrench.
1. Place a case under the inserting punch.
2. Engage the clutch and turn the hand wheel until the top ram is at
the bottom of its stroke.
3. Use a 111/11;" wrench to loosen the insert punch holder lock nut.
4. Use a 11/4_'’ wrench to turn the punch holder until the insert punch is
1/16" above the case head.
5. Use a Ii“/16” wrench to tighten the lock nut on the insert punch holder.
6. Disengage the clutch.
I49]
CALIBER .30 PRIMER INSERT Adjustments
___———_—=_———__—__—_—__—_——_—____
No Case Short Case The no case short case detector punch is located at station 1. The purpose
Detector of this detector is to stop the machine if there is no case or short case in the
transfer bar at station 1. The no case or short case detector actuates a
detector ﬁnger. The detector ﬁnger and the stop dog should have a clear-
ance of .005 when the no case or short case detector ﬁnger contacts a case
at station 1. Due to constant use, the clearance between the detector ﬁn-
ger and stop dog may change and in_that case, the no case or short case
detector will fail to stop the machine. For this reason, the no case or short
case detector can be raised or lowered to bring the clearance between the
detector ﬁnger and stop dog back to what it should be.
No Case Detector


_
. 4 L84 ' ht -" :.
H .
VIEW OF TOOL HOLDERS AND RAM ENLARGED VIEW OF NO
CASE OR SHORT CASE
DETECTOR PUNCH
Tool: V2 " wrench.
Procedure: 1. Insert a case under the detector punch.
2. Use a %” wrench to loosen the lock nut on the detector punch.
3. Turn the detector punch up into the holder about two complete turns.
4
. Engage the clutch and turn the hand wheel until the ram descends to
a point where the detector ﬁnger is about ‘AH above the stop dog.
5. Lower the detector punch until it contacts the head of the case ﬁrmly
enough to pivot the detector ﬁnger to a point where it is clearing the
right side of the stop dog about .005.
6. Use a V2" wrench to tighten the lock nut on the detector punch.
7. Disengage the clutch.
[50]
CALIBER .30 PRIMER INSERT Adiusimenfs
Transfer Bar In The transfer bar is equipped with two stop screw adjustments. The pur-
and Out Movement pose of these stop screw adjustments is to regulate the distance of travel
that the transfer bar will make toward the cases in the case track. If the
transfer bar travels too far toward the cases, or not far enough, the cases
will be dented or smashed. When this condition exists, the stop screws
must be readjusted until the punches are centered with the primer pocket.


Spring Housing —
P ~ \. ‘Iv
as
Lf~<"¢~
13/16" Lock Nut
7/16” Adjusting Nut
Rocker Arm
VIEW SHOWING TRANSFER BAR ADJUSTMENT
Tools: 1%" wrench, 7/f6" wrench.
Procedure: 1. Engage the clutch and turn the hand wheel until the transfer bar has
reached the end of its stroke toward the cases under each station.
Disengage the clutch.
2. Use a 1%" wrench to loosen the lock nuts on the stop adjusting screws
of both ends of the transfer bar rocker arm that actuates the transfer
bar toward the cases.
3. Use a K6" wrench to turn the stop adjusting screws until the cases are
tight, then back off until the cases are held rather loose.
4. Use a 1%" wrench to tighten the lock nuts while the stop screws are
held in position.
[51]
CALIBER .30 PRIMER INSERT Adiustments

Case Supporting The case supporting stems are the tools which raise the case up off the
Stems case track and support the case while the tools in the upper ram act on
it. The four case supporting stems are at the piercing station, burring
station, primer insert station, and the crimping station. If the supporting
stems do not push the cases up far enough off the case track, the stems
can be individually adjusted by loosening the lock nut on the stem
holder and raising the stem in the ram to the correct distance.
1%” Lock Nut
Stem
CASE SUPPORTING STEM ADJUSTMENT
Tools: 1%” wrench, %" wrench, 5/16” Allen wrench, spanner pin.
Procedure: 1. Place a case at the station above the stem to be adjusted.
2. Engage the clutch and turn the hand wheel until the bottom ram is
at the top of its stroke.
3. Use a 1%” wrench to loosen the lock nut on the stern holder to be
adjusted.
4. Use a %" wrench to turn the stem until the case it contacts is raised
about %;".
Note: This is the correct clearance between case and track to be
maintained at the piercing station, burring station, and the primer
insert station.
5. Use a 1%" wrench to tighten the stem holder lock nut.
6. Disengage the clutch.
[52]
CALIBER .30 PRIMER INSERT Adiustments


= % <— L'i:r:;:' Sr"
Secondary Stern I
Holder


~\\~


S.
Spanner Collar
\
Spanner Collar on Case
Crimping Station Stem Stem Holder
CRIMPING STATION STEM ADJUSTMENT CROSS SECTIONAL DRAWING OF
CRIMPING STATION STEM ADJUSTMENT
CRIMPING STATION STEM
Procedure: Note: This stem adjustment is just a little different from that given
on page 51.
1. Place a case in the track at the crimping station.
2. Engage the clutch and turn the hand wheel until the bottom ram is at
the top of its stroke.
Use a 11/4" wrench to loosen the lock nut on the stem holder.
Use a % " wrench to turn the stem holder until the case which the stem
contacts above is raised up to within I/1/6" from the stripper.
Use a 11/4" wrench to tighten the lock nut on the stem holder.
The spring tension on the secondary stem holder is to be adjusted
at this point. Turn the hand wheel until the crimping tool is acting on
the case.
Use a %” Allen wrench to loosen the spanner collar set screw.
Use a spanner pin to turn the spanner collar until the tension is in-
creased enough so that the crimping tool when acting oh the case can
produce the proper crimp by merely compressing the spring about
1/(6 rr-
Caution: If the spring tension is not suﬁicient, the burring punch
may have to be lowered until by the time the action of the crimping
tool creates proper crimp on the primer, it will have pushed the case
down against the case track. The case must not touch the case track
when the burring punch is acting on it.
9. Use 5/16" Allen wrench to tighten the spanner collar set screw, and dis-
engage the clutch.
3.
4.
@511
90?]
[53]
CALIBER .30 PRIMER INSERT Adjustments

Esca pement Door The escapement door slide is the metal plate which pushes the escapement
Slide door back and forth. When cartridges pass inspection, the plate slides
forward and the escapement door is closed. The plate slide has an adjust-
able stop bolt that creates a positive closing position of the door each
time it is closed. If the door does not close properly, this ‘adjustable stop
bolt can be adjusted to bring the closing position in to proper place.
3/4" Lock Nut

VIEW SHOWING ESCAPEMENT DOOR SLIDE ADJUSTMENT
Tools: 1%" wrench, 1/2” wrench.
Procedure: 1. Place a case with a primer under the no primer detector station and
engage the clutch.
2. Turn the hand wheel until the detection of a good case is made and
the escapement door has closed.
3. Use a 3/4" wrench to loosen the adjustable stop bolt lock nut.
4 Use a 1/2” wrench to turn the adjustable stop bolt until the plate
pushes the ﬁnger against the case ﬁrmly enough at that position
that the case will remain in a vertical position until it is advanced to
the crimping station.
[54]
CALIBER .30 PRIMER INSERT
Adjustments
Procedure: (Cont.) 5. Use a 3/4 " wrench to tighten the adjustable stop bolt lock nut.
Shellac Tool
TOOIS:
Procedure:
6. Disengage the clutch.
Note: The metal ﬁnger that contacts the case at this station has an
adjustable spring tension. This spring has to be readjusted from time
to time. The Allen holding screw can be tightened until the spring
tension is increased enough to hold the case properly.
A set screw at the front end of the shellacking mechanism is forced against
a rocker arm which presses the forked end of the shellac tool against the
case head. The length of time that the shellac tool rests on the case head,
and therefore the amount of shellac deposited on the case head, is de-
termined by the adjustment of the set screw. If there is an insuﬂicient
amount of shellac deposited on the case head, the set screw should be
adjusted so that the tool rises about 1/4" as it is being pressed against
the head of the case.


S:
e
A
VIEW SHOWING SHELLAC TOOL ADJUSTMENT
%" wrench, 1/4" wrench.
1. Operate the machine and observe the amount of shellac that is being
placed on the case head.
2. Turn off the power, engage the clutch, and turn the hand wheel until
the shellac tool rests on the case head.
3. Use a %" wrench to loosen the lock nut on the set screw at the front
end of the shellacking mechanism.
4. Use a 1/4" wrench to turn the set screw until the tool is raised about
% II-
5. Hold the set screw in place and tighten the lock nut.
[55]
CALIBER .30 PRIMER INSERT
Adjustments

Shellac Tool
The shellac tool shellacks the case head around the primer. The purpose
of this operation is to seal and waterproof the primer. The tool is actuated
by a rocker arm and a connecting rod attached to an eccentric wheel on
the end of the crankshaft. An adjustment made on a movable plate cam
above the shellacking tool holder determines the depth that the tool is
dipped into the shellac.

Tool:
Procedure:
VIEW SHOWING SHELLAC TOOL ADJUSTMENT
%; " wrench. \
1. Operate the machine to observe how far the tool is dipped into the
shellac. Just the tip of the tool should be inserted.
2. Use a 1/2" wrench to loosen the cap screws on the movable plate
located above the tool holder. In order to decrease the amount that
the tool is dipped into the shellac, the plate should be moved back
toward the shellac container. To increase the amount that the tool
is dipped into the shellac, move the plate in the reverse direction.
3. After the plate has been moved in the proper direction, tighten the
cap screws. '
4. Operate the machine and observe the action of the shellac tool. It
may be necessary to readjust the movable plate several times before
the proper position is reached.
I55]
CALIBER .30 PRIMER INSERT Adjustments
Turnover Finger The turnover ﬁngers are small metal ﬁngers attached to a small clutch
Assembly assembly in front of station 6. The ﬁngers are used to pick up the primers
from the primer feed track. The primers slide down the feed track, up-
side down, and are conveyed by a belt to a position where the turnover
ﬁngers pick them up, invert them and place them on top the cases in such a
position that the insert punch can insert the primer in the primer pocket.
<1 II II


-.; ‘Q;


.\i.
‘s ‘ f A -
E. I ‘ ' 5/16' Allen
._ . ‘__-,-I " Screw
‘I 0\‘_ H Ti:#
' - '
.. ,_ . I. "/ " Lock
, . M
22'' Allen
rew
"/3" Lock
Nut
3/ " All
8 Sci: .. Clutch
Ad'usting
Col ar
Turnover /
Fingers
VIEW SHOWING TURNOVER FINGER AND CLUTCH ADJUSTMENT
Tools: 7/8" wrench, %" Allen wrench, 54;" Allen wrench.
Procedure: 1. Insert a case without a primer into the primer insert station.
2. Engage the clutch and turn the hand wheel until the top ram is at
the top of its stroke.
3. Use a 7 8" wrench to loosen the adjusting nuts on the male adjustable
cone bearings.
4. Use a %” wrench to loosen the Allen screws on the turnover ﬁnger
bracket holding the male bearings.
5. To adjust the ﬁngers so that the primer which they hold is centered
over the pocket of the case, turn the male cone bearings back and
forth.
6. Use a 3/8" wrench to tighten the Allen screws on the turnover ﬁnger
bracket holding the male bearings.
7. Use a 7/8" wrench to tighten the adjusting nuts on the male adjustable
cone bearings.
8. Disengage the clutch.
I 57 l
CALIBER .30 PRIMER INSERT Adjustments
CLUTCH ADJUSTMENT
Procedure: (Cont.) 1. Use a 5/15” Allen wrench to loosen the set screw in the clutch adjusting
collar. Then turn the collar clockwise until the drag exerted on the
turnover ﬁngers is sufficient to cause the gear rack to turn the ﬁngers
over and hold them down momentarily while the inserting punch
inserts the primer in the pocket.
2. Use a 5/16” Allen wrench to tighten the set screw on the clutch ad-
justing collar.
[58]

CALIBER .30 PRIMER INSERT Adiusfments
Tronsfer Bar The transfer bar conveys the cases from station to station. It is moved
Alignment from left to right by the advance arm which is actuated by a barrel cam
on the crankshaft. The notches in the transfer bar must be in line with
the concave portion of the latch ﬁngers. If the transfer bar fails to convey
the cases or if the cases are nicked while they are being carried from sta-
tion to station, the transfer bar should be adjusted.

3/16" Allen .
Screw
VIEW SHOWING TRANSFER BAR ALIGNMENT ADJUSTMENT
Tools: %” Allen wrench, hammer, punch.
Procedure: 1. Engage the clutch and turn the hand wheel until the transfer bar is
at its farthest position to the right.
2. Remove the door at the rear of the machine by releasing the latch
and lifting it up and away from the machine.
3. Use a %” Allen wrench to remove the Allen screws, one on each side
of the barrel cam.
(If it is necessary to move the transfer bar to the right to align the
notches in the transfer bar with the stations, the cam must be moved to
the left or vice versa.)
4. To move the cam to the right, use a hammer and a punch to loosen
the spanner nut on the right side of the cam and turn the spanner
nut on the left side against the cam until the notches in the transfer
bar are in line with the latch ﬁngers. Reverse the procedure to move
the cam to the left.
5. Make certain that the spanner nuts are tight against the cam, and
insert and tighten the Allen screws. ' '
6. Place the door back onto the machine and latch it in place.
[59l‘
CALIBER .30 PRIMER INSERT
Adjustments
Transfer Bar
Positive Stop
The positive stop screw for the transfer bar is adjusted so that the rocker
arm just presses against the head of the screw. The purpose of the screw is
to compensate for any play in the rocker arm bushing or in the cam groove.
If the positive stop screw is not correctly adjusted, the stopping point of
the transfer bar will vary.

Tools:
Procedure:
TRANSFER BAR POSITIVE STOP ADJUSTMENT V
11/16" wrench, %" wrench.
1. Engage the clutch and turn the hand wheel until the transfer bar
rocker arm is as far as it will go toward the positive stop set screw.
2. Use a 11/15” wrench to loosen the lock nut on the positive stop screw.
3. Use a % ” wrench to turn the screw until it rests against the rocker arm.
4. Hold the stop screw in place and tighten the lock nut.
[60]
CALIBER .30 PRIMER INSERT Adjustments

Varnish Tool The varnish tool varnishes the mouth of the case. The head of the tool
should be completely inserted in the mouth of the case. The distance of
travel the varnish tool will make into the mouth of the case can be regu-
lated by setting the rocker arm connection at various positions in order
to meet speciﬁcations. This is accomplished by loosening lock nuts on the
varnish tool rocker arm connection and sliding it to the desired position.
5/15" Lock Nuts

VIEW SHOWING VARNISH TOOL ADJUSTMENT
Tools: % " wrench, %” wrench.
Procedure: 1. Place a case in the varnish station.
2. Engage the clutch and turn the hand wheel until the varnish tool is
at the top of its stroke.
3. Use a %” wrench to loosen the lock nuts on the varnish tool rocker
arm connection.
4. Slide the connection until the varnish tool is inserted completely into
the mouth of the case.
[61]
CALIBER .30 PRIMER INSERT Adjustments
Procedure: (Cont.) 5. Use a V16” wrench and tighten both lock nuts.
Note: After making this adjustment, readjust the varnish to stop
screw adjustment.
1. Use a 5/16” wrench to loosen the lock nut on the stop screw adjustment.
2. Use a %” wrench to turn the stop nut until it causes the varnish tool
to close and spread the varnish into the mouth of the case.
3. Use a 5/16” wrench to tighten the stop screw lock nut.
[62]
CALIBER .30 PRIMER INSERT Adiustments
Flosh Hole Detector The ﬂash hole detector punch is held in the upper ram at station 4. Its
purpose is to detect any case which has not had a ﬂash hole pierced in the
primer pocket. If no ﬂash hole has been punched into the web, the detector
punch actuates a detector ﬁnger. The detector ﬁnger contacts a stop dog
which moves the stop bar of the clutch lever and stops the machine. If a
case without a ﬂash hole passes the machine, the ﬂash hole detector punch
must be lowered until it will protrude about Kg” below the ﬂash hole.
Note: Station 5 is identical to station 4.
Flash Hole Detector; Rum
Tl
.' I


1/2” Lock
/ Nut
1/3" Allen
ll Detector
Punch

VIEW OF RAM AND TOOL HOLDERS ENLARGED VIEW OF
DETECTOR PUNCH
Tools: %" wrench, %” Allen wrench.
Procedure: 1. Place a case with a ﬂash hole beneath the ﬂash hole detector punch and
engage the clutch.
2. Turn the hand wheel until the top ram is at the bottom of its stroke.
3. Use a %” wrench to loosen the lock nut on the stem.
4. Use a %3" Allen wrench to loosen the set screw in the stem holder
clamp.
5. Lower the stem holder by turning it counterclockwise until the ﬂash
hole punch is extended about 1/15" below the ﬂash hole.
6. Use a %;” Allen wrench to tighten the set screw in the stem holder
clamp.
Use a %" wrench to tighten the lock nut on the stem.
Disengage the clutch.
9°?“
[63]
CALIBER .30 PRIMER INSERT
Adjustments

Piercing Punch

Tools:
Procedure:
The ﬂash hole punch, located at station 3 on the upper ram, is a tool
used to punch the ﬂash hole in the web in the head of the case. When the
top ram descends, the ﬂash hole punch pierces a hole through the base of
the primer pocket. If the ﬂash hole punch does not pierce the web thick-
ness, it will have to be lowered. The ﬂash hole punch is held in the upper
ram by a holder which can be raised or lowered and held in any position by
a lock nut. Punch
Holder
111/“; I
Lock Nut
Piercing
Punch
Piercing Punch Station
ENLARGED VIEW
OF PIERCING
PUNCH STATION
1"/ls” wrench, 1%" wrench.
1. Engage the clutch and turn the hand wheel until the ram is at the
bottom of its stroke.
2. Use a 11%” wrench to loosen the piercing punch holder lock nut.
3. Use a 1%” wrench to turn the punch holder until it extends into the
die in the stem about 1/Q”.
4. Use a 11%;” wrench to tighten the lock nut on the piercing punch
holder.
5. Disengage the clutch.

I 64 I
CALIBER .30 PRIMER INSERT Adjustments
-___—_____—*__&
No Primer or The inverted primer detector is the punch located at station 7.
lnverted Primer Its purpose is to detect an empty primer pocket or an inverted primer.
Detector If the cases pass this station without the primers or with inverted primers,
the detector punch operates the escapement door mechanism to allow
the case to fall into the reject box. If the detector fails to do this, it will
have to be readjusted. Loosen the detector punch lock nut and lower the
detector punch to a position where it will actuate the escapement door
mechanism properly.
No Primer or Inverted
Primer Station Ram


A .
0 .
.-~. .. -. 3 I_.- ._.4-__.e
l :0.
~‘
VIEW OF RAM AND TOOL HOLDERS


ENLARGED VIEW OF NO
PRIMER OR INVERTED
PRIMER STATION
-—~‘
aI_I'
Tool: 1/2" wrench.
Procedure: 1. Place a case‘ with a primer under the no primer detector.
2. Engage the clutch and turn the hand wheel until the top ram is at
the bottom of its stroke.
3. Use a V/’ wrench to loosen the no primer detector punch lock nut.
4. Turn the no primer detector punch until the detector ﬁnger just
contacts the T-bar of the escapement door mechanism enough to
lock it in the back position.
Note: This is about 1/16" from the top edge of the T-bar.
5. Use a VJ’ wrench to tighten the no primer detector punch lock nut.
6. Disengage the clutch lever.
l 65 l
CALIBER .30 PRIMER INSERT Adjustments

Push-In Finger The primer push-in ﬁnger pushes the primer into the turnover ﬁnger. If
the push-in ﬁnger is not in adjustment, the primers will jam or fail to enter
the turnover ﬁnger properly. The push-in ﬁnger should be adjusted so that
the front portion of the push-in ﬁnger is in line with the inner surface of
the feed guide when the ﬁnger is at its extreme backward position.


Turnover I
Fingers
Push-in
Finger -
Vs '
Allen
Screws "
VIEW SHOWING TOP PUSH-IN FINGER ADJUSTMENT
Tools: %;" Allen wrench, %” wrench, %” wrench.
Procedure: 1. Engage the clutch and turn the hand wheel until the push-inﬁnger is at
its extreme backward position. I
2. Use a %;" Allen wrench to loosen the Allen screws that hold the push-in
ﬁnger to the rocker arm.
3. Adjust the ﬁnger by moving it forward or backward until the front
portion of the push-in ﬁnger is in line with the ﬁrst primer cup track
guide.
4. Tighten the cap screws.
5. Engage the clutch and turn the hand wheel until the push-in ﬁnger is
moved to its extreme forward position.
6. Use a %" wrench to loosen the lock nut on the adjusting screw located
at the lower portion of the rocker arm.
7. Use a 14 " wrench to turn the adjusting screw until the push-in ﬁnger
inserts the cup into the turnover ﬁngers.
8. Hold the adjusting screw in place and tighten the lock nut.
9. Disengage the clutch.
I66]
CALIBER .30 PRIMER INSERT
Adjustments

Burring Punch The burring punch is a tool in the top ram at the second station, which
slightly chamfers the edge of the primer pocket. The burring punch is
held in the upper ram by a holder which can be raised or lowered and held
in any position by a lock nut. If the primers are being inserted sidewise
or in a tipped position, it is indicated that the primer pockets are not
being chamfered, and an adjustment is necessary.
VIEW OF RAM AND TOOL HOLDERS
TOOIS:
Procedure:


Burring Punch
1] '
Station 1 /'15; L°cl‘
Ram
ENLARGED VIEW
. OF BURRING
PUNCH HOLDER
111/16" wrench, 11/4" wrench.
1.
2.
99”?‘
Insert a case without a primer under the burring station.
Engage the clutch and turn the hand wheel until the top ram is at the
bottom of its stroke.
3. Use a 111/I6" wrench to loosen the tool holder lock nut.
4.
Use a 11/, " wrench to turn the tool holder until the burring tool enters
the primer pocket and there is a clearance of approximately 1,61”
between the head of the case and the shoulder on the top end of the
burring punch.
Use a 1"/16" wrench to tighten the lock nut on the tool holder.
Disengage the clutch.
A mercury cracking test should be made on some of the cases run after
this adjustment.
[67]
CALIBER .30 PRIMER INSERT
Adjustments

Seating and
Crimping Punch

VIEW OF RAM AND TOOL HOLDERS
TOOIS:
Procedure:
The crimping punch, at station 9, seats the primer in the primer pocket
of the case and crimps it. The crimping punch must seat the primer be-
tween .001 and .007 below the head of the case. When the primers are not
being seated below the head of the case, the crimping punch must be low-
ered. This is made possible by loosening the lock nut and lowering the
piercing punch holder.
Seating and
Crimping Station
Tool
Holder

ENLARGED VIEW
OF SEATING AND
CRIMPING STATION
111/1/6” wrench, 1%" wrench.
Note: Before making an adjustment at this station, check the case sup-
porting stem to see that it raises the head of the ease up to within about
V16" from the stripper and that the spring tension on the stem is sufficient
to support the stem and case above the case track during the crimping
operation; otherwise the crimping punch will crack the case head or mash
the mouth of the case against the case track.
1.
2.
PF“
$99‘
Place a case with a primer to be seated and crimped under the crimping
station.
Engage the clutch and turn the hand wheel until the ram is at the
bottom of its stroke. 0
Use a 1“/I6" wrench to loosen the crimping punch holder lock nut.
Use a 1% " wrench to turn the crimping punch holder until the punch
is lowered to the position where it seats and crimps the primer between
.001 and .007 below the surface of the case head.
Use a 11%;" wrench to tighten the crimping punch holder lock nut.
Disengage the clutch lever.
A mercury cracking test should be made on the ﬁrst six or seven cases
run after completion of the adjustment.
I68}
CALIBER .30 PRIMER INSERT Adjustments
Brake, Clutch, The brake is the mechanism that stops the machine and is located on the
Clutch Release driveshaft. The clutch is the mechanism by which the power is transmitted
to the driveshaft, and it is located on the driveshaft. The clutch release is
the mechanism that automatically disengages the clutch thereby allowing
the brake to stop the machine. The three mechanisms must be set and
adjusted in proper relationship.


ll _
f"“‘. -
I ‘/Brake Shoe
* -I.
’ .
I
N), § v_ K
. Q.“
.\_ Q ‘ 3
~¢._


Q
-
-
_


VIEW OF AUTOMATIC
THROWOUT MECHANISM


I '0 ‘ ‘IIIIIIIIIIE I In I‘ lllll
BRAKE AND CLUTCH ASSEMBLY
Tools: 7/Q" Allen wrench, 34 " wrench, 111/16” wrench, 7/8" wrench.
Procedure: Note: The automatic clutch release rod eccentric timing must be such
that the release rod should be at the extreme end of its downward stroke
when the top ram of the machine is at the extreme of its top stroke.
1. Use a 7/52" Allen wrench to loosen the Allen screws on the eccentric cam.
2. Be sure that the top ram of the machine is at the top of its stroke.
Then move the eccentric cam of the automatic clutch release rod to
the extreme of its bottom stroke.
3. Use a 7/Q" Allen wrench to tighten the Allen screws on the eccentric cam.
[69]
CALIBER .30 PRIMER INSERT
Adjustments
Clutch
1.
Time Brake with 1.
Clutch
Note: Be sure the clutch is disengaged.
Engage the clutch. Use a 111/16" wrench to loosen the lock nut on the
adjustable brake release wedge rod.
Use a 3/4 ” wrench to loosen the adjustable brake release wedge rod.
Note: This allows the wedge to keep the brake released when the
clutch is disengaged.
Disengage the clutch and pull the clutch toggle pin out. Then turn the
clutch yoke clockwise to tighten and counterclockwise to loosen, until
the clutch can be engaged without an undue amount of pressure on
the clutch lever.
Note: When proper adjustment is completed, be sure the clutch toggle
pin has locked into one of the notches thereby locking the adjustment
securely.
Use a 1% ” wrench to turn the adjustable brake release wedge rod until
the wedge will disengage the brake a fraction of a second before the
clutch is engaged.
Note: When the upper wedge roller and lower wedge roller are resting
on-the ﬂat part of the wedge, this is the correct position.
Use a 111/16" wrench to tighten the adjustable brake release wedge rod
lock nut.
[70]
CALIBER .30 PRIMER INSERT ' Adiusimenis

Stop Clutch 1. Loosen the stop clutch turnbuckle lock nuts with a %” wrench.
Tufnbuckle Note: If you desire the stop clutch to stop the machine faster, turn
AdIustrnent the turnbuckle to the right. If the machine is stopping too fast, turn
the turnbuckle to the left.
Caution: Do not turn more than one complete turn at a time before
checking.
2. Use a V8" wrench to tighten the stop clutch turnbuckle lock nuts.


Hand Lever
Brake Shoe
Spring and Bolt


/
Adjustable Wedge Bolt
CROSS SECTIONAL DRAWING OF HAND LEVER ENGAGING MECHANISM
I
Lock Nut

---—— Turn Buckle

Eccentric Cam __ ‘ I
Rocker Arm
CROSS SECTIONAL DRAWING OF ECCENTRIC CAM OF AUTOMATIC THROWOUT
[71]
CALIBER .30 PRIMER INSERT
Troubles and Corrections
Objective
Cases Not Fed
Properly
Jam at Positioning
Mechanism
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as
it operates.
When making an analysis of the trouble that occurs, check the components
entering the machine to see whether or not they meet speciﬁcations before mak-
ing any adjustments on the machine.
Visual inspection reveals that the cases are not being fed properly to
the positioning mechanism.
The causes are:
1.
The hopper conveyor belt is
slipping and is not carrying the
cases to the feed throat.
The tapered pin on the paddle
wheel drive gear is sheared.
The paddle wheel does not
rotate.
The corrections are:
1. Loosen the nut on the knurled
idler pulley and force the pulley
up against the conveyor belt
until the belt is taut. Tighten
the nut on the idler pulley.
. Remove the drive belt guard
and remove the drive belt. Re-
move the housing and take out
the driveshaft. Drive out the
broken pin. Place a new pin in
the gear and the shaft and re-
assemble the hopper.
Visual inspection reveals that the cases are jammed at the positioning
mechanism.
The causes are:
1.
The receiving ﬁnger is not in
line with the track. The cases
are not falling from the feed
ﬁnger into the track.
The corrections are:
1. Take out the feed tube and re-
move the turnover mechanism.
Adjust the receiving ﬁnger in
line with the track by turning
the eccentric pin until the ease
falls freely from the receiving
ﬁnger into the case track.
Remember to check the components entering the machine before making any
adjustments.
[72]
CALIBER .30 PRIMER INSERT
Troubles and Corrections
Jam at Positioning 2.
Mechanism
(Cont.)
Scratches on
Body of Case
The mouth of the positioning
mechanism is not in line with
the receiving ﬁnger. The case is
not being fed freely into the
case track.
The causes are:
1.
Too much tension on the latch
ﬁnger spring causes scratches
on the case as it is removed
from the latch ﬁnger.
Burrs on the latch ﬁnger will
cause scratches on the case.
Burrs on the transfer bar cause
scratches as the cases are con-
veyed from one station to the
other by the transfer bar.
2. Adjust the mouth of the turn-
over mechanism in line with
the receiving ﬁnger. Loosen
the Allen screws that hold the
turnover mechanism to the
track. Shift the mechanism un-
til it is in line with the receiving
ﬁnger. Tighten the Allen screws.
Visual inspection reveals that the body of the case is being scratched as it
passes through the machine.
The corrections are:
1. Release the tension on the latch
spring by using a screwdriver to
turn the eccentric pin counter-
clockwise. The latch ﬁnger
should hold the case ﬁrmly but
not so tight as to scratch the
case when it is being moved
from station to station by the
transfer bar.
. Remove the latch block and re-
move the burr with a ﬁne grade
of emery cloth. Replace the
latch block and tighten the
latch block bolt. Adjust the
latch ﬁnger.
. Take off the transfer bar and
remove the burrs with emery
cloth. Remove the bearing
block cap plate by ﬁrst remov-
ing the cap plate screws. Re-
move the pin that connects the
advance arm to the transfer
bar. Remove the two latch
blocks on the extreme left end
of the machine. Take out the
Allen screws from the track
holder and remove the track
holder. Remove the transfer
bar and remove the burrs with
ﬁne emery cloth. Reassemble.
Remember to check the components entering the machine before making any
adjustments.
[73]
CALIBER .30 PRIMER INSERT
Troubles and Corrections

Scratches on Neck
or Shoulder
Ragged Flash Hole
Primer Set Too Deep
Visual inspection reveals scratches on the neck or shoulder of the case.
The cause is: The correction is:
1. Remove the burrs or brass on
the guide rails. It will be
necessary to remove all of the
latch blocks and remove the
burrs with a ﬁne grade of
emery cloth. Replace the latch
blocks.
Visual inspection reveals ragged ﬂash hole. Observation also reveals that
the punch is pulling the case up from the stem.
1. Brass or burrs on guide rails.
The cases are scratched as they
are carried between the rails.
The causes are: The corrections are:
1. The ﬂash hole punch is dull. 1. Remove the punch by remov-
ing the Allen screws in the
punch holder. Place a new
punch in the punch holder and
tighten the Allen screws.
2. The ﬂash hole die is dull. 2. Remove the die stem by re-
moving the Allen screw that
holds it into the stem holder.
Drive out the die and place a
new die into the die stem.
Tighten the Allen screw.
l
Gaging reveals that the primer is being inserted too deep into the primer
pocket of the case.
The causes are: The corrections are:
1. Remove the stem beneath the
inserting station. Lower the
ram and remove the Allen screw
that holds the stem. Remove
the stem and remove any for-
eign material on the top of the
stem. Place the stem back in-
to the stem holder and tighten
the Allen screw.
1. Accumulation of brass or for-
eign matter on the stem beneath
the inserting tool. This raises
the case too high and allows the
primer to be forced too far into
the primer pocket.
. Defective die on stem at the
piercing station causes a burr
underneath the ﬂash hole. The
burr causes the case to be raised
too high at the inserting sta-
tion.
. Remove the die stem at the
piercing station by removing
the Allen screw on the stem
holder. Remove the stem and
drive out the die. Place in a
new die and place the stem
back into the stem holder.
Tighten the Allen screw.
Remember to check the components entering the machine before making any
adjustments.
I74]
CALIBER .30 PRIMER INSERT
Troubles and Corrections
Primer Set Too Deep 3. The stem beneath the inserting
(Cont.)
Primer Set Too
Shallow
Primer ls
Flottened
tool is too high.
4. The crimping tool is adjusted
too low.
3. Loosen the lock nut on the tool
holder; turn the stem holder to
the left to lower the inserting
stem. Tighten the lock nut.
Check the adjustment for accu-
racy and readjust, if necessary.
. Loosen the Allen screw in the
punch holder. Loosen the lock
nut on the set screw on top of
the tool holder and turn the set
screw. Raise the punch holder
a slight amount by turning the
set screw, tighten the Allen
screw. Tighten the set screw
and lock nut.
Gaging reveals that the primer is not seated deep enough in the primer
pocket.
The cause is:
1
._ The crimping tool is adjusted
too high. It does not force the
primer far enough into the
pocket.
The correction is:
1. Loosen the Allen screw in the
punch holder, and loosen the
lock nut on the set screw lo-
cated on top of the tool holder.
Turn the set screw thereby
lowering the crimping tool.
Tighten the lock nut and the
Allen screw. Check the adjust-
ment and readjust, if necessary.
Visual inspection reveals that the primer is being ﬂattened.
The causes are:
1.
The burring tool is too small in
diameter. Too much pressure
is necessary to insert the primer
into the pocket.
. The burring tool is adjusted
too high. It is not removing
the burr from the pocket.
. The stem beneath the burring
tool is too low. It is not holding
the case high enough.
The corrections are:
1. Remove the clamp nut on the
tool holder and remove the
tool. Place a new tool into the
tool holder and tighten
the clamp nut.
. Loosen the lock nut on the tool
holder. Turn the tool holder
thereby lowering the tool.
Tighten the lock nut.
. Loosen the lock nut on the stern
holder. Turn the stem holder
thereby raising the stem. Tight-
en the lock nut.
Remember to check the components entering the machine before making any
adjustments.
= [75]
CALIBER .30 PRIMER INSERT
Troubles and Corrections
Primer ls
Flattened (Cont.)
4. The crimping tool is worn. It
ﬂattens the primer during the
crimping operation.
5. The crimping tool is adjusted
too low. It is forcing the primer
too far into the primer pocket.
4. Remove and replace the crimp-
ing punch. Loosen the clamp
nut on the punch holder and
allow the punch to drop out.
Place a new punch in the holder
and tighten the clamp nut.
. Loosen the Allen screw in the
punch holder. Loosen the lock
nut on the set screw on top of
the tool holder and turn the set
screw. Raise the punch holder
a slight amount by turning the
set screw; tighten the lock nut
and the Allen screw.
Primer Not Evenly Visual inspection or gaging reveals that the primer is crooked.
Seated
The causes are:
1.
The turnover ﬁngers do not
center the primer in line with
the pocket.
The stem beneath the inserting
tool is bent. The case is not
aligned with the primer.
. The latch ﬁnger spring at the
inserting station is weak or
broken. It does not line the
case with the inserting punch.
The corrections are:
1. Center the turnover ﬁngers.
Turn the adjusting nut on each
side of the turnover ﬁnger shaft
until the finger centers the
primer directly over the primer
pocket.
. Remove and replace the stem.
Remove the Allen screw on the
stem holder and take out the
stem. Place a new stem in the
stem holder and tighten the
Allen screw.
. Remove the latch block by re-
moving the bolt that holds it in
place. Remove the plate on
the latch block, and remove
and replace the ﬁnger spring.
Reassemble the latch block
and place it back on the ma-
chine. Tighten the latch block
bolt.
Remember to check the components entering the machine before making any
adjustments.
[76]
CALIBER .30 PRIMER INSERT
Troubles and Corrections

Dents on Case
Visual inspection reveals dents on the body of the case.
Body The cause is:
1.
The notches on the transfer bar
are not in line with the latch
ﬁngers. The cases are scratched
as they are conveyed from sta-
tion to station.
The correction is:
1. Align the notches on the trans-
fer bar with the lower stems.
Loosen the set screws on the
cam that controls the move-
ment of the transfer bar and
turn the cam until the notches
in the transfer bar are in line
with the lower stems.
Primer Is Not
Feeding Correctly
Visual inspection reveals that the primer is not being fed to the push-in
ﬁnger.
The corrections are:
1. Loosen the lock nut on the belt
adjusting screw and turn the
adjusting screw to increase the
tension on the feed belt.
The causes are:
1. The primer feed belt is too loose.
It is not conveying the primers
to the push-in ﬁnger.
2. The primer drive belt is loose. 2. Remove the guard and adjust
It is not properly driving the the V-belt pulley so that the
pulley that actuates the feed belt is taut.
belt.
Remember to check the components entering the machine before making any
adjustments.
[77]
CALIBER .30 PRIMER INSERT
Tool Servicing
Objective
Servicing A New
Punch or Stem
Servicing A Used
Punch or Stem
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the inser-
tion of primers and ﬂash holes in the cases. Dies and punches are costly
and great care must be exercised in the servicing of these tools. While ad-
justers will not be concerned with tool servicing in the Primer Insert De-
partment at present, such necessary steps as listed should be known in the
event that they may be needed in the future. Adjusters will be concerned
primarily with the removal of small scratches that appear on the working
surfaces of stems and punches. They must be careful when using an
abrasive on any tool not to alter its dimensions materially.
All tools that cannot be corrected by polishing those punches that are bent,
will be returned to the Tool Department, in exchange for new ones. Under
no circumstances will any attempts be made to straighten bent or sprung
punches.
Before an abrasive of any kind is applied to a new punch or stem, its di-
mensions should be carefully checked with a micrometer or proﬁle gage,
and its working surface should be examined for ﬁnishing or handling marks
and lack of polish. A highly polished punch aids in stripping and allows
better working conditions.
As a punch is used its working surface wears accumulating scratches.
Excessive wear is determined by measuring with a micrometer or check-
ing with a proﬁle gage. Obviously, an undersize punch must be replaced
with one of approved dimensions. Scratches, if not too deep, may be
removed by polishing. The question of how soon a new punch will need
polishing can be answered only from experience, since many variable
factors enter into the problem.


FIG. 1
OVER-ALL VIEW OF SPEED LATHE
I78]
CALIBER .30 PRIMER INSERT
Tool Servicing
FIG. 2
CORRECT METHOD OF PLACING
PUNCH IN CHUCK
Polishing
Lapping

FIG. 3
INCORRECT METHOD OF PLACING
PUNCH IN CHUCK
Polishing is done with a ﬁne abrasive, for example, crocus cloth. A ﬁnal
operation called draw polishing is done after the chuck has been stopped.
To draw polish a punch or stem, move the abrasive cloth lengthwise
over the entire working surface, avoiding rotary motion of the punch or
the abrasive. Continue this operation until all marks- are removed and
the desired high polish or mirror like ﬁnish is obtained.
An adjuster will not be required to lap more than .0005 inch from a new
punch or stem. If more than this must be removed to bring the punch or
stem to correct size, it should be returned to the Tool Servicing Depart-
ment for correction. Lapping is done with a piece of abrasive cloth
wrapped around and moved back and forth along the axis of the punch
as it revolves in the high speed chuck. If the abrasive were held sta-
tionary, deep rings would be cut into the surface, and the ﬁnish would
be ruined.
The punch or stem is shown in Fig. 2 correctly chucked, and in Fig.
3 incorrectly held. Avoid excessive overhang of the punch as this is a
safety hazard; make sure that the jaws are correctly set and tightened
securely. Do not allow the jaws to grasp the working surface of the
punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with a cross-hatched effect.
[79]
CALIBER .30 PRIMER INSERT
Machine Lubrication
Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬁngs
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—-tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[80]
CALIBER .30 PRIMER INSERT
Machine Lubrication

Selecting a Some of the factors that govern the selection of a lubricant are:
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
\
1. Speed of the shaft or slide.
. Load on the shaft or slide.
. Opportunities for leakage from the bearing.
. Cleanliness of surroundings.
2
3
4. Constant or intermittent operation.
5
6. Temperature of surroundings.
7
. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.“q.°‘$"tl>‘.¢*°.l\'>
Frequency of lubrication.
I 81 I
CALIBER .30 PRIMER INSERT
Machine Lubrication
Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
. Bottle oiler.
. Ring oiler.
. Plain oil cups.
2
3
4
5. Drop feed cups.
6. Wick feed cups.
7. Mechanical, force feed, central lubricating system.
8. Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the fitting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
[82]
CALIBER .30 PRIMER INSERT Machine Lubrication

LU BRICATION CHART

. . N 0. of Fittings, Frequency of
I/ubmcant Mach/me Part Grease Cups, etc. Lubrication H ours
Brake and clutch shaft start lever 1 24
Clutch release collar . . . . . . . 1 8
Primer belt idler pulley—right end . 1 24
LIGHT GREASE Primer belt idler pulley—left end . . 1 24
(Blue Gun) Brake shaft housing . . . . . . . 1 48
Primer belt pulley shaft . . . . . . 2 24
Eccentric follower . . . . . . . . 1 24
Leader pins . . . . . . . . . . . 4 28
Rocker shaft brackets . . . . . . . 2 24
Conveyor belt pulley bearing . . . . 4 24
Rocker arm counter bearing . . . . 1 48
Rocker arm bearing shaft . . . . . 1 48
Driveshaft . . . . . . . . . . . . 2 8
Starting lever shaft (front and back). 2 24
Idler pulley on conveyor belt on case
hopper . . . . . . . . . . . . . 1 8
Transfer bar bearing gibs . . . . . 4 8
Transfer bar bronze bearing caps . . 2 8
Rocker shaft connecting pin to trans-
fer bar . . . . . . . . . . . . 1 8
Push rod connection of cross-shaft
rocker arm . . . . . . . . . . 4 8
Varnish & shellac assembly. . . . . 17 8
Gibs on escapement door . . . . . . 4 8
MEDIUM OIL Top of escapement door shafts . . 2 4
(Red Oiler) Detector stations assembly on top of
top ram . . . . . . . . . . . . 4 8
Varnish & shellac tool gibs . 2 4
Roller of case turnover mechanism 1 8
Automatic control bar . . . . . . . 1 8
Knockout clutch and brake adjust bar 1 8
Hopper . . . . . . . . . . . . . 8 8 .
Transfer bar arm . . . . . . 1 8
Turnover ﬁnger shaft . . . 1 8
Cam roller . . . . . . . . . . . . 1 8
Primer belt gear housing . . . . . . 5 8
Crankshaft bearing and leader pin
(cups) . . . . . . . . . . . . . 18 8
Gears in gear box where necessary . 3 1 wk.
Crankshaft barrel cam 1 8


[83]
CALIBER .30 PRIMER INSERT
Index
Adjustment, Brake Clutch Release, 69
Burring Punch, 67
Case Supporting Stems, 52
Clutch, 55, 70
Escapement Door Slide, 56
Flash Hole Detector, 63
No Case Detector, 50
No Primer or Inverted Primer De-
tector, 65
Piercing Punch, 64
Primer Insert Punch, 49
Push-in Finger, 66
Seating and Crimping Punch, 68
Shellac Tool, 57, 58
Stop Clutch Turnbuckle, 71
Time Brake with Clutch, 70
Transfer Bar Alignment, 59
Transfer Bar In and Out
Movement, 51
Transfer Bar Positive Stop, 50
Turnover Finger Assembly, 54
Varnish Tool, 61
Anti-friction Bearings, 80
Barrel Cam, 10
Bearing Block, 35, 36
Bottom Tool Slide, 28
Brake, 3, 9
Clutch Release Adjustment, 69
Burring Punch, 17 , 38
Punch Adjustment, 67
Punch Holder Assembly, 32
Station, 17
Tool, 32
Tool Holder, 32
Cam, 14, 15, 27
Roller, 27
Cannelure Depth Gage, 47
Cap Nut, 30, 31, 32, 33
Cams, 2
Case Ejector Station, 24
Supporting Stems Adjustment, 52
Cases Not Fed Properly, 72
Clutch, 2, 3, 9
Adjustment, 55, 70
Coil Spring, 34, 35, 36, 37
Connecting Link, 28
Rod, 28
Conveyor Belt, 5
Countershaft, 2, 9
Crankshaft, 2, 3, 8, 10
Crimping, 26
Assembly Tool Holder, 30
Punch, 26
Punch Holder, 30
Punch Holder Assembly, 30
Station Punch, 53
Tool, 30
Cross-Shaft, 5, 10, 19, 35, 36
Dents on Body of Case, 77
INDEX
Detector Finger, 19, 21, 34, 35, 36
Finger Pin, 34
Flash Hole Punch Holder
Assembly, 36
Pin, 36
Punch, 21, 34, 35, 36, 38, 39
Punch Hexagon Nut, 36
Punches, 4
Shaft, 9, 34, 35, 36
Shaft, Bushing, 22
Spindle, 21
Station, 44
Detection, 22
Dial Indicator Gage, 46
Die, 18, 38
Disposal, 42
Drying Track, 42
Eccentric Cams, 3
Ejector Shaft, 22
Escapement Block, 24
Door Shaft, 22
Door Slide Adjustment, 56
Finger, 22
Feed Block, 3, 7
Throat, 41
Tube, 3, 7, 41
Flash Hole Detector, 19
Hole Detector Adjustment, 63
Hole Punch, 18, 33
Hole Punch Assembly, 33
Hole Punch Holder, 33
Floating Punch, 17
Floor Space 1
Flow Chart, 43
Flush Pin Gage, 46
ﬁiction, 80
Gage Care, 46
Gib, 24, 27
Gibs, 3
Grease, 81
Height, 1
Hexagon Nut, 35, 36
Holding Finger, 25
Hopper, 3, 5
Box, 3
Horizontal Slide, 27
Inserting Assembly Tool Holder, 31
Punch, 20
Punch Holder Assembly, 31
Tool, 31
Inverted Detector, 21
Primer Tool Holder Assembly, 34
Jam at Positioning Mechanism, 72
L Shaped Arm, 28
Lapping, 79
Latch Blocks, 3, 4, 12
Fingers, 21
Lock Collar, 36
Lower Cross Arm, 28
Lubricating Film, 80
Lubrication, 80
Chart, 83
Hints on, 82
Methods, 81
Machine Description, 1
Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 82
No Case Detector, 16
Case Detector Adjustment, 50
Case Tool Holder Assembly, 35
Primer Detector, 21
Primer or Inverted Primer
Detector Adjustment, 65
Opening Finger, 24
Over-all Height, 44
Overhead Hopper, 41
Paddle Wheel, 3, 5
Wheel Hopper, 41
Piercing Punch Adjustment, 64
Pin, Shellac, 40
Pocket Depth, 44
Diameter, 44
Polishing, 79
Positioning Mechanism, 41
Power, 2
Primer Diameter, 44
Feed Belt, 3, 11, 44
Insert, 20
Insert Punch, 39
Insert Punch Adjustment, 49
Insert Stem, 39
Is Flattened, 75
Is Not Feeding Correctly, 77
Not Evenly Seated, 76
Set Too Deep, 74
Set Too Shallow, 75
Production, 1
Punch, 12, 15, 18, 38, 39
Punches, 4, 6
Push-in Finger, Adjustment, 66
Ragged Flash Hole, 74
Ram, 4, 7, 11, 13, 17, 18
Rams, 3, 6
Receiving Block, 41
Reset Shaft, 22
Retaining Stud, 30
Stud and Lock Nut, 31, 32
Scratches on Body of Case, 73
Scratches on Neck or Shoulder, 74
Seating, 26
Seating and Crimping Punch
Adjustment, 68
Selecting Lubricant for Given
Bearing, 81
Servicing New Punch or Stem, 78
Used Punch or Stem, 78
[84]
CALIBER .30 PRIMER INSERT
Index
Shaft, 11, 14, 19
Detector, 16
Shellac, 27
Tool, 33
Tool Adjustment, 57, 58
Tool Holder, 34
Tool Holder Assembly, 34
Snap Gage, 47
Space Rod, 30, 31, 32, 33
Speed of Crank, 1
Split Nut, 37
Station 1-16, 50
1-Detector, 41
2-17, 44
2—Burring, 41
3-18, 44, 64
3-Piercing Punch, 41
4-19, 63
4-Detector, 41
5-19, 63
5-Detector, 41
6-20, 44
6-Primer Insert, 42
7-21, 44
Station (Cont.)
7-Detector, 42
8-24, 45
8-Escapement Door, 42
9-26, 45
9-Crimping and Seating, 42
10-27, 45
10-Shellac and Varnish, 42
Stations, 4
Stem, 4, 6, 17, 38, 39, 40
Holder Shaft, 26
Stems, 13
Stop Clutch Turnbuckle
Adjustment, 71
Stripper Block, 17
Plates, 4, 13
Stroke, 1
Time Brake with Clutch Adjustment,
70
Toggle Switch, 2
Tool Holder Lock Nut, 30, 31, 32, 33
Mouth Varnish, 40
Tools, 1
Transfer Bar, 3, 4, 10, 12, 21, 24, 41, 44
Transfer Bar Alignment Adjustment,
59
Bar Block, 3
Bar In and Out Movement
Adjustment, 51
Bar Positive Stop Adjustment, 60
Transmission, 2
Turnover Finger Assembly
Adjustment, 54
Finger Mechanism, 14, 15
Twin Ring Gage, 47
Type of Feed, 1
Varnish, 27
Shaft, 37
Station, 29
Tool Adjustment, 61
Tool Holder, 37
Tool Holder Assembly, 37
Tool Slide, 37
Varnishing Pin, 37
Vertical Slide, 27
Visual Inspection, 46
Web Thickness Flash Hole, 44
Weight, 1
[85]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
V. and 0.
Primer Insert Press

BY
Training Department
Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, ,1 941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917 , C30, Title 1, Sec. 1; 40 Stat. 217 . Act of March 28,
1940; Public No. 443, 7 6th Congress, 3rd Session).
II
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
‘ Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
III

CALIBER .30 V. AND O. PRIMER INSERT PRESS
IV
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Catalogue Data

CATALOGUE DATA
Manufacturer V. and 0. Power Press Company, Hudson, New
York
Machine V. and O. Vertical Dial Feed Power Press; three
Description V-belt drive, ﬂywheel to crankshaft, crankshaft to
connecting rod to ram.
Machine Motor 1 h.p.; 220-440 volts; 3-phase; 60-cycle; 1740
R.P.M.
Type of Feed Liberty Paddle Wheel Hopper
Feed Motor Paddle Wheel Hopper driven by a rubber covered
coil spring type belt from machine motor.
Stroke 4"
Production 85 per minute
Crankshaft Speed 85 R.P.M.
- Piece No.
Tools Burring punch P-64
Seating and crimping punch P-65
Primer inserting punch P-66
Flash hole detector P-68
Flash hole punch P-69
Inverted primer detector P-70
Height Over-all 7 ft.
Weight Approximately 3500 lbs.
Floor Space 4 ft. x 4 ft.
[1]
CALIBER .30 V. AND 0. PRIMER INSERT PRESS Machine Description

MACHINE DESCRIPTION
The purpose of the Caliber .30 V. and 0. Primer Insert Press is to pierce
a flash hole in the bottom of the primer pocket through the web thick-
ness of the case. The machine then burrs the shoulder of the primer
pocket, after which it inserts and seats the primer in the case pocket and
crimps the primer into place. As a ﬁnal operation, the machine moisture—
proofs the primer and the inside of the case mouth.

— Motor
Ram
/ Recoil
Pvc|{<'I1dIti__ Sprmg
ee
Guard
Hopper /,, » / Covering
Box Flywheel
Idler/_
Pulley
Crankshaft
/- Ram
Connecling/
Rod
_ Feed
Uni!
Feed Tube
Case
\ Guide
Ring
CALIBER .30 PRIMER INSERT v. AND 0. PRESS
I 2 l
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Description

Power and
Transmission
Paddle Wheel
Hopper
Crankshaft
Ram
Indexing
Dial
The V. and O. Power Press, illustrated on page 2, is powered by a 1
h.p. motor through 3 V-type belts connecting the motor to the ﬂywheel.
The motor is mounted on an adjustable bracket above the machine
frame. Power is applied to the motor by means of a toggle switch, located
at the front end of the machine frame.
The ﬂywheel is mounted on the right end of the crankshaft and incorpo-
rates a rolling key clutch which controls power from the ﬂywheel to the
crankshaft. The clutch is electrically operated and controlled by a toggle
switch which is mounted at the right of the motor switch on the forward
edge of the machine frame.
The machine is equipped with a constant pressure brake which is mounted
around the crankshaft between the ﬂywheel and the machine frame. The
brake is adjusted to stop the ram at top dead center when the clutch is
disengaged. The machine is protected by an elaborate electrical system
which automatically disengages the clutch when a faulty case is present
at one of the detector stations.
The cases are fed through a chute from an overhead source. They are
picked up from the bottom of the hopper by a series of paddles which lift
them to a conveyor belt. The cases roll from the paddles, lengthwise onto
the conveyor .belt. The belt conveys the cases to the feed tube opening
where they fall, head ﬁrst, into the feed tube mouth. The feed tube mouth
is so arranged that should a case be conveyed mouth ﬁrst to the opening,
the mouthend will overshoot the opening and allow the case to drop into
the feed tube, head ﬁrst.
The crankshaft is held in a horizontal position above the machine bed.
It is held by, and rotates in, two ﬁtted bearings. The crankshaft is
equipped with a single throw bearing to which the ram connecting rod
is attached. Through the use of the clutch, the crankshaft may be
stopped independently of the ﬂywheel. A pulley wheel which has two
belt grooves machined around its outer circumference is attached to the
left end of the crankshaft outside the machine frame. The outside face
of the pulley wheel has a slot machined across its surface to which the dial
indexing arm is attached. Thus, the crankshaft actuates the shellacing
station and the primer dial through the use of two round leather belts and
the indexing dial through an operating arm from the pulley wheel slot.
The ram is held by, and guided in, its vertical stroke by 2 V-guides with
an adjustable gib in the left side. The lower surface of the ram is machined
to hold the working punches and the detector punches. The ram, through
linkage, actuates the case inserting unit and the case transfer unit. Two
geared shafts are attached to the ram which operate the primer turnover
ﬁngers and the shellac station.
The indexing dial is centrally located on the machine bed directly beneath
‘the ram. The dial is actuated by a pawl ﬁnger, through linkage, from the
crankshaft. Sixteen stems are evenly spaced around the outer edge of the
dial plate. The stems carry the cases in a vertical position past the vari-
ous stations where each operation is performed.
I3]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Description

Primer
Hopper
Station I ,
Feed Block
Station 2,
Flash Hole Punch
Station 3,
Flash Hole Detector
Station 4,
Burring
Station 5,
Primer Insert
Station 6,
Inverted Primer
Detector
Station 7,
Crimping
The primer hopper is mounted at a slight angle on the rear edge of the
machine bed directly behind the indexing dial. The hopper is slanted to
allow the primers to ﬂow downward towards the machine bed where they
are picked up by the primer dial. The primer dial rotates actuated through
a round leather belt from the pulley wheel on the left end of the crankshaft.
As the primers ﬂow through the primer hopper mouth onto the primer dial,
they are carried around the dial to the inserting ﬁngers which feed them
into the turnover'ﬁngers. The turnover ﬁngers position the primer above
the case head for the primer inserting operation.
The feed block is located on the machine bed at the front edge of the in-
dexing dial. The cases drop through the feed tube to the feed block. The
feed block operates, through linkage, from the ram. The case inserting
ﬁnger is equipped with an electric detector which automatically stops the
machine if no case is fed into the dial.
The dial indexes, carrying the case to station 2 which is known as the ﬂash
hole punch. The ﬂash hole punch is held in a tool holder in the bottom
surface of the ram. The punch descends, carried by the ram, and pierces
the ﬂash hole through the web thickness of the case. This hole allows the
ﬂash of the primer cap to ignite the propellent powder which forces the
bullet from the case out through the gun barrel.
The cases then move to station 3 which is known as the ﬂash hole detector
station. The ﬂash hole detector punch is machined to a diameter small
enough to pass through the ﬂash hole, thus indicating the presence of the
ﬂash hole. This station is equipped with an electrical detector device
which automatically stops the machine if no ﬂash hole has been pierced
at the preceding station.
After the dial indexes again, the case is carried to station 4 which is known
as the burring station. The burring punch is held in a tool holder which
ﬁts into the lower surface of the ram. The burring punch removes any
rough edges or burrs which may have been left by the heading operation
and also produces a slight chamfer around the edge of the primer pocket
to facilitate the primer inserting operation.
The case is then transferred to the primer inserting station. Here the
primer is transferred from the primer dial by a set of turnover ﬁngers
which position the primer cup for insertion into the case pocket. The in-
serting punch is held in a tool holder which is carried in the lower surface
of the ram. The primer is inserted to a point about ﬂush with the case
head.
The case is moved from the insert station to the inverted primer detector
station. The inverted primer punch does not have a tool holder, but is
held directly in place in the lower surface of the ram. This station is
equipped with an electrical detecting system which automatically stops
the machine if a primer has been omitted or inserted in an inverted posi-
tion.
As the dial indexes, the case is carried to the crimping station. Here the
primer is seated to the proper depth and crimped securely in place. The
crimping tool is held by a tool holder in the lower surface of the ram.
[41
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Description

Station 8,
Sheﬂac
Station 9,
Varnish
The case is then moved to the next operation on the dial which is known
as the shellac station. Here the primer receives a coating of shellac which
Waterproofs the primer pocket against moisture. The shellac station is
actuated through linkage from the ram.
The dial indexes once more, before the case is removed, carrying the case
to the case transfer tube which removes the component from the dial,
transferring it to the drying track. The transfer lift is attached to the
lower surface of the ram and is arranged to allow the cases to pass through
a tube which raises them to the elevated track on which they pass out of
the machine.
As the cases are pushed along the drying track by each succeeding case,
they pass the mouth varnishing station. Here the case mouth is varnished
to waterproof the union of the bullet and the case against moisture.
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description
Puddles ---" Be"
H _, P 1|
°%Z‘i' vi/’hZZ|
PuHey"'


§%gyI.__ hﬂer
-‘ 7 Pu"ey
Feed
Tube
‘_ Conveyor
Be“
SIDE VIEW OF PADDLE WHEEL HOPPER
Puddle Wheel The paddle wheel hopper is mounted on a bracket at the left side of the
Hopper machine frame. The paddle wheel of the hopper is driven by a round belt
from the pulley wheel mounted on the left end of the crankshaft. The
paddle wheel shaft extends through the rear of the hopper frame and has
a bevel gear attached to its outer end. A cross-shaft is held in a horizontal
position across the back of the hopper frame and has a small bevel gear at-
tached to the inner end which meshes with the paddle wheel bevel gear.
A pulley wheel is attached to the opposite end of the cross-shaft and is con-
nected to the crankshaft pulley by the round belt.
The conveyor belt travels around two pulleys which are mounted to the
right side of the hopper frame. The conveyor belt runs from the paddle
wheel to the case feed tube. The belt is driven by the rear pulley wheel
which is attached to the paddle wheel cross-shaft. As the paddle wheel
rotates, the cases are picked up by the paddles and lifted to the conveyor
belt. The conveyor belt carries the cases to the feed tube through which
they fall by gravity to the feed block.
[6]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description


I


Machine
Motor
- Hopper Box
SIDE VIEW or THE PADDLE WHEEL HOPPER
[7 I
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Description
Feed Tube “' i


Dial Connecting
Indexing\ Rod
Arm
Primer Dial
Idler Pulley
Ram
VIEW OF THE CRANKSHAFT
Crankshaft The crankshaft rotates in two machined bearings directly above the in-
dexing dial and ram. The crankshaft throw is machined at the center of
the crankshaft and actuates the vertical stroke of the ram through the
connecting rod. The clutch is attached to the right end of the crankshaft
outside the machine frame and is electrically operated from a solenoid
switch mounted to the outside of the machine frame directly below the
clutch. The clutch is controlled by an electric switch mounted below the
machine bed which must be reset through the use of a manually operated
shaft which extends from the electric unit to the front of the machine bed.
The clutch is also electrically controlled from the various detector stations
which act to force the clutch arm up. As the clutch arm strikes against the
clutch dog, it releases the rolling key mechanism which disengages the
clutch, allowing the ﬂywheel to turn independently of the crankshaft.
The clutch is known as a rolling key type and gives a positive connection
between the ﬂywheel and crankshaft when the clutch is engaged.
[8]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description

Crankshaft Bearings
Flywheel Shaft


Crankshaft /
_ —- Brake Band
Connecting Rod
Clutch Release Rod
__ Clutch Release
Detector Shaft
VIEW OF THE CRANKSHAFT
\
[9]
CALIBER .30 V. AND O.
Machine Description
PRIMER INSERT PRESS


Cranlcshalt /
Bearings
Connecting
Rod and
Ram
/ Crankshaft
/ Connecting Rod
ll I3.
VIEW OF THE CRANKSHAFT AND RAM
The connecting rod is attached to the crankshaft throw and held in place
by the bearing cap. The lower end of the connecting rod is attached by a
ball and socket arrangement to the ram which allows the connecting rod
to rock at its point of contact with the ram when the machine is in motion.
The connecting rod is adjustable to increase or decrease the ram’s stroke -
whichever may be necessary. The adjusting stud is threaded into the
lower end of the connecting rod and attached at the opposite end to the
wrist pin in the ram. The connecting rod shaft is split. A stud is connected
to both sides across the split at the front side of the connecting rod. When
the stud is tightened, it locks the adjustment securely in place. The ram
travels in its vertical stroke in two machined bearing surfaces in the ma-
chine frame. The bearing surfaces machined on the ram are V-shaped and
ride against a bronze gib which may be adjusted by three set screws. The
set screws enter through the machine frame to contact the gib bearing.
The lower surface of the ram is machined in a semi-circular shape which is
designed to conform to the position in which the cases are held in the dial
plate. The tools are arranged in the lower surface of the ram in a semi-
[10]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description
Connecting Rod circular position to contact the cases as they travel around, carried by the
and Ram (Cont.) indexing dial. A heavy coil spring is attached to the rear of the ram and
absorbs vibration produced by the ram’s stroke and also assists in the re-
turn stroke of the ram.
Turnover
Finger
Shaﬂ

VIEW or THE RAM
l 11 l
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description

I Turnover
<nfT Finger
I
F
I
Case
Guide
Ring
Index
Dial
Case
Supporting
Stems
VIEW OF THE INDEX DIAL
Indexing The indexing dial is located in the center of the machine bed directly below
Dial the ram. The dial consists of two rings. The lower ring revolves about a
circular plate which is bolted to the machine frame. The case supporting
stems are attached in an upright position to the lower ring which rides
against the machine bed. The outer circumference of the lower ram has
sixteen evenly spaced notches into which the pawl operating ﬁnger ﬁts
to move the dial on every stroke of the ram. The dial has a second ring,
held directly above the lower ring, through which the supporting stems
extend. As the cases are pushed onto the supporting stems by the case
inserting ﬁnger, the second ring supports the cases as they travel about
the dial. An adjustable friction block is bolted to the stationary section
of the lower plate and overlaps the movable lower ring, acting as a friction
brake to avoid the back-lash of the dial. Two stripper blocks are attached
to the stationary section of the lower plate, and on top of one of the blocks
is mounted a stripper plate which extends out over the edges of the cases
as they pass beneath stations 1, 2, 3, and 6. The stripper plate is necessary
to hold the cases securebr in place on the supporting stems as the working
tools are withdrawn by the upper ram after each operation.
[12]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description


7\ C052 Supperﬁng
O ' Stems
’‘k)
, ~~u
Case Guide __
Ring
__ Case Holding
“ / Jaws
Dial Friction __ \
Brake \
TOP VIEW OF THE CASE GUIDE RING
I13]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Description
Shellac '
Container
Index Pawl
Holding Finger
Bearing Block
Pawl, Transfer
Slide and
Locking
Finger


Dial Alignment
Holes
j / Index Dial
' s__ Holding Finger
‘ Rocker Arm


VIEW OF THE INDEXING PAWL
The transfer slide travels back and forth in a machined groove on the left
side of the machine bed. The pawl ﬁnger is attached to the back end of the
transfer slide by a wrist pin arrangement which allows the pawl ﬁnger to
move in and out of the notches on the index dial. The pawl ﬁnger is forced
against the index dial by a pressure spring. The holding ﬁnger rocker arm
is located between the index dial and the forward side of the transfer slide,
and is actuated by a rocker arm attached at its pivotal point to a vertical
stud in the machine frame. The holding ﬁnger is pressed forward by the
rocker arm into the notches of the index dial by a coil tension spring. The
rocker arm is actuated from a bearing block mounted on the forward end
of the transfer slide.
The transfer slide is connected by a shaft to a V-shaped rocker arm which
is attached at its pivotal point to a stud held in the machine frame.
The other end of the transfer slide rocker arm is connected by an adjust-
able operating shaft to the eccentric cam wheel on the left end of the crank-
shaft. The operating shaft is inserted through a large coil spring which is
held in place between the rocker arm and two adjusting nuts on the shaft.
[14]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description
Pawl, Transfer Slide As the transfer slide moves back, the bearing block strikes the end of the
and Locking Finger holding ﬁnger rocker arm, pulling the holding ﬁnger out of a notch in the
(Cont.) indexing dial. At the same time the pawl ﬁnger moves back, carried by the
transfer slide, and sinking into another notch on the dial, engages the dial
for the next stroke of the machine. The dial moves forward until the hold-
ing ﬁnger is released by the bearing block and moves forward to stop the
dial.
I15]
CALIBER .30 V. AND O. PRIMER‘ INSERT PRESS
Machine Description

Index
Operating
Arm

VIEW OF THE ROCKER ARM AND TRANSFER SLIDE
Connecting
Rod
Ram
Feed Tube
Sheﬂac
Container
Case Guide
Ring
Push-in
Finger Shaft
I ' Index Pawl
I Index Dial
. c
' \
1
.¢
5
~
~ ~— or
‘ - A..-1'
VIEW OF THE INDEX DIAL
Holding
Finger
Bearing Block
Holding
Finger
\
Connecting
Rod
Index
Operating
Arm
Primer Dial
Idler Pulley
She"ac
Container
Rocker Arm
Primer
Dial Pulley
VIEW OF THE INDEXING DIAL
MECHANISM
[16]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description


Feed Tube -


Case Feed
_ Arm
Case Feed
Pins
I
SIDE VIEW OF THE FEED UNIT REAR VIEW OF THE FEED UNIT
Feed The feed block is mounted on the front of the machine bed directly in front
Unit of the indexing dial. The case feed tube is connected to the upper left side
of the feed unit. The cases slide from the feed tube under a case lip, where
they are held in a slanting position with the head down. The case is
shoved from the case lip by two push-in pins which enter the feed chute to
push the case further into the feed chute throat. The push-in pins are
held in a horizontal position near the upper end of the push-in pin arm;
the arm is pinned to the top of the case feed block. The arm is held in a
forward position by a coil spring which is attached to the front of the feed
unit. The forked lower end of the push-in pin arm is held against the
push-in block control arm; thus the push-in pin arm derives its action
from riding against the control arm.
A pin extends through the right side of the feed chute throat; as the case
drops through the feed chute throat, it drops against the pin and is held
there momentarily. This delaying action against the head of the case
causes the case to turn mouth down as it drops from the feed throat into
the rear of the feed block. The case is held in a vertical position in the feed
block and is pushed forward through the feed block to the case holding
ﬁnger.
I17]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description
_—_—_—__$_—_—§_—-————————-—-—
Feed Unii The control arm is attached to a horizontal shaft which actuates the arm
(Cont.) from power supplied through linkage from the ram. The lower end of the
control arm is connected to the push-in block by being ﬁtted over two
projections, one at each side of the block. The feed block travels back
and forth in a machined track in the base of the feed unit. The horizontal
shaft extends out to the left of the machine and has a metal driving arm
attached at right angles to the shaft. The driving arm slides back and
forth in a bronze block attached to the operating bracket of the ram. The
operating bracket consists of two arms, the second of which actuates the
varnishing tool and the conveyor ﬁnger.
Feed Tube Case Guide Ring PusIr~in Finger Shaft Dial Friction Brake Case Supporting Stems

Index Pawl Index Dial Holding Finger Case Guide Ring Case Holding Jaws
VIEW OF THE INDEX DIAL TOP VIEW OF THE CASE GUIDE RING
I18]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description

Push-in Turnover Turnover Finger Push-in Primer
Finger Arm Finger Shaft Finger Arm Hopper

Primer Hopper Turnover Finger Shaft Turnover Finger
REAR VIEW OF THE PRIMER ASSEMBLY FRONT VIEW OF THE PRIMER HOPPER
Primer Hopper The primer hopper is attached to the machine bed at a slight angle which
and Dial allows the primers to slide down to the hopper mouth. The primer feed
dial is mounted on the machine bed directly in front of the primer hopper.
The primer dial is belt driven from the pulley on the left end of the crank-
shaft. The primer dial pulley is mounted on the outer end of a horizontal
cross-shaft which extends through the machine frame to a position be-
neath the primer dial. A bevel gear is attached to the inner end of the
cross-shaft and meshes with a bevel gear attached to the lower end of the
primer dial shaft. The belt runs from the crankshaft pulley to a two-step
pulley which is mounted to a stub shaft on the left side of the machine
frame. A second belt runs from the second step of the pulley to the pulley
on the primer feed dial shaft. This arrangement steps down the crankshaft
speed to the correct speed for the primer dial.
The primers are carried around the dial through a narrow track formed
by a steel plate mounted above the dial. The agitator, which is located
across the front of the primer hopper mouth, agitates the primers into
a single ﬁle as they ﬂow toward the push-in ﬁnger. The push-in ﬁnger
travels back and forth in a gib track located along the edge of the primer
dial. By means of a metal shaft and an arm, the push-in ﬁnger is connected
to, and actuated by, a cross-shaft which extends through the machine
frame above the primer hopper. The cross-shaft is actuated from the
crankshaft through the same rocker arm which actuates the index dial.
The arm which actuates the push-in ﬁnger, also actuates the primer agi-
tator on its backward stroke. The pressure against the push-in ﬁnger is
controlled by a coil spring; if a jam occurs, the coil spring stops the action
of the push-in ﬁnger and absorbs the resultant shock.
[19]
CALIBER .30 V. AND O.
PRIMER INSERT PRESS Machine Description
Primer
Turnover
Fingers
Turnover
Fingers
Sheﬂac
Mechanism
.’

The turnover ﬁngers are attached to a cross-shaft held in place between
two brackets bolted to the machine frame. The cross-shaft has a spur
gear attached near its left end which meshes with a gear rack attached to
the left side of the ram. As the ram moves up and down, the spur gear
rotates the shaft which in turn moves the ﬁngers in a half circular path
from the primer dial to the insert station. The shaft is held in place in the
brackets by male and female cone bearings which allow it to rotate. The
shaft action is controlled by a friction clutch‘ which is located at the left
side of the spur gear. The tension against the clutch is controlled by a
coil tension spring which is adjustable to allow proper tension on the clutch.
The cone bearings are threaded in the brackets. By adjusting the bear-
ings, the ﬁngers may be correctly centered over the case.
\>


-.. Turnover Finger
Shaft
-— Push-in Finger Arm
REAR VIEW OF THE PRIMER ASSEMBLY
The shellac mechanism consists of a spur gear held in place on a shaft
which is supported by a bracket bolted to the machine frame. The shellac
arm is attached to the outer face of the spur gear and is adjustable for the
correct stroke of the shellac tool. The spur gear is actuated by a gear rack
which is attached to the ram. As the ram moves up and down, the spur
gear actuates the shellac tool in a dipping motion between the shellac reser-
voir and the case head. The shellac reservoir is supported by the spur
gear bracket and is ﬁlled from a glass shellac container attached to the for-
ward side of the reservoir.
[20]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Description


Turnover ,. I ‘ . _ Turnover
Finger _ ' ' Finger
Shaft
Stripper -f
Case
" Supporting
Stems
Case /
Guide '
Ring
Sheﬂac
Container
Shellac
Sheﬂac
Tool
Shaft
Index
Dial
I-
VIEW OF THE SHELLAC MECHANISM
[21]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Tool Holder Description

TOOL HOLDER DESCRIPTION

Station 2, Adjusting Stud: The adjusting stud is externally threaded
Flash Hole Punch its entire length for application to the upper end of the tool
' Tool Holder holder shaft. The stud has a counter sunk Allen head for the
use of an Allen wrench in adjusting.
Space Rod: The cylindrical space rod is machined to a smooth
surface, small enough in diameter to ﬁt inside the tool holder.
It is used as a space rod between the adjusting stud and the
ﬂash hole punch.


Flash Hole Punch: The ﬂash hole punch is cylindrical in
shape and has a circular ﬂat head machined at its upper end.
The underneath side of the head is tapered from the head cir-
cumference to the punch shaft. The ﬂash hole punch is in-
serted in the lower end of the tool holder. As the ram descends,
the punch forces its way through the web thickness of the
primer pocket thus forming the ﬂash hole.
Tool Holder Shaft: The cylindrical tool holder shaft is ex-
ternally threaded from the mid-section within an inch of its
lower end for application of two spanner nuts. The lower end
of the tool holder is machined to a smooth surface and shoul-
dered to a small diameter which conforms to the primer pocket
of the case. The tool holder is hollow for the insertion of the
space rod, adjusting stud and the ﬂash hole punch.
Spanner Nuts: The two circular spanner nuts are internally
threaded for application to the tool holder shaft and have six
evenly spaced holes drilled around the outer circumference for
the use of a spanner wrench.
I221
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Tool Holder Description


Smﬁon 3, Lock Nut: The hexagonal lock nut is internally threaded for
Detedor Punch application to the threaded portion of the tool holder shaft.
Tool Holder The lock nut contains a domed-shaped ridge around its upper
surface which is lined around its inside circumference by a rub-
berized composition which prohibits its working loose on the
tool holder shaft.
Coil Spring: The coil spring is large enough in diameter to
ﬁt over the upper end of the tool holder shaft and is used to
hold the tool holder shaft at its bottom position.
Tool Holder Shaft: The cylindrical tool holder shaft is
machined to a smooth surface at its upper end over which the
coil spring ﬁts. Slightly below the upper end, the shaft is
externally threaded for the application of the lock nut. The
shaft from the end of the threads to the lower end of the shaft is
machined to a smooth surface and polished to allow it to slide
freely in the ram. A hexagonal headed nut is machined to the
lower end of the shaft and has a small set screw threaded hori-
zontally through one face of the nut which contacts the detec-
tor punch, holding it securely in place. The lower end of the
tool holder shaft is hollowed for the insertion of the detector
punch.
Detector Punch Holder: The detector punch holder is
cylindrical in shape and highly polished. It is machined to a
diameter small enough to be inserted into the punch holder
shaft. A small hole is drilled in the lower end of the punch
holder for the insertion of the detector pin.
The detector pin is machined to a diameter small enough to
enter through the ﬂash hole. The detector pin is pressed into the
hole in the punch holder and may be removed when it becomes
worn out or broken.

[23]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Tool Holder Description

Station 4,
Burring Punch
Tool Holder
/
Burring Punch Tool Holder Shaft: The cylindrical punch
holder shaft is externally threaded near its center portion for
the application of two spanner adjusting nuts. A ﬂat is ma-
chined near the upper end of the tool holder shaft which is con-
tacted by the set screw to hold the shaft securely in the ram.
The lower end of the tool holder shaft is hollowed for the inser-
tion of the burring punch. A small set screw is threaded hori-
zontally through the side of the shaft to contact the burring
punch, locking it securely in the shaft.
Spanner Nuts: The two circular spanner nuts are internally
threaded for application to the tool holder. Six evenly spaced
holes are drilled in the outer circumference of each spanner
nut for the use of a spanner wrench.
Burring Punch: The upper end of the burring punch is
cylindrical in shape and has a ﬂat machined on its outer surface
which is contacted by the set screw of the tool holder to lock
the punch securely in place. The lower end of the punch has a
large circular shoulder, one side of which is ﬁled away leaving a
ﬂat surface which faces the front of the machine when the tool
is directly inserted,in the tool holder. The ﬂat is necessary to
clean the stripper at this station. The lower surface of the
collar has a circular extension which conforms to the diameter
of the case pocket and which is slightly rounded at the point
of intersection with the collar. As the projection enters the
pocket of the case, the rounded surface produces a slight
chamfer around the edge of the primer pocket.
[24]
CALIBER .30 V. AND 0. PRIMER INSERT PRESS Tool Holder Description
Station 5,
Primer Insert Punch
Tool Holder
Inserting Punch Holder: The cylindrical inserting punch
holder has a ﬂat machined on its outer surface near the upper
end of the holder which is contacted by a set screw to lock it
securely-in the ram. The punch holder is externally threaded
near its lower end for the application of two spanner lock nuts.
The lower end of the punch holder is hollowed for the insertion
of the inserting punch and has a small set screw threaded hori-
zontally through the lower end which contacts the punch
locking it securely in place.


Spanner Nuts: The two circular spanner nuts are internally
threaded for application to the tool holder shaft. Six evenly
spaced holes are drilled around the outer circumference of
each nut for the use of a spanner wrench.


Inserting Punch: The cylindrical inserting punch is ma-
chined to a smooth surface and polished, and its lower end is
slightly concave to conform to the primer head. A ﬂat is
machined to the surface at the upper end of the punch which is
contacted by the set screw in the tool holder to lock the punch
securely in place.
[25]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Tool Holder Description


Station 7, Lock Nut: The hexagon headed lock nut is internally threaded
Crimping Punch for application to the adjusting stud.
Tool Holder
Spanner Nut: The circular spanner nut is internally threaded
for application to the tool holder shaft and has four evenly
spaced holes drilled around its outer circumference for the use
of a spanner wrench. This nut adjusts the spring tension and is
locked by an Allen set screw.
Secondary Holder: The secondary holder is cylindrical in
shape and has a machined ﬂange around its circumference at
approximately the center of the holder; The holder is hollow
for the insertion of the primary holder shaft. A small Allen
set screw is threaded through the side of the holder just above
the ﬂange and is used to prevent the secondary holder from
turning on the primary holder shaft.
Cushion Spring Rings: The spring consists of ﬁve rings
whose edges are tapered to allow the rings to ﬁt together.
The spring when properly assembled, provides the cushion
I | action which absorbs the shock of the punch contacting the
\ case head.
Spring Housing: The cylindrical spring housing is cup-
shaped and has a hole drilled through the center of the enclosed
end through which the punch holder shaft is inserted. The
spring unit is placed on the end of the secondary holder and
covered by the spring housing.
Adjusting Stud: The adjusting stud is externally threaded
its entire length and contains a countersunk Allen head. The
adjusting stud is threaded into the upper end of the tool holder
shaft and acts as back stop for the tool.
Space Rod: The cylindrical space rod is made of tool_steel
ground and high polished. The rod is used as a spacer between
the crimping tool and the adjusting stud.
Primary Tool Holder Shaft: The upper end of the tool
holder shaft is externally threaded for the application of the
II spanner nut. The center portion of the shaft is machined to a
smooth surface and has a recessed slot machined in the center
of the shaft. The Allen set screw in the side of the secondary
tool holder rides in this recessed slot. The lower end of the
tool holder shaft contains a hexagon shaped housing into which
the head of the case enters as the crimping operation is per-
formed. One side of the housing is cut away to allow the
housing to pass by the stripper ﬁnger. An Allen set screw is
threaded through the upper end of the housing to contact and
lock the punch in place.
Crimping Punch: The cylindrical crimping punch is made
of tool steel, ground and highly polished. The lower end of the
punch is slightly concave to conform to the head of the primer
cup. The punch has a ﬂat machine along one side which the
Allen set screw contacts to lock the punch in place.
[26]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Tool Holder Description

Station 8,
Shellac Punch and
I
Tool Holder

Shellacing Tool Holder: The shellacing tool holder
consists of a round metal shaft held in place in the
operating mechanism. The forward end of the shaft is
slotted for attachment to the tool holder head. The tool
holder head consists of a rectangular head which has two
holes drilled longitudinally through its center for the
insertion of the shellacing pins. A rectangular metal
arm is attached to one face of the shellacing pin holder
for connection to the tool holder shaft. The shellacing
pins are allowed to ﬂoat freely in the tool holder head
and are held in place by two coil springs which in turn
butt against a metal shield attached to the upper sur-
face of the tool holder head. The tool holder head and
the metal shaft are held together by a strip of ﬂat spring
steel which is riveted in place in the slotted sections of
the tool holder head and shaft. The shellacing pins are
cylindrical in shape and have small slots in their lower
end which retain the necessary amount of shellac to
properly waterproof the primer cup.
[27]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Tool Holder Description

Station 9, Varnish Too] Holder: The varnish tool holder is a
Vamish Punch metal bar bent at a right angle. There is a hole drilled
Tool Holder through the horizontal arm which is attached to the
operating shaft. A small lip is formed by the lower end
of the varnish arm which is bent outward to a hori-
zontal position. There is a hole drilled through the end
of the lip for the insertion of the varnishing tool.
Varnishing Tool: The varnishing tool is cylindrical in
shape and its lower end is threaded for attachment to
the tool holder. The upper end of the tool has a
machined head which enters the mouth of the case,
varnishing the interior of the mouth. .

[28]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Tool Description
TOOL DESCRIPTION

M M’
FLASH HOLE PUNCH
FLASH HOLE DETECTOR PIN
<11 ~‘f.~1
BURRING PUNCH
INSERTING PUNCH
a.;“""5-""“‘_-f$=
INVERTED PRIMER DETECTOR PUNCH
CRIMPING PUNCH
Flash Hole Punch: The flash hole punch is cylindrical
in shape and has a circular ﬂat head machined at its
upper end. The flash hole punch is held in the tool
holder in the ram.
Flash Hole Detector Pin: The detector pin is ma-
chined to a diameter small enough to enter through the
flash hole. The detector pin is pressed into the hole in
the punch holder and may be removed when it becomes
worn out or broken.

Burring Punch: The upper end of the burring punch
is cylindrical in shape with a machined ﬂat along one
edge by which the punch is locked securely in the tool
holder. The lower end of the punch contains a circular
shoulder which is machined to a flat surface along one
side. A projection extends from the bottom face of the
shoulder and is machined to a diameter to enter into the
case pocket to produce a slight chamfer around the poc-
ket edge which facilitates the entrance of the primer.
The burring punch is held at station 3 of the ram.


Inserting Punch: The cylindrical inserting punch has
a machined ﬂat near its upper end by which it is locked
securely in the tool holder. The working end of the
punch is machined to a concave surface which conforms
with the head of the primer. The inserting punch is
held at station 4 of the ram.

Inverted Primer Detector Punch: The cylindrical
inverted primer detector punch has a flat machined in
the upper end by which it is held securely in the ram.
The lower end is tapered to a smaller diameter which in
turn is machined to a sharp point at the lower end. The
punch is inserted at station 5 of the ram.

Crimping Punch: The cylindrical crimping punch is
highly polished and has a machined flat in its upper end
by which it is held into the crimping punch holder. The
lower end of the punch is machined to a concave surface
which conforms to the head of the primer. 'l‘he crimp-
ing punch is held at station 6 of the ram.
[291
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Tool Description

SHELLAC TOOL


VARNISH TOOL
Shellac Tool: The shellacing tools are cylindrical in
shape and have elongated slots machined in their lower
ends. These slots pick up and hold the required amount
of shellac to waterproof the edges of the primer pocket
properly. The two tools are held in the tool holder so
that one tool contacts each side of the primer pockets.
Varnish Tool: The cylindrical varnish tool has a
crowned head machined at its upper end. The lower end
of the tool is externally threaded for the application of a
hexagonal nut by which it is locked into the tool holder.
[30]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Process Sequence

Purpose of
V. and O.
Primer Insert
Machine
Case
Overhead
Hopper
Paddle Wheel
Hopper
Feed Tube and
Feed Check
Feed Finger
and Feed Jaw
No Case
Detector Station
Piercing Station
PROCESS SEQUENCE
The purpose of the V. and O. primer insert machine is to pierce a ﬂash
hole in the web of the case at the center of the primer pocket. The machine
then removes the burr on the inside shoulder of the primer pocket and
forms a radius on the bottom edge of the pocket; after which it inserts and
seats the primer in the pocket and crimps the edge of the pocket around
the primer. Shellac is placed around the primer, and the inside of the
mouth of the case is varnished to seal the ﬁnished cartridge against mois-
ture.
The cases are gravity fed from a truck or conveyor into the overhead
hopper and drop through a feed pipe, which has a control gate, into the
Liberty Paddle Wheel hopper.
The cases are picked up by the paddles on the rotating paddle wheel and
dropped onto a conveyor belt. The conveyor belt carries the cases to the
feed throat. Because of the construction of the feed throat, and because
the head of the case has more weight than the mouth, the cases drop
mouth-up through the feed throat. The cases are assisted in their travel
through the feed throat by a leather disc mounted on the inside face of the
conveyor belt pulley.
After the cases pass through the feed throat, they fall by gravity down
through a slotted brass feed tube to a feed check at the lower end of the
tube. The feed check pushes the cases, one at a time, into a turnover
mechanism. At the turnover mechanism the cases are turned mouth-
down.
They fall from the turnover mechanism by gravity into the back portion
of the feed jaw. A feed ﬁnger pushes the cases to the front part of the jaw.
The mouth of the case is now in line with the stem die on the indexing dial.
The case is forced down through the feed jaw onto the stem by a no case
detector punch. If there is not a case in the feed jaw, the no case detector
punch is forced against one of the prongs of the jaw. This action raises the
stem which controls an electric switch. The electric circuit is broken and
the clutch is automatically disengaged.
There are sixteen stem dies on the indexing dial and each stem accommo-
dates one case in a mouth-down position.
As the cases are carried by the indexing dial, they arrive, one at a time,
at the piercing station. The piercing punch descends into the primer
pocket, and pierces the web. The hole produced at this point is known as
the ﬂash hole. The ﬁrst prong of a three-pronged stripper mounted at this
point holds the case down onto the stem so that it will not be carried up by
the ﬂash hole punch as the punch ascends.
I31]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Process Sequence
Flash Hole
Detector Station
Burring Station
Primer Hopper
Push-in Finger
and Turnover Finger
Primer Insert
Station
Inverted Primer
Detector Station
Crimping Station
Shellac Station
Transfer Station
Drying Track and
Varnish Station
The case is carried beneath the second prong of the stripper to the ﬂash
hole detector station. The detector punch descends into the ﬂash hole.
If there has not been a hole punched in the case at the piercing station,
the punch disengages the clutch automatically in the same manner as the
no case detector punch.
At the next station beneath the third prong on the stripper, the burring
tool descends into the primer pocket and removes the burr on the top in-
side edge of the primer pocket preparatory to the insertion of the primer.
As the burring tool ascends, the case is moved to the next station for the
insertion of a primer.
The primers are loaded into the primer hopper manually. They are placed
in the hopper, with the open end up, and ﬂow down, by gravity, to a feed
disc. The primers, still mouth-up are fed by a feed disc, single ﬁle, along
the feed track. To aid them in entering the track single ﬁle and to prevent
jams as they enter the track, they are agitated.
A push-in ﬁnger receives the primer from the feed track and inserts it into
a turnover ﬁnger. The turnover ﬁnger inverts the primer and places it in
line with the primer pocket of the case.
At the primer insert station a punch descends to force the primer part
way into the primer pocket. After the insertion has been made, the punch
ascends and the dial conveys the case to an inverted primer detector
station.
The inverted primer detector punch descends to the top of the primer. If
the primer is inverted, or if there is no primer in the primer pocket, the
punch actuates a stem which automatically disengages the clutch in the
same manner as the no case detector and the ﬂash hole detector.
As the inverted primer detector punch ascends, the case is conveyed to the
crimping station. At this station the primer is inserted all the way into
the primer pocket, and the edge of the primer pocket is crimped around
the primer.
After the crimping operation at the next station, shellac is deposited on
the case head around the primer. The shellacing tool, after it has been
inserted into a container of shellac, is carried to the head of the case and
deposits the shellac. As the shellacing tool recedes, the dial conveys the
case to the next station. -
At the last station of the indexing dial a collet descends around the case.
As the collet ascends, it raises the case from the stem die on the indexing dial.
As the collet descends onto the succeeding cases arriving at this station,
the preceding cases are forced up through the collet tube.
As the case reaches the top of the collet tube, the extractor groove is forced
into a drying track. The cases are pushed along the track by a conveyor
ﬁnger.
At a point about three-fourths of the way along the track the varnish tool
ascends into the mouth of the case and deposits varnish around the inside
surface of the mouth. The cases are pushed off of the track and drop into
a container.
I32]
oouenbeg SS9DO.|d SSEItId RIHSNI HI-IWI2Id 'O CINV 'A 08' HI-IEII-IV)
Overhead
Hopper
Hopper
Box
Paddle
Wheel
I
Cogéiegror Manual
I Feed
Feed Feed Slide
Throat
I
gezd Feed
u e Track
I r
Feed Turnover
Check Fingers
No Case Piercing Flash Hole Burring P“ Primer P‘ Inverted “ Crimping Shellac Case t-— Varnish
Detector Mechanism Station Detector Station Insert Primer Station L1ft Station
Station Station Station Detector Station
Station


FLOW CHART


I Container l

I88]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Product Description

PRODUCT DESCRIPTION
The case, when received by the primer insert machine, is semi-ﬁnished; it
contains the extractor groove and the primer pocket as shown in Fig. 1.
The case pocket dimensions should be as follows:
Pocket depth .125—.129
Pocket diameter .2093—.2098
The primer is a completely assembled unit, consisting of a brass cup which
contains the priming mixture, the foil and the anvil, when it is received by
the Primer Insert Department. See Fig. 2. The primer dimensions should
be as follows:
Over-all height .121—.126
Primer diameter .210—.2105
After the primer inserting operation the product is a ﬁnished case. A
ﬂash hole has been pierced through the bottom of the primer pocket, that
is, through the web thickness of the case. The primer has been inserted
and crimped into the primer pocket. The primer is seated from .001 to .007
below the head of the case. See Fig. 3. The primer has been shellaced
around the edge to make it moisture proof and the mouth of the case has
been varnished.


Primer
Primer Pocket ’|\/Head HQMIQF Primer CUP
Web Thickness é-,E_E'xt'°ct°' Gmove Extractor Gr°°ve_¥ Primer Mixture
-j\ Web Thickness —-l Foil
Q Q Flash Hole /5 Q A,,,,,|
Bedy_5 Q Q Q
s > S S
\
S \ B d Q S
\ Q ° Y-’\ \
\ Q Q \
Q \ \ R
\ \ \
Chamber > E \ Q
I \ Q E
\ \ Q \
\ \ Q \
\ \ Q \
\ \ \ \
Q \ \ \
Q \ \
2 : t *
Q : Shellac 3 I S
Shoulder— Primer Cup ' Shoulder - \
~ Primer Mixture
ec l Anvil Neck
Mouth Ct Flash Hole 2 Varnished Mouth,
FIG. 1 FIG. 2 FIG. 3
UNFINISHED CASE PRIMER FINISHED CASE
I34]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Inspection

Visual
Gage Care
Gages
INSPECTION
The cases are received at the primer insert machine from the Inspection
Department and are placed in a paddle wheel hopper which automatically
feeds them to the machine. The cases pass through the hopper feed tube
and drop singly into the transfer bar.
The primer insert machine passes the cases through a series of ten opera-
tions in which the primer pocket radius is checked, the ﬂash is pierced, the
ﬂash hole is checked at two detector stations, the primer is inserted, the
primer is seated and crimped, the primer is shellacked and the mouth and
neck of the case are varnished to waterproof the component. After the
cases have passed through the ten stations, they are inspected for primer
seating depth with a dial indicator gage. They are also visually inspected
to make sure that every case has a ﬂash hole, shellac around the primer and
varnish in the mouth and neck. If any of these are lacking, there must be
an immediate adjustment of the machine to correct the fault. Whenever
defective cases are found, the lot from which they come must be removed
and properly identiﬁed so that the bad lot will not be mixed with good
cases.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a case to a gage. A protected location should be used for storage
of gages to prevent their being damaged when not in use. The most accu-
rate checks are made when the cases are cool, since heat causes expansion
of the metal and results in a temporary variation in the case size.
DIAL INDICATOR GAGE
The primer seating depth is gaged at fre-
quent intervals with a dial indicator gage.
This manual gaging provides a check on


Q the accuracy of the machine. The primer
'1 p X is seated in the case pocket from .001 to
' + .007 below the case head.
i
The foregoing inspection methods are those most commonly employed in
the manufacture of Caliber .30 cases. Other methods may be developed,
however, to maintain the manufacturing standards.
[35]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments
Objective
Cautions
‘ ADJUSTMENTS
/
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect
the machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles which will be en-
countered; therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be clean and free from all
foreign objects at all times.
Keep all primer cups in their proper place.
No adjustments are to be made on this machine while it is in motion.
In order to insure proper adjustment of the machine and alignment of its
tools, always turn the machine over by hand before engaging the clutch.
Safety guards must be in their proper places on the machine except when
repairs or inspections are being made.
In making an adjustment, remove only those guards necessary to make the
adjustment.
Inspect the machine periodically during the day’s run to determine whether
or not all connections and adjustments are secure.
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Adjustments
Index Dial The index dial located on the machine bed carries the case supporting dies.
Its purpose is to convey the cases through the successive operations of the
machine. The dial must stop directly on the station or the cases in the dial
\ will not be directly under the respective punches. To insure the dial’s
stopping on the station, the operating arm of the pawl can be shortened or
lengthened in its stroke and the eccentric connection can be adjusted to
give the proper amount of movement to the index dial so that it will
assume sixteen positions.


6
— Crankshaft
I
Q
t-
T R
V
- -4,
can I
1/alt Nut ‘
_ - /~ goanecting
. W " ' ’ ' 0
Index
Operating _ j , - ,. . - ' .
Arm > ‘ - g ' W _., fl " -r ' -j 7 / Ram
VIEW SHOWING THE INDEX DIAL ADJUSTMENT
MANUAI. REVlSlON—CAI.lBER .30 V. AND O. PRIMER INSERT PRESS
The following adjustment procedure supersedes that previously shown on pages 37 and 38.
Tools: 11/i6” wrench, 1%” wrench, 7/8” wrench.
Procedure: Note: Remove primer push-in operating arm from clevis.
1. Engage the clutch and turn the ﬂywheel until the clutch disengages and the
crank is at top dead center.
2. Set the dial so that the left side of the holding ﬁnger is even with the right side
of the recess in the dial. '
3. Use a M,” wrench to set the eccentric so that the spacer washer is 9/1}," from the
outer circumference of the crankshaft pulley.
4. Use a 1%" wrench to run the connecting rod lock nut to the outer end of the
connecting rod and lock with the inner nut.
5. Use a 1%" wrench to turn the operating arm adjusting nut until the index
pawl falls in the 3rd recess from the holding ﬁnger and locks the operating arm
lock nut.
6. Turn the ﬂywheel manually, through one complete revolution to check the
adjustment. This should bring the index dial back to the same position as in
step N o. 2.
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments

Procedure:
(Cont.)
8.
9.
10.
11.
12.
13.
14.
15.
Turn the adjusting nut until it is contacting the rocker arm connection.
Use a 7/8" wrench to loosen the eccentric connection and slide it from
the center of the track to the extreme position nearest the outside
circumference; then tighten the connection just enough to hold it
temporarily.
Use a V8” wrench to loosen the eccentric connection and move the
eccentric rod until the space between the eccentric rod adjusting nut
and rocker arm sleeve connection is lessened by %. Then use a 7/8"
wrench to tighten the eccentric connection.
Turn the 11/4 " adjusting nut on the eccentric rod until it contacts the
rocker arm sleeve bearing connection ﬁrmly enough to eliminate any
play in the rocker arm.
Use a 1%” wrench to tighten the lock nut against the adjusting nut
on the eccentric rod.
Use a 11/4" wrench to tighten the spring tension adjusting nut until
the tension on the spring is suﬂicient to actuate the rocker arm.
Tighten the spring tension lock nut. r
Operate the machine by hand to check the accuracy of the adjust-
ments.
Note: The index dial should be far enough away from the stations
when the ram is at top dead center to allow the cases to be removed
manually from the case supporting dies.
Close the ﬂywheel guard door.

VIEW SHOWING TI-IE PAWI. ADJUSTMENT
I 38 I
MANUAL REVlSlON—CALIBER .30 V. AND O. PRIMER INSERT PRESS
Station
Alignment
Detector
TOOIS:
Procedure:
This revision supersedes Page 39.
The purpose of the station alignment detector is to disengage the clutch when the
index dial fails to stop on station. If the detector does not disengage the clutch
when the dial stops off station, or the machine shuts off due to misalignment of
the detector punch, the detector assembly should be adjusted.
%" Allen wrench, 11/16" wrench, pliers.
1.
2.
99‘?
Use a V32” Allen wrench to loosen the spring retaining collar in order to remove
tension from the clutch release shaft.
Use an 11/16” wrench to loosen the adjusting nut on the lower end of the clutch
release shaft.
Use pliers to remove the cotter pin and clevis pin from the top of the shaft,
allowing the assembly to drop down in the dial until the dial alignment punch
touches the bed of the machine.
Tighten the adjusting nut.
Raise the assembly and replace the clevis pin and the cotter pin.
Use a 5/2” Allen wrench to raise and lock the spring retaining collar to restore
tension to the clutch release shaft.
CALIBER .30 v. AND O. PRIMER INSERT PRESS Adjustments
Station The purpose of the station alignment detector is to disengage the clutch if
Alignment the index dial does not stop on station. If the detector does not disengage
Detector the clutch when the dial stops off station, the detector should be lowered
by turning it clockwise so that the clutch operating arm will be raised to
contact the notch on the clutch disengaging collar.


Turnover Alignment
Finger / Detector
I, Stripper
Stripper -'
Case Case
Guide / Supporting
Ring Stems
VIEW SHOWING THE STATION ALIGNMENT DETECTOR
Tool: 7/8" wrench.
Procedure: 1. Open the ﬂywheel guard and engage the clutch.
2. Turn the ﬂywheel until the dial is moved about halfway between the
stations. Back up the ram enough to pull the pawl away from the
ratchet. Then continue turning the ﬂywheel until the station align-
ment detector has completed its full action.
3. Use a 7/3 ” wrench to turn the detector until it actuates to disengage the
clutch.
4. Turn the ﬂywheel backwards until the pawl slips back into the ratchet.
Then turn the ﬂywheel until the dial is on station.
5. Close the ﬂywheel guard.
I39]
CALIBER .30 V. AND O. PRIMER INSERT PRESS _ Adjustments

Pitman The Pitman is the adjustable connecting rod which connects the ram to
the crankshaft. Its purpose is to regulate the length of the stroke of the
ram. If the ram does not travel low enough on its downward stroke, it
can be lowered by turning the Pitman connection.
Crankshaﬂ


. '— Pitman Connection
t
' l‘ I , ., -
VIEW OF THE CRANKSHAFT
Tools: %" wrench, %” spanner pin.
Procedure: 1. Open the ﬂywheel guard and engage the clutch.
2. Turn the ﬂywheel until the ram is at the bottom of its stroke.
3. Use a 3/5" wrench to loosen the lock bolt on the Pitman connection.
4
Use a %" spanner pin to turn the Pitman connection until the ram is
positioned low enough.
9‘
Use a 7/8” wrench to tighten the lock bolt on the Pitman connection.
6. Close the ﬂywheel guard.'
[40]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS I Adjustments
Idler Pulley The idler pulley is the adjustable belt tension regulator. Its purpose is to
press against the belt ﬁrmly enough to take out any slack in the hopper
conveyor belt. If the hopper conveyor belt is not conveying the cases to
the feed tube throat smoothly, a readjustment of the idler wheel will have
to be made. The idler wheel can be pressed more ﬁrmly against the belt
until it is taut.
Hopper ‘j ,j 1- I , I J“. I , ’_ 1/2” Sttld


Conveyor
"T Belt
Pulley
Feed Tube _
VIEW OF THE PADDLE WHEEL HOPPER
Tool: %" wrench.
Procedure: 1. Use a %” wrench to loosen the idler wheel stud.
2. Push the idler against the belt until it is taut.
Note: If the belt cannot be made taut, it will have to be replaced.
3. Use a 1/3" wrench to tighten the idler wheel stud.
I41]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments
Case Feed
Finger
Operating
Arm
The case feed ﬁnger operating arm is the lever which actuates the feed
ﬁnger. Its purpose is to move the feed ﬁnger in such a manner as to allow
a case to slide out of the feed tube into the feed channel and to push it far
enough in the feed channel to slide into the case holding jaws. Whenever
this action does not take place correctly, an adjustment on the case feed
ﬁnger operating arm is necessary. The operating arm can be placed at any
position on the operating shaft in order to get the proper action of the case
feed ﬁnger.


Shellac
Container
Eccentric
Case Guide
Ring
Tool:
Procedure:
_- Feed Tube
I . . Allen Set Screw
I Feed Finger
' Operating Arm
VIEW OF THE FEED FINGER OPERATING ARM
1/4" Allen wrench.
1.
2.
Open the ﬂywheel guard and engage the clutch.
Turn the ﬂywheel by hand until a case drops down in front of the case
feed ﬁnger. Then continue turning the ﬂywheel until the feed ﬁnger is
at the extreme of its delivery stroke.
Use a 1/4" Allen wrench to loosen the lock bolt on the feed ﬁnger oper-
ating arm.
Move the operating arm until it pushes the case into the case holding
jaws.
Use a 1/4" Allen wrench to tighten the lock bolt on the feed ﬁnger
operating arm.
Close the ﬂywheel guard.
I 42 I
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Adjustments
Piercing The ﬂash hole punch located at the second station punches the ﬂash hole
Punch through the web of the case. When the ram descends, the ﬂash hole punch
pierces a hole through the base of the primer pocket. If the ﬂash hole
punch does not pierce the web thickness, it will have to be lowered. The
punch is held in the upper ram by a holder which can be raised or lowered
by loosening a set screw and adjusting the spanner collar.


- Connecting Rod
‘ , ' Piercing Punch
_ Holder
Case Feed
Finger _'
VIEW SHOWING THE PIERCING PUNCH ADJUSTMENT
Tools: §/1'1-, " Allen wrench, 11/;" spanner wrench.
1. Engage the clutch and open the ﬂywheel guard.
2. Turn the ﬂywheel by hand until the ram is at the bottom of its stroke.
3. Use a 1%" spanner wrench to loosen the spanner lock collar and the
spanner adjusting collar.
Use a 5/16” Allen wrench to loosen the punch holder in the ram.
Lower the punch holder until the piercing punch enters the case sup-
porting die about }3/3".
Use a 5%” Allen wrench to tighten the tool holder set screw.
Use a 1%" spanner wrench to turn the spanner adjusting collar until it
is ﬂush with the ram. Also tighten the spanner lock collar.
Procedurei
9?‘ P‘?
[43]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Adjustments
Flash The ﬂash hole detector punch is located in the upper ram at station 3.
Hole Its purpose is to detect any case which has not had a ﬂash hole pierced
Detector in the primer pocket. If no ﬂash hole has been punched in the case
head, the detector ﬁnger contacts an electric switch which shuts off the
machine.


Flash Hole
Detector Punch
Case Feed __ Finger ‘
VIEW SHOWING THE FLASH HOLE DETECTOR ADJUSTMENT .
Tool: 3/4 ” wrench.
Procedure: 1. Open the ﬂywheel guard and engage the clutch.
2. Lower the ram to the bottom of its stroke by manually turning the
ﬂywheel.
3. Use a 3% " wrench to turn the ﬂash hole detector punch holder counter-
clockwise until the punch enters the case supporting die 1/52”.
4. Close the ﬂywheel guard.
5. Operate the machine and see if the ﬂash hole detector punch will
stop the machine when a case without a ﬂash hole punch is run past
this station.
Note: If it does not, a readjustment will have to be made.
[44]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments
Burring The burring punch is a tool located in the top ram at station 4, which
slightly chamfers the edges of the primer pocket. The burring punch is
held in the upper ram by a holder which can be raised or lowered and
held in any position by a spanner collar adjusting set screw. If the
primers are being inserted sideways or in a tipped position, also ﬂat
primers it is an indication that the primer pockets are not being cham-
fered, and an adjustment on the burring punch holder is necessary.
Punch


Turnover
Finger
TOOIS:
Procedure:
VIEW SHOWING THE BURRING PUNCH TOOL HOLDER
5/16" Allen wrench, 1%” spanner wrench.
1.
2.
Insert a case without a primer under the burring station.
Open the ﬂywheel gate and engage the clutch.
3. Turn the ﬂywheel until the ram is at the bottom of its stroke.
4.
5
6
Use a 1%” spanner wrench to loosen the spanner lock collar.
. Use a §1/6" Allen wrench to loosen the burring punch holder set screw.
. Use a 1%" spanner wrench to turn the adjusting spanner collar until
the burring punch has entered the case far enough to allow a clearance
of 16;" between the head of the case and the shoulder on the burring
punch.
Use a :/16"’ wrench to tighten the burring punch holder set screw.
Use 2 1%” spanner wrenches to tighten the spanner lock collar.
Close the ﬂywheel guard.
l 45 l
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Adjustments
Primer The primer agitator is the mechanism that agitates the primers to prevent
Agitator them from jamming at the mouth of the feed track. If the agitator arm
is not producing the correct action on the primers, it can be adjusted to
work more effectively. The adjustment nut at the back end of the push
in ﬁnger operating lever can be tightened or loosened until the proper
action is developed on the agitator.


_ Primer
Turnover Hopper
Finger \
Turnover
Finger
Shaft "'
k .
Case
Guide " ‘P9
Ring \f ‘ ‘ ‘
VIEW SHOWING PRIMER AGITATOR ADJUSTMENT
Tool: 1%” wrench.
Procedure: 1. Open the ﬂywheel guard and engage the clutch.
2. Turn the ﬂywheel -by hand until the ram is about half way on its
upward stroke.
3. Use an 11/115” wrench to turn the adjustment nut one way or the other
till the agitator moves sufficiently to prevent jamming of the primers
in the feed track.
Note: This is a trial and error adjustment. Proper position cannot be
determined until the machine is operated and the action of the agi-
tator is checked to see if correct action has been developed. Readjust
until the correct action has been obtained.
4. Close the ﬂywheel guard.
[46]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments
Turnover Finger
Assembly
Tools:
Procedure:
The turnover ﬁngers are small metal ﬁngers attached to a small clutch
assembly in front of station 5. The ﬁngers are used to turn the inverted
primers over and convey them to a case under the primer insert punch.
The ﬁngers must hold the primer in proper alignment with the primer
insert punch and the primer pocket in the case. _ If the turnover ﬁngers
do not hold the primer in alignment with the primer insert punch, the
cone bearings of the turnover ﬁnger assembly will have to be readjusted.

-
\
i! I M
-— Primer
Hopper
— Turnover
Finger
VIEW OF THE TURNOVER FINGER ASSEMBLY
1%" wrench, screwdriver.
1.
2.
Open the ﬂywheel guard and engage the clutch.
Turn the ﬂywheel until the turnover ﬁngers are resting over a case
at that station.
Note: Be sure that a primer is being held in the ﬁngers.
Use a 11_/15" wrench to loosen the lock nuts on the male adjustable cone
bearings.
To adjust the ﬁngers so that the primer which they hold is centered
over the pocket of the case, use the screwdriver to turn the male cone
be-arings back and forth.
Use a 1%,” wrench to tighten the lock nuts on the male adjustable
cone bearings.
Note: Be sure that the cone bearings hold the turnover unit securely
and yet allow free movement. '
I47]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments

Primer Insert The primer insert punch inserts the primer into the primer pocket of the
case. It is located at station 5. If the insert punch does not push the
primer into the pocket until the head of the primer is V16” above the case
head, the punch must be lowered. The punch holder is raised or lowered
by loosening a set screw and readjusting the spanner collar.
Punch
TOOIS:
Procedure:
VIEW OF THE PRIMER INSERT PUNCH ADJUSTMENT
5/f6” wrench, 1%" spanner wrench.
1.
2.
3.
Place a case under the inserting punch.
Open the ﬂywheel guard and engage the clutch.
Turn the ﬂywheel guard until the ram has descended to the bottom of
its stroke.
. Use a 11/;” spanner wrench to loosen the spanner lock collar on the
primer insert punch holder.
Use a 5/16" wrench to loosen the primer insert punch holder set screw.
Use a 1%" spanner wrench to turn the spanner adjusting collar until
the primer insert punch holder when pushed up into the ram and
locked will hold the punch 46" above the case head.
Use a 5/16" wrench to tighten the set screw when the tool holder is
pressed ﬁrmly up into the ram.
Use a 11/2” wrench to tighten the spanner lock collar.
. Close the ﬂywheel guard.
I48]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments
No Primer
Detector
The inverted primer detector is located at station 6. Its purpose is to
detect an empty primer pocket or an inverted primer. If the cases reach
this station without the primer or with an inverted primer, the detector
punch allows a rod to contact a shut off switch, thereby stopping the
machine. If the detector fails to do this, the switch contact rod must be
raised or lowered in the detector punch bracket.

Tool:
Procedure:
VIEW SHOWING THE PRIMER DETECTOR ADJUSTMENT
V16" wrench.
1. Place a case with a primer under the no primer detector station.
2. Open the ﬂywheel guard and engage the clutch.
3. Turn the ﬂywheel by hand until the ram is at the bottom of the
stroke.
4. Use a %" wrench to loosen the lock nut on the switch contact rod.
5. Turn the switch contact rod until the lower end of it touches the
switch.
6. Use a §/11;” wrench to tighten the lock nut.
7. Close the ﬂywheel guard.
8. To check the adjustment, operate the machine and run a case through
with an inverted primer to see whether the no primer detector will
stop it.
Note: If the detector fails to stop the machine, make a readjustment.
I 49 I
CALIBER .30 v. AND O. PRIMER INSERT PRESS . Adjustments

Seating The crimping punch located at station 7, seats the primer in the primer
and pocket of the case and crimps it. The crimping punch must seat the
Crimping primer between .001 and .007 below the head of the case. If the primers
Punch are not being seated below the head of the case, the crimping punch must
be lowered. To do this, loosen the lock screw in the primary tool holder
and turn the set screw until the crimping punch can be held in the proper
position. '
Ram
Turnover
VIEW SHOWING THE SEATING AND CRIMPING PUNCH ADJUSTMENT
Tools: %;" Allen wrench, 3/:5” Allen wrench, 1%” wrench.
Procedure: 1. Place a case with a primer to be seated and crimped under the crimp-
ing punch.
2. Open the ﬂywheel guard and engage the clutch.
3. Turn the ﬂywheel until the ram is at the bottom of its stroke.
4. Use a %” Allen wrench to loosen the crimping punch set screw.
5. Use an 1%" wrench to loosen the lock nut on the punch adjusting
screw.
6. Use a %6’’ Allen wrench to turn the adjusting screw until the crimping
punch is lowered enough to seat and crimp the primer between .003 and
.005 below the surface of the case head.
7. Tighten the lock nut and Allen set screw.
8. Close the ﬂywheel guard.
Lock Nut Adjusting Screw Space Rod Spanner Nut Tool Holder Shaft Crimping Tool
It-I
Q
VIEW SHOWING THE SEATING AND CRIMPING PUNCH REMOVED FROM THE MACHINE
ri


l 50 l
CALIBER .30 V. AND O. PRIMER INSERT PRESS Adjustments
Shellac The shellac tool is the instrument which places the shellac on the primer
Tool of each case. Its purpose is to place the shellac sealer around the primer
so that it will not deteriorate from moisture. The shellac tool should be
placed in proper alignment with the primers of the cases on the indexing
dial at this station. This can be done by loosening an Allen set screw and
shifting the shellac tool holder shaft into the proper position on the eccen-
tric which actuates it. The pressure with which the shellac tool contacts
the primers of the cases can be regulated by adjusting a concentric stop
screw. The distance the tool will dip into the shellac can also be regulated
by adjusting another concentric stop screw.


' "‘--I Shellac
E;Mi‘ Container
.-—
Shah __
Set ' I I I I I, V , ' _ Ring
Screw ' . . - 5 ~ '
VIEW SHOWING THE SHELLAC STATION
Tools: %" wrench, %” Allen wrench.
Procedure: 1 Engage the clutch and open the ﬂywheel guard.
2. Place a case in the case supporting die on the index dial at the shellac
station.
3. Turn the ﬂywheel until the shellac tool is directly over a case on the
index dial at the shellac station.
4. Use a 14;" Allen wrench to loosen the shellac tool holder shaft set screw.
5. Slide the shaft back and forth in its slide holder until the shellac tool
is in alignment with the primer of the case.
6. Use a %” Allen wrench to tighten the shellac tool holder shaft set screw.
Shaft Shellac Tool
l I


VIEW SHOWING THE SHELLAC
TOOL HOLDER REMOVED FROM THE MACHINE
I51]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments

Pressure
Adjustment


. Turn the ﬂywheel until the eccentric contacts the stop screw at the ex-
treme of its delivery stroke. ,
. Use a % ” wrench to loosen the stop screw lock nut.
. Turn the stop screw until the shellac tool contacts the primer in the
case ﬁrmly enough to compress the spring on top of tool to half its size.
. Use a %" wrench to tighten the stop screw lock nut.
Shellac Delivery
Container Position
’ Stop
Screw
Eccentric
Receiving
Position LocI<
Stop ' Nut
Screw
Lock Nut '
Dipping
Stroke


Case
'“ Guide
Ring
VIEW SHOWING THE SHELLAC STATION
. Turn the ﬂywheel until the eccentric on the shellac tool has brought
the tool to the extreme of its receiving position and contacts the stop
screw for that position.
. Use a 3/8” wrench to loosen the stop screw lock nut.
. Turn the stop screw until the eccentric cam lowers the shellac tool into
the shellac container to a depth ‘at which the tool is loaded with shellac
each time it dips.
Use a 1%," wrench to tighten the lock nut.
. Close all guards.
I52]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Adjustments
Case Transfer Lift
TOOI:
Procedure:
The case transfer lift is located at station 9. It is a pipe with an automatic
collet on the bottom end and is attached to the ram. Its purpose is to
transfer the cases from the index dial to the conveyor track above it. If
the top of the case transfer lift is contacting the conveyor track above, it
should be lowered so that it will function properly.
Allen Screws
Collet


Shellac __
Container
I .
I \’
IL»--s-=1-, K97
U"-"‘
VIEW OF THE CASE TRANSFER LIFT ASSEMBLY
% " Allen wrench.
1.
2.
Open the ﬂywheel guard and engage the clutch.
Turn the ﬂywheel guard until the case transfer lift is ﬁlled with cases
and has one extending out from the top ready to be stripped off by the
conveyor track. Continue turning the ram until it is at the bottom of
its stroke.
Use a §/Ii," Allen wrench to loosen the set screws in the case transfer lift
holding bracket.
Lower the case transfer lift until it is 1/4" from the case guide ring of
the index dial.
Use a §/11;" Allen wrench to tighten the set screws in the case transfer
holding bracket.
Close the ﬂywheel guard.
I 53 l
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Adjustments
Conveyor The conveyor ﬁnger is the lever which pushes the cases along the drying
Finger track to the varnish station. Its purpose is to push the cases along the
track far enough so that each succeeding case is aligned with the varnish
punch. If the cases are not aligned properly with the varnish tool, the
conveyor ﬁnger can be moved backward or forward by loosening the lock
nut and readjusting the adjusting nut until the proper position is reached.
Note: The conveyor ﬁnger must be held in a horizontal position when
tightening the lock nut.


"._
.. I N.
_ . Q N
' J“
U
‘sf
C.
. ‘Q "
/ Conveyor Finger
7/8" Nut
.~_ I _. -~ .I‘‘
''‘1'-‘. .=‘--I -
it - .
_ ' \ ‘I ,
- ‘ "S.
as! "-
VIEW SHOWING THE CONVEYOR FINGER ADJUSTMENT
Tool: %” wrench.
Procedure: 1. Open the ﬂywheel guard and engage the clutch.
2. Turn the ﬂywheel until the conveyor ﬁnger is at the extreme left.
3. Use a 7/8” wrench to loosen the lock nut; turn the adjusting nut until
the conveyor ﬁnger pushes the case nearest the varnish tool directly
in line with the varnish tool.
Note: In making the adjustment, be sure the drying track is ﬁlled
with cases from the starting point up to the varnish tool.
4. Use a %" wrench to tighten the lock nut on the conveyor ﬁnger.
[54]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Adjustments
Varnish The varnish tool varnishes the mouth of the case. The working end of the
Tool tool should be completely inserted in the mouth of the case. The distance
the varnish tool will travel into the mouth of the case can be regulated by
loosening a lock nut on the varnish tool and raising or lowering the tool to
the desired position. If the varnish is not entering far enough into the
mouth of the case, the tool will have to be adjusted.
/ Tool Holder

VIEW SHOWING THE VARNISH TOOL
Tool: 7/1;" wrench.
Open the ﬂywheel guard and engage the clutch.
Place a case at the varnish station directly in line with the varnish tool.
Turn the ﬂywheel by hand until the varnish tool is at the top of its
stroke.
Use a 146" wrench to loosen the lock nut on the varnish tool.
Turn the varnish tool by hand until it is in a position to varnish the
inside of the mouth of the case to the proper depth.
6. Use a "/15" wrench to tighten the lock nut on the varnish tool.
7. Close the ﬂywheel guard.
Procedure:
9"!“ .°°.l\'>!"
Tool Holder
Varnish Tool


VARNISH TooI. REMOVED FROM THE MACHINE
I 55 l
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Troubles and Corrections

Objective
Clutch Automatically
Disengaged
Stems Not
Aligned at
the Stations
TROLIBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
When making an analysis of the trouble that occurs, always check the
components being fed into the machine before checking faults on the
machine.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as it
operates.
Visual inspection reveals that the clutch has been disengaged by the auto-
matic clutch release mechanism. This may be due to the following reasons:
Inspection reveals that the clutch has been automatically disengaged by
the action of the station alignment punch.
The corrections are:
1. Align the punch with the sta-
The causes are:
1. The stems are not in line with
the punches at the various sta-
tions. The station alignment
punch does not enter the hole
provided for it on the indexing
dial, but hits against the top of
the dial and disengages the
clutch.
The stroke of the dial is such
that it is turned too far and the
case is conveyed past the sta-
tion; or the dial does not turn
suﬂiciently to bring the case to
the station.
tions. Turn the ﬂywheel until
the ﬂash hole punch is just
above the stem die. Turn the
nut on the end of the dial
operating rod until the punch is
in line with the die.
. Adjust the travel of the index-
ing dial by changing the posi-
tion of the arm attached to the
eccentric at the end of the
crankshaft. Loosen the nut on
the arm and slide the arm
toward the center to decrease
the amount that the dial moves
with each revolution of the
crankshaft; or slide the arm
away from the center to in-
crease the action of the dial. It
will be necessary to experiment
until the correct movement of
the dial is attained. Tighten the
nut on the arm.
[56]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Troubles and Corrections

Clutch
Disengaged
by No Case
Detector Punch
Clutch
Disengaged by
Inverted Primer
Detector
Ragged
Flash Hole
Inspection reveals that the clutch has been disengaged by action of the
no case detector punch.
The cause is:
1. There is no case in the feed
jaws and the punch is forced
against one of the prongs of the
jaws, automatically disengag-
ing the clutch.
The correction is:
1. Check to see whether or not
there are cases in the hopper.
If there are plenty of cases in
the hopper, but they are not be-
ing properly fed to the feed
jaws, refer to causes of cases
not entering feed jaws..
Inspection reveals that the clutch has been disengaged by the action of
the inverted or no primer detector.
The causes are:
1.
There is an inverted primer or
there has been no primer in-
serted in the primer pocket.
The stem attached to the de-
tector punch has been allowed
to descend far enough to disen-
gage the clutch automatically.
. The stem attached to the de-
tector punch is not properly ad-
justed. The stem automatically
disengages the clutch even
though a primer is correctly
placed in the primer pocket.
The corrections are:
1. Remove the case containing
the inverted primer. If there
is no primer in the case, check
the primer feed. Refer to
causes of primers not fed to
turnover ﬁngers.
. Adjust the stem by turning the
nuts located at the top of the
stem. The stem should be
raised until it fails to contact
the electric switch button when
a primer is correctly placed in
the primer pocket.
Visual inspection reveals that the ﬂash hole is not cleanly cut.
The causes are:
1.
The punch is dull and does not
make a clean cut as it pierces
the case at the center of the
primer pocket.
The stem die is dull. A ragged
hole is produced as the punch
is forced through the case into
the die.
The corrections are:
1. Remove and replace the punch.
Loosen the set screw in the
punch holder and allow the
punch to drop out. Place the
new punch in the punch holder
and tighten the set screw.
. Remove and replace the stem
die. In order to remove the
stem die it is necessary to re-
move the feed mechanism from
the machine bed. It is also
necessary to remove and disas-
semble the entire dial. The de-
fective stem die is pressed out
and the new stem die is pressed
into the dial. Reassemble the
machine.
I571
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Troubles and Corrections

No Flash Hole Inspection reveals that the clutch has been automatically disengaged by
in the Case the ﬂash hole detector punch.
Insufficient
Crimp
Insufficient
Shellac on
Case Head
The causes are:
1.
The ﬂash hole punch is broken
and does not punch a hole in
the primer pocket.
. The ﬂash hole punch is not
properly adjusted. It does not
descend far enough to pierce
the case.
The corrections are:
1. Remove the broken punch and
replace with a new or serviced
punch. Loosen the punch set
screw and allow the punch to
drop out. Insert a new punch
and tighten the set screw.
. Lower the ﬂash hole punch. It
is necessary to loosen the set
screw. Allow the punch holder
to drop out of the ram and turn
the spanner nuts towards the
top of the punch holder. Re-
place the punch holder, and
tighten the set screw. It may
be necessary to adjust the
punch several times before the
desired position of the punch
is attained.
Visual inspection reveals that the primer is not being crimped far enough
down into the primer pocket.
The cause is:
1.
The crimping punch is not
properly adjusted. The crimp-
ing tool is not lowered far
enough by the action of the
ram.
The correction is:
1. Adjust the crimping punch.
Loosen the Allen screw in the
primary tool holder and turn
the set screw on top of the tool
holder. Push the crimping tool
against the set screw and
tighten the Allen screw. It may
be necessary to readjust the
punch several times before the
proper crimp is attained.
Visual inspection reveals that there is not enough shellac deposited on the
head of the case around the primer.
The correction is:
1. Adjust the stop screw that
determines the depth that the
tool dips into the shellac.
Loosen the lock nut and turn
the screw so that the tool
descends deeper into the shel-
lac. Tighten the lock nut.
The cause is:
1. The shellac tool does not dip
far enough into the shellac con-
tainer.
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Troubles and Corrections
Cases Not Entering Visual inspection reveals that the cases are not entering the feed jaws.
Feed Jaws
Primers Not Entering
Turnover Fingers
The causes are:
1. The hopper belt is loose. It is
not conveying the cases to the
feed tube.
2. The push-in ﬁnger is not push-
ing the case into the feed jaws.
.Adjust the push
The corrections are:
1. Tighten the belt. Loosen the
nut on the idler pulley bracket
and push the knurled idler
pulley against the belt until
the belt is taut. Tighten the
nut on the idler pulley bracket.
in ﬁnger.
Loosen the Allen screw at the
left end of the rocker arm shaft
and push the ﬁnger far enough
forward to position the case at
the forward end of the feed
jaws.
Visual inspection reveals that the primers are not entering the turnover
ﬁngers.
The causes are:
1.
The primers are jammed at
beginning of the track. They
are not properly agitated to be-
gin their travel along the track.
The primer push in ﬁnger is not
inserting the primers into the
turnover ﬁngers.
The corrections are:
1. Adjust the primer agitator.
Allow the ram to be lowered
half way, and turn the nut
on the push in ﬁnger operating
rod until the agitator pin
presses against the spring agi-
tator.
.Adjust the primer push in
ﬁnger. Turn the ﬂywheel until
the push in ﬁnger is as far as it
will - go toward the turnover
ﬁnger. Turn the adjusting screw
on the push in ﬁnger until the
primer enters the turnover ﬁn-
ger.
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Tool Servicing

Objective
Servicing A New
Punch or Stem
Servicing A Used
Punch or Stem
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in the inser-
tion of primers and ﬂash holes in the cases. Dies and punches are costly
and great care must be exercised in the servicing of these tools. While ad-
justers will not be concerned with tool servicing in the Primer Insert De-
partment at present, such necessary steps as listed should be known in the
event that they may be needed in the future. Adjusters will be concerned
primarily with the removal of small scratches that appear on the working
surfaces of stems and punches. They must be careful when using an
abrasive on any tool not to alter its dimensions materially.
All tools that cannot be corrected by polishing those punches that are bent,
will be returned to the Tool Department, in exchange for new ones. Under
no circumstances will any attempts be made to straighten bent or sprung
punches.
Before an abrasive of any kind is applied to a new punch or stem, its di-
mensions should be carefully checked with a micrometer or proﬁle gage,
and its working surface should be examined for ﬁnishing or handling marks
and lack of polish. A highly -polished punch aids in stripping and allows
better working conditions. '
As a punch is used its working surface wears accumulating scratches.
Excessive wear is determined by measuring with a micrometer or check-
ing with a proﬁle gage. Obviously, an undersize punch must be replaced
with one of approved dimensions. Scratches, if not too deep, may be
removed by polishing. The question of how soon a new punch will need
polishing can be answered only from experience, since many variable
factors enter into the problem.

OVER-ALL VIEW or SPEED LATHE
[60 l
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Tool Servicing

FIG. 2
CORRECT METHOD OF PLACING
PUNCH IN CHUCK
Polishing
Lapping
FIG. 3
INCORRECT METHOD OF PLACING
PUNCH IN CHUCK
Polishing is done with a ﬁne abrasive, for example, crocus cloth. A ﬁnal
operation called draw polishing is done after the chuck has been stopped.
To draw polish a punch or stem, move the abrasive cloth lengthwise
over the entire working surface, avoiding rotary motion of the punch or
the abrasive. Continue this operation until all marks are removed and
the desired high polish or mirror like ﬁnish is obtained.
An adjuster will not be required to lap more than .0005 inch from a new
punch or stem. If more than this must be removed to bring the punch or
stem to correct size, it should be returned to the Tool Servicing Depart-
ment for correction. Lapping is done with a piece of abrasive cloth
wrapped around and moved back and forth along the axis of the punch
as it revolves in the high speed chuck. If the abrasive were held sta-
tionary, deep rings would be cut into the surface, and the ﬁnish would
be ruined.
The punch or stem is shown in Fig. 2 correctly chucked, and in Fig.
3 incorrectly held. Avoid excessive overhang of the punch as this is a
safety hazard; make sure that the jaws are correctly set and tightened
securely. Do not allow the jaws to grasp the working surface of the
punch.
Only a very ﬁne abrasive such as emery cloth is to be used in the lapping
operation. The surface of a properly lapped punch will have a dull grey
color with a cross-hatched effect.
I61]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bea rings
MACHINE LUBRICATION
The efﬁciency of all machinery depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found that
they are not smooth at all but are made up of innumerable microscopic hills
and valleys. When the jagged hills and valleys of two engaging bearing
surfaces come together, their meshing resists the sliding of one over the
other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated suﬂiciently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils
of different properties are obtained for the thousands of different types
of lubrication needed in industry. Lubricating Grease is a compound
of petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—-tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings to
protect the highly polished balls or rollers from rust and corrosion and to
reduce friction between the moving parts.
[62]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Lubrication

Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constancy of operation.
Cleanliness of surroundings.
.°”.°‘tI‘$'°.l\'>
Temperature of surroundings.
7. Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to have
the adhesiveness that is needed at low speeds. Instead, it must have high
ﬂuidity in order to ﬂow quickly through the small clearances that are found
in high speed bearings and thereby maintain an adequate-lubricating ﬁlm.
As the load on a 'shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high ﬁlm
strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable, where possible, to standardize the lubricants for a certain
plant to include a. few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface. The
method used depends to a great extent upon:
Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
HQSHPPDNP
Frequency of lubrication.
I 63 I
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method that
is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°.‘q9‘.°‘!l=‘.°°.[\'-ll-‘
Splash feed system.
Grease is applied to bearing surfaces through several different devices:
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a lubricated machine;
it shows poor workmanship. Evidence of good lubrication is usually shown
internally—not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrica-
tion.”
Carry a wiping rag with you when you oil or grease. Wipe the cup or ﬁtting
before you open the cup or apply the grease gun. Also wipe the oiler spout
or grease nozzle. Applications of lubricants are necessarily frequent. If a
little dirt is allowed to enter the ﬁtting each time, it can cause a lot of
trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor. A
grease gun should be in one of two places: in its rack or in the hands of the
oiler.
The grease barrel should be kept tightly covered at all times—except when
the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way into a
grease barrel can easily be forced into a bearing and cause the machine to
be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think that it
should be changed, take it up with your superior.
I64]
CALIBER .30 v. AND 0. PRIMER INSERT PRESS Machine Lubrication
LUBRICATION CHART

. . N 0. of Fittings, Frequency of
I/ubmcant Machine Part Grease Cups, etc. Lubrication H ours
Crankshaft bearings . . . . . . . 2 8
Clutch . . . . . . . . . . . . . 1 8
Ram connecting rod . . . . . . . 1 8
LIGHT GREASE Ram gibs . . . . . . . . . . . . 2 8
Eccentric (dial drive) . . . . . . 1 8
Primer driveshaft . . . . . . . . 2 8
Primer drive idler pulley . . . . . 1 8
Ram connecting rod ball socket . . 1 4
Clutch detector cam roller . . . . drop 4
Rocker arm driveshaft . . . . . . 1 8
Primer push-in ﬁnger adjusting rod. 2 8
Primer turn table shaft . . . . . . oil pipe 4
Primer push-in ﬁnger slide . . . . drop 8
Primer feed control arm . . . . . 1 8
Primer turnover ﬁnger rack gear . 2 8
Primer turnover ﬁnger rack slide . drop 4
Shellac rack slide . . . . . . . . drop 4
Case hopper . . . . . . . . . . 3 8
Ram recoil spring gear bushing . . oil rod 4
Case turnover block slide . . . . . 2 4
LIGHT OIL Case turnover cross-shaft . . . . . 2 8
Case turnover bronze slide . . . . oil hole 4
Case mover ﬁnger bronze slide . . 1 4
Case mover ﬁnger slide shaft . . . 1 8
Case mover ﬁnger rocker arm . . . oil hole 8
Varnish tool holder shaft . . . . . 1 4
Case dial block . . . . . . . . . 1 4
Case dial block detector shaft . . . oil shaft 4
Case dial turning latch . . . . . . 1 8
Case dial turning latch horizontal gib 1 4
Case dial slide adjusting arm . . . oil hole 8
Case dial lock slides . . . . . . . 2 4
Case dial rocker arm . . . . . . . 1 4
Solenoid switch control rocker arm 1 8


[65]
CALIBER .30 V. AND O. PRIMER INSERT PRESS
Index
Adjusting Stud, 10, 22, 26
Adjustment, Burring Punch, 45
Case Feed Finger Operating
Arm, 42
Case, Transfer Lift, 53
Conveyor Finger, 54
Dipping Stroke, 52
Flash Hole Detector, 44
Idler Pulley, 41
Index Dial, 37
N 0 Primer Detector, 49
Piercing Punch, 43
Pitman, 40
Pressure, 52
Primer Agitator, 46
Primer Insert Punch, 48
Seating and Crimping Punch, 50
Shellac Tool, 51
Station Alignment Detector, 40
Turnover Finger Assembly, 47
Varnish Tool, 55
Anti-friction Bearings, 62
Bearing Cap, 10
Burring Punch, 24, 29
Punch Adjustment, 45
Punch Tool Holder Shaft, 24
Station, 32
Case Feed Finger Operating Arm,
Adjustment, 42
Guide Ring, 13, 18, 21
Overhead Hopper, 31
Transfer Lift Adjustment, 53
Cases Not Entering Feed Jaws, 59
Clutch, 8, 20
Arm, 8
Automatically Disengaged, 56
Disengaged by Inverted Primer
Detector, 57
Disengaged by No Case Detector
Punch, 57
Coil Spring, 17, 23
Connecting Ram, 10, 11
Rod, 10, 11
Conveyor Belt, 6
Finger, 18
Finger Adjustment, 54
Crankshaft, 3, 8, 9
Speed, 1
Crimping Punch, 26, 29
Station, 32
Cross-shaft, 6
Cushion Spring Rings, 26
Detector Punch Holder, 23
Dial Indicator Gage, 35
Dipping Stroke Adjustment, 52
Drying Track and Varnish Station, 32
Feed Block, 6, 17
Finger and Feed Jaw, 31
Motor, 1
Tube and Feed Check, 31
Unit, 17, 18
Flash Hole Detector, Adjustment, 44
INDEX
Flash Hole Detector Pin, 29
Hole Detector Station, 32
Hole Punch, 22, 29
Floor Space, 1
Flow Chart, 33
Flywheel, 2, 8
Friction, 62
Gage Care, 35
Gages, 35
Grease, 63
Height, 1
Hints on Lubrication, 64
Idler Pulley Adjustment, 41
Index Dial, 14, 16, 18
Dial Adjustment, 37
Indexing Dial, 3, 12, 17
Dial Mechanism, 16
Pawl, 14
Inserting Punch, 25, 29
Punch Holder, 25
Insufficient Crimp, 58
Shellac on Case Head, 58
Introducing Lubricating Film Re-
duces Friction, 62
Inverted Primer Detector Punch, 29
Primer Detector Station, 32
Lapping, 61
Lock Nut, 23, 26
Lubrication, 62
Chart, 65
Methods, 63
Machine Description, 1
Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 64
No Case Detector Station, 31
Flash Hole in the Case, 58
Primer Detector Adjustment, 49
Objective of Tool Servicing, 60
of Troubles and Corrections, 56
Operating Shaft, 14
Over-all Height, 34
Paddle Wheel Hopper, 3, 6, 7, 31
Pawl, Transfer Slide and Looking
Finger, 14, 15
Piercing Punch Adjustment. 43
Station, 31
Pitman Adjustment, 40
Pocket Depth, 34
Diameter, 34
Polishing, 61
Power, 2, 3
Pressure Adjustment, 52
Primary Tool Holder Shaft, 26
Primer Agitator Adjustment, 46
Assembly, 19, 20
Dial, 19
Diameter, 34
Hopper, 3, 4, 19, 32
Insert Punch Adjustment, 48
Insert Station, 32
Primer Turnover Fingers, 20
Primers Not Entering Turnover
Fingers, 59
Production, 1
Purpose of V. and O. Primer Insert
Machine, 31
Push-in Finger and Turnover Fin ger,32
Ragged Flash Hole, 57
Ram, 3, 10, 12, 20
Recoil Spring, 11
Rocker Arm, 16
Seating and Crimping Punch Adjust-
ment, 50
Secondary Holder, 26
Selecting a Lubricant for a Given
Bearing, 63
Servicing a New Punch or Stem, 60
a Used Punch or Stem, 60
Shellac Mechanism, 20, 21
Station, 32
Tool, 30
Tool Adjustment, 51
Shellacing Tool Holder, 27
Space Rod, 22, 26
Spanner Nut, 26 h
Nuts, 23, 24, 25
Spring Housing, 26
Station Alignment Detector Adjust-
ment, 39
1—Feed Block, 4
2—Flash Hole Punch, 4
2—Flash Hole Punch Tool Holder, 22
3—Detector Punch Tool Holder, 23
4—Burring, 4
4—Burring Punch Tool Holder, 24
5—Primer Insert, 4
5—Primer Insert Pun ch Tool Holder,
25
6—-Inverted Primer Detector, 4
7—Crimping, 4
7——Crimping Punch Tool Holder, 26
8—Shellac, 4, 5
8—Shellac Punch Tool Holder, 27
9—Varnish, 5
9—Varnish Punch Tool Holder, 28
Stems Not Aligned at the Stations, 56
Stripper Plate, 12
Stroke, 1
Tool Holder Shaft, 22, 23
Tools, 1
Transfer Slide, 16
Station, 32
Transmission, 2, 3
Turnover Finger Assembly, Adjust-
ment, 47
Type of Feed, 1
Varnish Tool, 30
Tool Adjustment, 55
Tool Holder, 28
Varnishing Tool, 28
Visual Inspection, 35
Weight, 1
[66]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Straight Line .
Loading Machine

BY
Training Department
Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 194-1
United States Government Contract
W-ORD-4-81, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. .The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917 , C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description . . . . . . . . . . . . . . . . . . I . . . . . . . .‘ . . . . . . . . . . . . . . . 2
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Tool Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
III

CALIBER .30 STRAIGHT LINE LOADING MACHINE
IV
CALIBER .30 STRAIGHT LINE LOADING MACHINE Catalogue Data
CATALOGUE DATA
Manufacturer Waterbury Farrel Foundry and Machine Company
Waterbury, Conn.
Machine Horizontal multiple station, vertical action, auto-
Description matic straight line loading machine.
Machine Totally enclosed, explosion proof, 2 h.p.; 3 phase;
Motor 60 cycle; 220-440 volts; 1750 R.P.M.; fan cooled;
belt drive to countershaft.
Hoppers Case: Paddle wheel type located on top of machine
at left end.
Powder: Gravity funnel type located on front at
center of machine, feeding to station 2.
A.P. or Ball: Proﬁle dial type located on top of
machine at right end, feeding to station 4.
Tracer Bullet: Manually fed through brass tube to
station 4.
Production 60 per minute
Tools Piece No.
No Case Detector and Mouth Spread,
Detector Punch, taper AA-12
Powder Detector
Detector punch, cylindrical AA-13
Bullet Insert
Inserting punch, proﬁle AA-14
Bullet Seat
Seating punch, concave AA-11
Crimping
Crimping die, taper AA-10
Height 6 ft.
Weight 3500 lbs.
Floor Space 3% ft. x 7 ft.
CALIBER .30 STRAIGHT LINE LOADING MAcI-IINE Machine Description

MACHINE DESCRIPTION
The Caliber .30 Straight Line Loading machine deposits the correct
amount of propellent powder in the case, inserts the bullet in the case,
and crimps the mouth of the case into the bullet cannelure.


_ Powder Hopper
-_ Paddle Wheel
Bullet
/ Hopper
Hopper
REAR VIEW OF CALIBER .30 STRAIGHT LINE LOADING MACHINE
Power and The Waterbury Farrel Straight Line Loading Machine, illustrated above,
Transmission is powered through three V-type belts from a 2 h.p. motor to a pulley
mounted on the left end of the driveshaft. The motor is mounted below
the left end of the machine. Power is controlled to the motor by a toggle
type switch. The switch is located at the left front of the machine frame.
Power is controlled from the driveshaft through a friction type clutch
which is manually operated through linkage from the front of the machine
bed. The driveshaft is connected to and drives the camshaft and worm
conveyor shaft through a series of interlocking spur gears. The machine
action is stopped when the clutch is disengaged by a wedge brake on the
driveshaft clutch. The worm conveyor shaft and the identiﬁcation rack
are equipped with individual constant pressure brakes which keep the
I2]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Power and
Transmission
(Cont.)
Hoppers
Camshaft
Worm Shaft
identiﬁcation rack and worm conveyor shaft from overriding. The bullet
hopper is driven by a round leather belt from a pulley wheel on the right
end of the camshaft. The case hopper is also driven by a round leather
belt from a pulley wheel on the left end of the camshaft.
The ﬁve rams are actuated through rocker arms from the camshaft. The
rocker arm push rods are attached to the cams by a bearing arrangement
which imparts a positive action to each ram. The transfer bar is actuated
from right to left by a barrel cam located on the right end of the camshaft.
The in and out motion of the transfer bar is actuated from two inverted
cams, one of which is located at each end of the camshaft. The indicator
worm conveyor shaft is driven by interlocking spur gears from the cam-
shaft. The spur gear attached to the worm conveyor shaft is equipped
with a shear pin which will shear in the event the indicating system jams.
The bullet hopper is mounted on the upper surface of the frame at the
right end of the machine. The hopper is mounted at a forty-ﬁve degree
angle in relation to the machine frame and is equipped with a proﬁle dial.
The dial contains slots which conform to the shape of the bullets. By
means of this arrangement, they are lifted to the feed tube opening. The
bullets are fed into the hopper from an overhead source.
The case hopper is mounted on the upper surface of the frame at the left
end of the machine. The case hopper is the Liberty Paddle Wheel type,
which lifts the cases from the hopper bottom to the conveyor belt where
they are carried to the feed tube opening. The cases are emptied into the
hopper from containers in which they are brought into the Loading
Department. The cases may also be fed into the machine from an over-
head source through a chute.
The powder hopper is a sheet metal funnel-shaped container into which
the powder is emptied from the upper end. The hopper is suspended,
neck down, above the charging block by a block and tackle suspended
from the ceiling.
The camshaft is held by, and rotates in, three ﬁtted bearings in a horizon-
tal position along the rear edge of the machine bed. The camshaft contains
a barrel cam, four inverted cams, and a series of eccentric cams which
through linkage actuate the various machine parts. The camshaft re-
volves in a counterclockwise motion, driven through spur gears from the
driveshaft.
The worm shaft is held by, and rotates in, three ﬁtted bearings along the
rear of the machine, above the camshaft. A small barrel cam is attached
to the right end of the worm shaft and drives the transfer ram which
pushes the cartridges from the inverting wheel into the identiﬁcation rack.
The worm shaft is equipped with guide rails along each side which provide
the track through which the ball bearings travel, conveyed by the worm
shaft. Each detector station is equipped with a detector punch. The
detector punch, when actuated by a faulty case, drops down allowing the
cam ﬁnger to contact the detector triggers. The upper end of the detector
trigger moves to the left, allowing the indicator paddle to move the ball
[3]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description
Worm Shaft
(Cont.)
Driveshaft
Case Feed Unit
Transfer Bar
Ra ms
Identifying
System
bearing to the opposite side of the worm conveyor shaft. The ball bearing
conveyed by the shaft passes beneath the operating arms, stopping the
action of the powder dial, powder detector, the bullet inserting station,
and opens the trap door for the rejection of the faulty case.
The driveshaft is held by, and rotates in, three ﬁtted bearings in a horizon-
tal position along the rear of the machine frame. The driveshaft contains
the master clutch from which the machine action is controlled. The
crimping head is driven through a round leather belt from a pulley on the
right end of the driveshaft. The right end of the driveshaft extends
through the machine frame and a hand wheel is mounted on the drive-
shaft by which it may be turned.
The case feed unit receives the cases from the feed tube and positions them
for insertion into the transfer bar. The cases are pushed forward by the
feed bars. The feed bars are actuated through linkage from the driving
arm of the transfer bar.
The transfer bar is actuated in a rectangular motion through linkage from
the operating cams on the camshaft. The transfer bar conveys the cases
through the various machine stations which ﬁll the case with powder,
detect a high, low or correct powder charge, insert the bullet, seat the
bullet, crimp the cartridge and transfer it to the identifying system. The
transfer bar carries twelve cases progressively through the machine.
The ﬁve rams are held in the ram bed in a vertical position by adjustable
gib plates. Each ram carries its individual working punch and all are
actuated through linkage from the eccentric cams on the camshaft. The
crimping ram is ﬁtted with a tapered die which performs the actual crimp-
ing operation.
The identifying system consists of the inverting wheel and the identifying
rack. The inverting wheel is driven by a ratchet and pawl arrangement
through linkage from the camshaft. The inverting wheel receives the
cartridges from the transfer bar and carries them upward to the top of the
wheel where they are inserted, head up, in the identifying rack. The
identifying rack is a wheel held on a horizontal plane and is actuated from
the inverting wheel. The identiﬁcation system is located at the right end
of the machine.
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Case Hopper
__ Powder
Hopper
_ Hopper
Box
SIDE VIEW OF THE CASE HOPPER
The case hopper is mounted on top of the machine frame at the left end
of the machine. The hopper paddle wheel is driven by a round leather belt
from a pulley on the left end of the camshaft. The hopper driveshaft is
mounted in a horizontal position along the rear of the hopper frame. The
driving belt pulley is mounted in the forward end of the driveshaft and is
connected by the belt to the camshaft.
The driveshaft extends beyond the rear of the hopper and has a small
pinion gear which connects with the ring gear on the paddle wheel shaft.
The paddle wheel shaft extends through the rear end of the hopper and
has a paddle wheel attached to the inner end. The hopper conveyor belt
is driven by a pulley attached to the hopper driveshaft.
The endless conveyor belt travels along the inside of the hopper frame be-
tween the driving pulley and the idler pulley. The conveyor belt carries
the cases from the paddle wheel to the feed tube. If the cases are placed on
the conveyor belt by the paddle wheel, head ﬁrst, they will drop directly
into the feed tube, but if they are placed on the conveyor belt, mouth ﬁrst,
they will override the feed tube opening and drop back, head ﬁrst, into the
feed tube opening. The cases ﬂow, head ﬁrst, by gravity into the case
feed unit.
[5]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


Conveyor
Paddles
VIEW OF THE INTERIOR OF THE PADDLE WHEEL HOPPER
Conveyor
Belt

SIDE VIEW or THE PADDLE WHEEL HOPPER
I 6 l
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Powder
Hopper
Charging Block
VIEW OF THE POWDER HOPPER
The powder hopper is funnel-shaped and ﬁtted with an interior cardboard
funnel into which the powder is poured. The hopper is ﬁlled by hand from
containers brought into the Loading Department from the Powder De-
partment. The powder hopper is suspended from the ceiling by a block
and tackle. The small end of the funnel is attached to the powder charging
unit. The large end of the hopper is covered by screen wire to keep any
foreign particles from getting into the powder.
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IBER
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PPER
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Bullet
Hopper
_ Powder
Hopper
Hopper
Dial
Pulley
VIEW OF THE BULLET HOPPER
The bullets are fed into the hopper through a feed tube from an overhead
source. The bullet hopper contains a revolving disc set at an angle of 45°
within the hopper base. The outer circumference of the disc is notched to
ﬁt the proﬁle of the bullets. Bullets dropping into’ these notches will, on
reaching the throat of the feed gap, drop into the coiled spring feed tube,
base ﬁrst. Bullets resting in these notches in an inverted position will
overshoot the feed tube a short distance, and fall backward into the feed
throat, base ﬁrst.
This hopper feeds the bullets faster than is necessary and is provided with
an overﬂow. At the top of the feed tube the bullets jump a gap into the
tube. If there is room, the bullets will enter the feed tube and continue to
the bullet insert station. If the feed tube is full, the bullets will fall through
a chute into a container, where they may be poured back into the hopper
by hand.
[9]
CALIBER .30 STRAIGHT LINE LOADING MAC:-IINE Machine Description


._.--—— Hopper Box
____‘ Dial Hopper
Overﬂow
Bin
OVER-ALL VIEW OF THE BULLET HOPPER
I10]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


' l Powder
Case Feed
Tube _ Hopper
Powder .
Dial " , §:‘°"‘-j'"9
ac
Case Fﬁed
nit .
OP‘-"=*i'r': -— QZLIIIIZI
Case Fﬁﬁlt ’ . ﬁgitating
Ommet
Corer J’ Operating
Arm
Rocker
Arm
VIEW SHOWING THE CASE FEED UNIT
Case Feed Unit The case feed unit is bolted to the bed, at the left end of the machine. The
feed tube ﬁts into a sleeve in the top of the feed block. The cases drop into
the feed channel of the block where they are pushed forward by the feed
bars. The feed bars slide back and forth in two machined channels, one in
the base of the block, the other in the top of the block. The forward end
of the feed bar is machined to ﬁt the circumference of the case. The right
side of the feed bar, at its forward end, is rounded slightly to allow the
case to roll off the feed bar as the transfer bar moves it forward. The feed
bar rocker arm is attached at its pivotal point to a vertical pin at the
forward end of the feed block casting.
The forward end of the rocker arm is attached to the feed bars by two
connecting links which compensate for the length of travel of the feed bars
in relation to the rocker arm. The outer end of the rocker arm is attached
to the operating arm which connects to the transfer bar driving arm. Thus
the feed bars are actuated directly from the transfer bar driving arm and
indirectly from the inverted cam on the camshaft. The feed block holds
one case, which is pushed forward to the transfer bar by‘ the pressure of
the feed bars.
I11]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description
CH E FEED STUD
. J Tr/Be


can/are / OPE/QA T/A/G


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LEVER
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OPE/€A4T/A/G /ft?!"
STUD’
DRAWING OF THE CASE FEED UNIT
[12]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description
Transfer
Bar
Fingers

Transfer Bar
I »?*s
VIEW OF THE TRANSFER BAR
The cases are moved across the machine from station to station by the
action of the transfer bar. The transfer bar is driven from the camshaft
and contains twelve sets of transfer ﬁngers. The lateral movement of the
transfer bar is actuated through a side rocker arm by a barrel cam on the
camshaft. The side rocker arm is attached to its pivotal point by a wrist
pin arrangement which allows it to swing freely. The in and out move-
ment of the transfer bar is actuated from two inverted cams on the cam-
shaft. The transfer bar is connected to the inverted cams by two driving
arms located on the machine bed. The driving arms travel in and out on
the machine bed.
The transfer ﬁngers are fastened in the bar in pairs by pins and are held in
a forward position by springs. These springs are used to prevent jams. If
a case jams, the ﬁngers give and thus prevent bending or breaking metal
parts of the machine. The ﬁngers are in pairs, upper and lower, and are
slotted to conform with the circumference of the case at the point where
they grasp it.
[13]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description
Cam
Follower
Acfuating
Bartel
Cam
Transfer ____
Bar
Tra n sfer


_'
I8‘-' ‘
Holding
Bar
Bar ‘-
Fingers
Transfer
_ Bearing
Action
Rocker
Arm
VIEW OF THE BARREL CAM
At each station the cases are held in place by spring action stationary
holding ﬁngers. These stationary ﬁngers are located in the holding bar,
which runs parallel to the transfer bar and is bolted to the machine bed.
While the operation is performed, these ﬁngers hold the cases against the
parallel guide tracks ﬁrmly enough to keep the cases from falling over,
but not so ﬁrmly as to prevent the transfer ﬁngers from moving the cases
from one station to the next.


vIEw or THE HOLDING BAR
I 14 l
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Powder Hopper
Charging Block
Anvil
Agitating Hammer
Charging
Block


_ Agitating Hammer
Operating Arm
VIEW OF THE CHARGING BLOCK
The charging block is a rectangular metal block which has a powder valve
cut through the center of the block. This valve can be adjusted to regulate
the amount of powder, by volume, that is to be used in charging the case.
The charging block carries the powder charge from the powder hopper to a
position above the charging dial funnel. The block is mounted in a casting
bolted to the front of the machine bed. The charging block arm is held on
a horizontal cross-shaft in the charging block housing. The outer end of
the cross-shaft has a rocker arm attached which is actuated from an
eccentric cam on the camshaft through an operating arm. The charging
block is equipped with an agitating hammer which strikes against an anvil
attached to the end of the charging block.
There are distinctly two types of agitations used on the charging block.
The agitating hammer hits the charging block anvil fourteen times, in
order to settle the powder in the powder valve. The powder block also
receives two shakes at the end of its forward stroke in order to clear the
powder valve of all powder; and two shakes at the end of the backward
stroke to settle the powder.
[151
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description

Charging Block These two types of agitation are actuated through linkage from agitating
(Cont.) cams on the camshaft to the charging block.
Powder Valve
Set Screw Anvil


CHARGING BLOCK REMOVED
[15]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


Powder
Charging -_
Dial
Funnel "
Broke /
Shoe
Inspection
Gale
VIEW OF THE POWDER CHARGING DIAL
Powder The powder charging dial is located below the charging block and in line
Charging with the transfer bar ﬁngers. The charging dial contains six funnels and
Diol handles three cases at a time, one case being inserted while the preceding
one is being ﬁlled with powder and the third is at the inspection gate of the
charging dial. The charging dial is equipped with a ratchet and pawl drive
which is actuated by a yoke attached to the transfer bar.
The cases ﬁt into machined slots along the circumference of the charging
dial. As the cases are brought toward the charge block to receive the
powder charge, the case mouth is forced into the port of the charging dial,
to receive the powder charge, by a rise in the case track. As the cases leave
the inspection gate, the extractor groove is gripped by a stripper plate and
the case mouth is pulled from the charging dial port.
A locking arm is employed to hold the charging dial in position as the pawl
is brought back for the next stroke. The locking arm is pinned to a casting
on the machine bed and is actuated by the yoke striking against a pin
extending from the lower side of the arm. A coil tension spring brings the
arm into contact with the charging dial slots while the yoke releases it for
the next stroke.
[17]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


S’ I . \: Co ct'ng
IQBIIGOII \ . _ I Q /_ Pinllne I
__ Connecting
Link
E”:
ee
Tube
Indicator
/ Paddle
C _____.
Fins: -’-’ Trigger
\ Reset
Plate
Gib /
Tapered
Punch
VIEW OF MOUTH SPREAD AND DETECTOR STATION
Station I, A case upon entering the machine from the case feed unit is grasped by the
Mouth Spread transfer ﬁngers and moved laterally to station 1. This detector and mouth
and Detector spread station has a tapered punch that descends and opens the mouth of
the case slightly to facilitate the insertion of the bullet. At this station the
punch also acts as a detector and determines whether there is a case, a
short case, or no case in the machine.
There is a cam ﬁnger attached to the cam block at the top of the ram
which may be adjusted to its proper clearance by raising or lowering the
tapered punch as it rests on the case. The cam ﬁnger is adjusted to a posi-
tion where it will contact the trigger at the right of the cam ﬁnger which in
turn releases the indicator paddle that pushes the ball bearing to the oppo-
site side of the indicator worm shaft when there is no case or a short case
present.
When there is a case of the right length present in this station, the cam
ﬁnger will clear the trigger. When there is no case or a short case at this
[13]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Station I,
Mouth Spread
and Detector
(Cont.)
station, the ball bearing is pushed to the opposite side of the indicator
worm shaft and rides under the operating arms. This stops the powder
charging operation at station 2, the bullet inserting operation at station 4
and opens the trap door at station 6, where the component, if short, will
fall into a container under the machine.
The ram is actuated by an eccentric cam on the camshaft through a push
rod and rocker arm. The rocker arm is mounted at its pivotal point on the
upper surface of the ram bed. The rear end of the rocker arm is connected
by the push rod to the cam. The forward end of the rocker arm is pinned
to the ram head by a wrist pin and link which allows the ram to move up
and down when the machine is started.
[19]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Description

Powder Hopper
Charging Block
Agitating __
Hammer
Station 2,
Powder
Charging

Agitating Hammer
Operating Arm
VIEW OF POWDER CHARGING STATION
The cases are inserted into the charging dial by the transfer ﬁngers at this
station. As the case is inserted into the slot on the charging dial, the dial
indexes and forces the case along the guide track and up an incline until the
mouth of the case enters the port under the funnel. The case is then moved
to a position directly under the charging block when the charging block is
at the end of its forward stroke. At this position the powder is shaken from
the powder valve, through the funnel, into the case.
As the case continues to move around the dial to an incline where the
extractor groove slides under a stripper plate and as the case is moved over
the incline, the mouth of the case is forced out of the port under the funnel
to a position where the transfer ﬁnger grasps the case and takes it to the
next station. The advantage of the powder dial is speed, for the reason
that the movements of the case settle the powder before it reaches the next
station. The powder dial is actuated from the transfer bar by a yoke and
ratchet.
I20]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description

Section 2, The charging block is designed from brass and has an adjustable valve
Powder Charging which determines the correct powder charge by volume. This valve is
(Cont.) adjusted by a set screw in the end of the block and is locked in position by
a lock nut. In operation the charging block moves back and forth in a
channel and is so timed that its forward stroke coincides with the passing
of the funnels on the powder dial beneath it. The charging block is actu-
ated from the camshaft by an adjustable operating arm.
7‘
A '_..
Q
.
.\'-‘
-I


'-_- Clutch Operating
Lever
Steel
Ball
__...- P d Bl l<
C;l'.:Ier:Iing°1cArm
Clutch Pins
Clutch Collar <*_— Yoke
VIEW OF POWDER CLUTCH ASSEMBLY
[21]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description

Connecting Link
Bullet Inserting __
Station


Powder Detector /
Station € Statton
Cam Block C / - Indicator Paddle
Cam Fingers ..
Trigger
Gib
Reset Plate
VIEW OF THE POWDER DETECTOR STATION
Station 3, The case is moved from the charging dial to the powder detector station
Powder by the transfer ﬁngers. This detector station has a cylindrical punch which
Detector enters the case mouth to rest on the powder charge. Here the powder
charge is gaged for high, low or correct powder charge by volume; the level
to which the powder comes in the case shows whether there is a high, low or
~ correct powder charge. The punch is adjustable, either up or down and is
locked in the tool holder by a lock nut.
There are two cam ﬁngers attached to the cam block at the top of the ram
which may be regulated for a given powder charge by raising or lowering
the punch as it rests on the powder charge. The cam ﬁngers are adjusted to
a position where they will contact the trigger at the right of the cam
ﬁngers, which in turn releases the indicator paddle that pushes the ball
bearing to the opposite side of the indicator worm shaft when the charge
is either high or low.
[22]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description

Station 3, When the powder charge is correct, the edges of the cam ﬁngers are even
Powder Detector and will pass the trigger. When the powder charge is either high or low,
(Cont.) the ball bearing is pushed to the opposite side of the indicator worm shaft
and rides under the operating arms. This stops the bullet inserting opera-
tion at station 4 and opens the trap door at station 6, letting the faulty
component fall out into a container under the machine.
The powder detector ram is actuated by an eccentric cam on the camshaft.
The motion is transmitted through a push rod to the rocker arm. The
rocker arm is mounted at its pivotal point to the upper surface of the
vertical ram bed. The forward end of the rocker arm is attached by a
wrist pin and link arrangement to the ram head.
[23]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


Connecting / Connecting Link
Pm
‘._. Bullet Seating
Bullet Inserting Station
Station
Powder Detector
Station
Indicator Paddle
Cam Finger
Trigger Reset Plate
VIEW OF THE BULLET INSERTING STATION
Station 4, The transfer ﬁngers move the case to the next station. At this station the
Bullet bullets are transferred from the feed tube to a position above the case
Inserting mouth. The bullets are brought forward by a pair of spring feed jaws
which are actuated from an eccentric cam on the camshaft. The bullet is
inserted into the case mouth by the inserting punch which also acts as a
detector. If the bullet is not present, the punch drops down too far
actuating the indicator system and the case is discharged at the sixth station.
The inserting punch is adjustable either up or down and is locked by a lock
nut. The inserting punch ram is actuated from an eccentric cam on the
camshaft. The action of the cam is transmitted through a push rod to the
rocker arm. The rocker arm is attached at its pivotal point above the
vertical ram bed. The forward end of the rocker arm is pinned to the ram
head.
[24]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description

Operating
Lever
Operating
Arm

VIEW OF THE CAM FOLLOWER LOCK ADJUSTMENT
I25]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


Connecting Pin
I
l
-\
Connecting
Linlr
Bullet
Insert
Station
Ram
Powder
Detector
Station
_ Gib
\ Bullet Seating
‘ Station
Co c v
Pdhi \
VIEW OF THE BULLET SEATING STATION
Station 5, The transfer ﬁngers carry the cartridge to the next station where the bullet
Bullet is seated to the correct depth. This operation is performed by the seating
Seating punch which is held in the ram. The punch is adjusted for correct height
by a set screw in the ram head. The punch ram is actuated by an eccentric
cam on the camshaft. The motion of the cam is transmitted to a rocker
arm through apush rod. The rocker arm is attached at its pivotal point to
a position above the vertical ram bed. The forward end of the rocker arm
is pinned to the ram head and actuates the ram in a vertical stroke.
0
I261
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


Transfer ___,
Bar 1
Holding
"— Fingers
Trap
Door W
FRONT VIEW OF THE TRAP DOOR
Station 6, The transfer ﬁngers carry the cartridge to station 6 where no actual work
Trap Door is performed other than discharging defective cases. Those cases which
were indicated as faulty by the preceding detector stations are dropped
through the trap door into a container under the machine.
Tension Spring
7 Counter Balance
Operating Arm

REAR VIEW or TRAP DOOR STATION
I27 I
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description

Station 7, At this station the case is crimped around the bullet cannelure by the
Crimping crimping head. The crimping action is performed by a tapered die mounted
in the crimper head. More or less crimp may be applied by raising or
lowering the crimping head. The crimping ram is actuated in a vertical
stroke by an eccentric cam on the camshaft. The motion of the cam is
transmitted through a push rod to the rocker arm. The rocker arm is
attached above the vertical ram bed. The forward end of the rocker arm
is pinned to the ram head.


‘ Transfer Rum
—- Spanner Nut
VIEW OF THE CRIMPING STATION
Register The transfer bar moves the cartridges from the crimping station past a
register which tabulates the number of cartridges the machine turns out.
The register is attached to the upper surface of the guide rail. It is
equipped with a lever which extends out over the cartridge track where
the cartridges trip the lever as they pass.
[281
CALIBER .30 STRAIGHT LlNE LOADING MACHINE
Machine Description

Cartridge
lnverting
Wheel
Lacquer
Cup
Actuating
Arm
VIEW OF THE CARTRIDGE INVERTING WHEEL
The cartridge is transferred by the transfer bar into the inverting wheel.
The vertical inverting wheel receives the cartridges one at a time into
machined slots which hold the cartridge by the extractor groove. The
inverting wheel carries the cartridges upward to the identifying rack. The
inverting wheel is driven by a ratchet and pawl arrangement from an
eccentric cam on the right end of the camshaft. The connecting rod ex-
tends from the cam to a rocker arm which contains the pawl, operating
the ratchet.
[29]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Machine Description


Guard
Covering
Identiﬁcation
Rack
Inverting —' "
Wheel
Lacquer
Cup
Lacquer
Reservoir / Cartridge
- , Chute
VIEW OF THE IDENTIFICATION RACK
Identiﬁcation The identiﬁcation rack is driven by the inverting wheel through a spur
Rack gear on the forward end of a driveshaft. Directly behind the spur gear
there is a ratchet mounted on the shaft. On the rear end of the driveshaft
there is a pinion gear that meshes with the bevel gear on the identiﬁcation
rack. This series of gears between the inverting wheel and the identiﬁca-
tion rack are in mesh at all times. There is a brake mounted on the drive-
shaft back of the pinion gear that applies constant pressure on the shaft to
eliminate back lash or lost motion in the identiﬁcation rack. The two
circles described as the inverting wheel and identiﬁcation rack meet at the
top of the inverting wheel where the cartridges are transferred from the
inverting wheel to the identiﬁcation rack.
The cartridges are pushed from the transfer ﬁngers into the inverting wheel
by the inserting ﬁngers and they are pushed from the inverting wheel
into the identiﬁcation rack by the transfer ram. The inserting ﬁngers are
actuated by the transfer bar. The transfer bar is actuated by a barrel cam
on the right end of the worm conveyor shaft.
As the cartridges are pushed onto the identiﬁcation rack, the identiﬁcation
rack indexes, and as it passes the lacquer reservoir, the lacquer well raises
to a position where the tip of the bullet is painted. The lacquer well is
actuated by a driving segment gear and a spur gear keyed to the driveshaft.
The lacquer used to identify the cartridges is of two colors, red and black.
The red lacquer is used for tracer cartridges while the black is used for
A.P. cartridges.
I301
PAWL AND RATCHET

I CHARGING BLOCK


HOLDING CLAMPS


__L:I$PuSI-I RDDS
ELECTRIC PAINT CUP IDENTIFYING RACK
MOTOR I
I
I I
BELT I DRIVE SHAFT OPERATING ARM I INVERTING WHEEL
r I I
I
GEAR I BELT ICRIMPING UNIT I
AND I PAWL AND RATCHET—OPERATING ARM—CAM I
CLUTCH I CAM SHAFT - I
I I I I I I I I I I I T I I J
IBELT I I I I I IOPERATING ARM I I I I I I IBELT
I I I I I I I I I I I I
IBULLET HOPPER CLUTCH I ITBIIIIZNSSLFIIIZIIES SIIDESI I I IBIILLET FEED I I I I I I I
I I I I I I ' I I ' I I I IcAsE HOPPER COUNTER SHAFT
I I I I IIIRATCHETAND IIIIII I
IRING AND PINION I I I I I ‘OPERATING ARM I ' I I I I I
I IBEII I I I I I ' I I I I I GEARS IPADDLE WHEEL
IPROFILE DIAL I I I I I IAGITATING HAMMER I I I I I I
‘ I I ' I I ' I I
I I I I I I
CASE FEED T"-—'I I ICLUTCH AND OPERATING I I I I I I SLIDES
. I IROCKER II ARM I I I I I I
I I I I I I | I
TRANSFER BAR I I I I I I I I I I HOLDING CLAMPS
I I I | I
I I I I I
I I I I
I
CHARGING DIAL
I-—-—___
POWDER DIAL LOCK ARM
I
I
I
I
I
I
I
I

INDICATOR SYSTEM SHAFT
I
I
I
I
I TRANSFER
RAM
CAM AND STUD
I
I
I
I
I
I
I
I
I
I
I
I
I
ARM I
I
I
I
I
I
I
I
I
I
GEARS I
I
I
I
I
CAM AND OPERATING ARM

IK;;I’/17"
I
I
IROCKER ARM STATION I

ROCKER ARM STATION 3

ROCKER ARM STATION 4

ﬁ
ROCKER ARM STATION 5

ROCKER ARM STATION 7
LHVHD H3/V\OcI

"°!Id!13$9CI 9"!\P°W EINIHDVW EDNICIVO1 3NI'I LH-z>IvzILS 08' a5IaI'IvD
I18]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Tool Holder Description
Mouth Spread and
Case Detector
Tool Holder

TOOL HOLDER DESCRIPTION
/
/
Coil Spring: The coil spring is large enough in diam-
eter to slide over the upper end of the tool holder and is
used to hold the tool holder at its lowest position. The
coil spring ﬁts between the tool holder shoulder and the
shoulder of the ram.
Detector Pin: The cylindrical detector pin has a milled
screwdriver slot at one end and is shouldered at that
end. The pin is externally threaded at the opposite end
for insertion into the tool holder shaft.
Tool Holder Shaft: The tool holder shaft is machined
to three diameters; the largest diameter is at the bottom
end of the tool holder. The tool holder is internally
threaded at the lower end for the insertion of the punch.
A machined ﬂat surface on the upper end of the tool
holder is contacted by the cam block which holds the
tool holder securely in the ram. The upper end of the
tool holder has a hole drilled horizontally through the
shaft. The hole is internally threaded for the insertion
of the detector pin.
Punch: The cylindrical punch is externally threaded
for approximately half the length of the punch. A hex-
agon lock nut is threaded onto the punch and is used to
lock the punch securely in the ram. The lower end of
the punch is tapered to enter the case mouth. If a case
mouth is bent, the punch corrects it. The punch is also
a no case detector.
[32]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Tool Holder Description

Powder Detector
Tool Holder
\
- \ \
_"‘ \
6 \‘
_: ,\
_ )\
IF‘

/
Coil Spring: The coil spring is large enough in diam-
eter to slide over the upper end of the tool holder and is
used to hold the tool holder at its lowest position. The
coil spring ﬁts between the tool holder shoulder and the
shoulder on the ram.
, Detector Pin: The cylindrical detector pin has a
milled screwdriver slot at one end and is shouldered at
that end. The pin is externally threaded at the opposite
end for insertion into the tool holder shaft.
Tool Holder Shaft: The tool holder shaft is machined
/ to three diameters; the largest diameter is at the bottom
end of the tool holder. The tool holder is internally
threaded at the lower end of the insertion of the punch.
A machined ﬂat surface on the upper end of the tool
holder is contacted by the cam block which holds the
tool holder securely in the ram. The upper end of the
tool holder has a hole drilled horizontally through the
shaft. The hole is internally threaded for the insertion
of the detector pin.
Punch: The cylindrical powder detector punch is
externally threaded from the upper end for a distance
slightly more than one half its length. A hexagon lock
nut is threaded onto the punch and is used to lock the
punch securely in the tool holder. The lower end of the
punch is machined to a diameter conforming to the
opening of the case mouth. The punch enters the case
mouth to rest lightly on the powder charge, thus indi-
cating a high, low, or correct powder charge.
[33]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Tool Holder Description

Coil Spring: The coil spring is large enough in diam-
eter to slide over the upper end of the tool holder and is
used to hold the tool holder at its lowest position. The
coil spring ﬁts between the tool holder shoulder and
the shoulder of the ram.
Bullet Inserting
Tool Holder


Detector Pin: The cylindrical detector pin has a milled
screwdriver slot at one end and is shouldered at that
end. The pin is externally threaded at the opposite end
for insertion into the tool holder shaft.
Tool Holder Shaft: The tool holder shaft is machined
to three diameters; the largest diameter is at the bottom
end of the tool holder. The tool holder is internally
threaded at the lower end for the insertion of the punch.
A machined ﬂat surface on the upper end of the tool
holder is contacted by the cam block which holds the
tool holder securely in the ram. The upper end of the
tool holder has a hole drilled horizontally through the
shaft. The hole is internally threaded for the insertion
of the detector pin.
Space Ring: The cylindrical space ring is inserted on
the lower shoulder of the tool holder shaft.
. Punch: The punch is machined to one diameter and is
concave on the lower end to conform to the proﬁle of the
bullet nose. The upper end of the punch is externally
threaded one half its length. A hexagon lock nut is
threaded onto the punch and is used to lock the punch
securely in the tool holder.
'l34l
CALIBER .30 STRAIGHT LINE LOADING MACHINE Tool Holder Description
Tool Holder externally threaded from the stud head to the lower end.
Bullet Seating / Adjusting Screw: The square head adjusting screw is
i The adjusting stud is inserted in a block in the seating


I punch ram.
. Lock Nut: The hexagon headed lock nut is internally
I threaded for application to the adjusting stud. The
lock nut is used to lock the adjusting stud securely in
place.
-- / Punch: The cylindrical seating punch is tapered at the
' lower end and is slightly concave to conform to the pro-
ﬁle of the bullet nose. The inserting tool is held in the
ram by a square headed set screw which is threaded
through the tool holder block. At this particular station
the ram acts as the tool holder.
.~ .I ‘_ v I . . \ I N‘ i . ..
‘ . MJWMM<MM-‘W
I35]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Tool Holder Description
Spanner Nut: The cylindrical spanner nut is intern-
ally threaded for application to the crimping die housing
stud shaft. By means of the spanner nut the crimping
unit is locked securely in the ram head.
Crimping Die
Tool Holder

Crimping Die Housing: The crimping die housing is
circular in shape. The interior has been machined to
different diameters to accommodate the taper die and
the die holder plate. The die holder plate is held
in place by three slotted set screws. The crimping
head housing is equipped with a stud shaft which is
inserted in the ram head and locked in place with a
spanner nut. The lower end of the stud shaft is extern-
ally threaded for the application of the spanner nut.
Crimping Die: The crimping die is circular in shape
and the outside has been machined to two diameters.
The interior of the die is slightly tapered so that when
the crimping die head is lowered into position, the
mouth of the case will be pressed ﬁrmly into the can-
nelure of the bullet. The crimp around the bullet is
increased or decreased by raising or lowering the ram at
the point where it connects with the push rod.
Die Holder Plate: The die holder plate is circular and
has been machined in diameter to ﬁt the machined sur-
face in the crimping die housing. The die holder plate is
set in the crimping die housing ﬂush with the face of the
housing and is held in place by three slotted set screws.
The center of the die holder plate has a machined hole
in the center that ﬁts over the shoulder of the die. When
the die holder plate is in position, the die ﬂoats between
the housing and the die holder plate.
[36]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Tool Description
TOOL DESCRIPTION
MOUTH SPREAD AND NO CASE
DETECTOR PUNCH


POWDER DETECTOR PUNCH


CRIMPING DIE


Tool Name: Punch—No-case and Mouth Spread.
Detect0r—Tapered
Piece No.: AA-12
Location: Held vertically in ram at station 1
Normal Life: 1,000,000 pieces
This punch is constructed from tool steel, hardened,
ground and polished.
Tool Name: Punch-—High, Low or Correct Powder
Detector~CylindricaI
Piece No.: AA-13
Location: Held vertically in ram at station 3
Normal Life: 250,000 pieces
This punch is made from tool steel, hardened and
ground. The tip is brass and has been ground and
polished.
Tool Name: Punch——Bullet Inserting-—Proﬁle
Piece No.: AA-14
Location: Held vertically in ram at station 4
Normal Life: 250,000 pieces
This punch is designed from tool steel, hardened, ground
and polished. The tip of the punch is concave to fit the
proﬁle of the bullet.
Tool Name: Punch——Bullet Seating—~Comave
Piece No.: AA-11
Location: Held vertically in ram at station 5
Normal Life: 500,000 pieces
This punch is made of tool steel, hardened, ground and
polished. The tip of the punch is slightly concave to
insure proper contact with the bullet point.
Tool Name: Crimping Die
Piece No.: AA-10
Location: Held vertically in ram at station 7
Normal Life: 850,000 pieces
The die is machined from tool steel, hardened, ground
and polished. The interior is tapered to insure proper
crimping.
[37]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Process Sequence
Case
Overhead
Hopper
Case Paddle
Wheel Hopper
Conveyor
Belt
Feed Tube and
Case Feed Unit
Transfer
Fingers
Station I ,
Mouth Spread
and Case Detector
Indicator
System
Station 2,
Powder Charge
PROCESS SEQUENCE
The cases are fed by gravity from a truck or conveyor into an overhead
hopper and ﬂow down through a pipe, past a gate control into the paddle
wheel hopper. '
The cases flow down the incline of the paddle wheel hopper to the paddle
wheel by gravity. The paddle wheel rotates, clockwise, picks up the cases,
and conveys them up to the edge of the hopper, where they roll onto the
conveyor belt in a horizontal position.
The endless conveyor belt travels along the inside of the hopper frame
between the dnving pulley and the idler pulley. The conveyor belt carries
the cases from the paddle wheel to the feed tube. If the cases are placed
on the conveyor belt by the paddle wheel, head ﬁrst, they will drop directly
into the feed tube; but if they are placed on the conveyor belt, mouth ﬁrst,
they will override the feed tube opening and drop back, head ﬁrst, into the
feed tube opening. The cases ﬂow, head ﬁrst, by gravity into the case
feed unit.
The cases fall by gravity, head ﬁrst, into the feed tube and pass into the
case feed unit, where they rest on top of the feed bars. As the feed bars
move back, the case drops into the feed unit in a vertical position, mouth
up. The feed bars advance the case through a guide channel and make
room for another case.
The transfer ﬁngers convey the cases, single ﬁle along the guide track, one
station at a time, to the holding ﬁngers at the seven different work stations.
At this station, a taper punch moves down, and spreads the mouth of the
case slightly. If there is a short case or no case located at this station, the
indicating system will shut off the powder charging and bullet inserting
stations, and open the trap door located at station 6. If a short case is
detected at station 1, it falls out through a trap door, into a container below
the machine.
When the indicator system on the machine indicates no case, short case,
high or low powder charge, or no bullet, an indicator paddle at the station
where the component is not correct will push a 5/8 ” steel ball to the opposite
side of the indicator worm shaft and the ball will travel under a series of
operating levers, thereby stopping any further operations on that par-
ticular case.
The powder is poured, by hand, from a container into a cardboard funnel
and tube inside of the sheet iron funnel shaped, gravity fed hopper. The
cases are inserted into the powder charging dial by the transfer ﬁngers.
The charging block moves back and the powder valve is ﬁlled with the
correct charge. As the dial indexes, the case stops under the charging block
which moves in to allow the correct charge of powder to drop through the
[38]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Process Sequence
Station 2,
Powder Charge
(Cont.)
Station 3,
Powder Detector
Bullet Overhead
Hopper
Bullet Profile
Disc Hopper
Bullet Tube
and Feed Check
Station 4,
Bullet Inserting
Station 5,
Bullet Seating
Station 6,
Trap Door
Station 7,
Crimping
funnel into the case. As the dial continues to index, it conveys the case
past the inspection gate to the point of exit where the transfer ﬁngers grasp
the case, conveying it to the next station. The correct powder charge is
assured by agitators working from the camshaft directly to the charging
block.
As the case is being conveyed to the powder detector station, the powder
settles in the case. At this station the cylindrical detector punch moves
down, entering the mouth of the case to detect a high, low or correct pow-
der charge. If the powder charge is incorrect, the indicator system will
shut off the bullet feed at station 4 and open the trap door at station 6. If
the charge is correct, the transfer ﬁngers move the case to the next station.
The bullets are gravity fed from a truck or conveyor into the overhead
hopper and flow through a pipe to the proﬁle disc hopper.
The bullets fall to the bottom of the hopper, where they are picked up by a
proﬁle disc set at a 45° angle. The proﬁle notches, on the outer edge of the
disc, convey the bullets to the top of the hopper and into the feed gap by
turning counterclockwise. The bullets then fall through the feed gap into
the coil spring feed tube, base ﬁrst.
As the coil spring feed tube overﬂows, the excess bullets fall through a
chute into a container, where they may be poured back into the hopper
by hand.
The bullets ﬂow by gravity through the coil spring feed tube down to the
feed check. The feed check allows only one bullet at a time to enter the
feed jaws, base ﬁrst.
As the case reaches the bullet insert station, the feed jaws move in, holding
the bullet in alignment between the mouth of the case and the proﬁle
inserting punch.
The proﬁle inserting punch moves down, pressing the bullet into the mouth
and neck of the case. If no bullet is present, the indicator system will
indicate no bullet and the trap door at station 6 will open to let the case
to the next station.
At this station, the concave seating punch moves down, seating the bullet
to the necessary depth. This punch is set to produce the correct over-all
length of the cartridge. The transfer ﬁngers then convey the case to
station 6.
At this station, cases with a high or low powder charge, short cases or cases
with no bullet will drop through the trap door into a container under the
machine. All good cartridges will ﬁnd the trap door closed and pass on to
the next station.
At this station, the crimper head moves down over the bullet and mouth of
the case and crimps the mouth of the case into the cannelure of the bullet.
The inner surface of the die is tapered to insure better sealing qualities.
I39]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Process Sequence

Station 7,
Crimping
(Cont.)
Cartridge
Inverting
Idenﬁﬁcoﬁon
Rock
At the completion of this operation, the case, powder and bullet have been
assembled and the product is known as a cartridge. The transfer ﬁngers
convey the cartridge through a series of four dwells, or “no work” stations,
past the counter and insert it into the inverting wheel by means of inserting
ﬁngers.
The inverting wheel, turning clockwise, conveys the cartridge up to an
inverted position, nose down, where it is pushed into a horizontal revolving
identiﬁcation rack by the transfer ram.
The cartridge hangs, nose down, on the identifying rack. As the rack
indexes, each bullet tip is painted, by the lacquer cup for proper identiﬁca-
tion and then passes over the wiper to eliminate excess lacquer. The suc-
ceeding cartridges force the identiﬁed cartridges to the center of the rack
and after 5% revolutions of the rack, the cartridges are dry.
The cartridge is pushed off the rack by a stationary push-off arm to a chute
and dropped down into a padded container. This container is padded to
prevent possible dents and detonation.
[40]


EINIHDVW E)N|ClVO'l 3Nl-I .lHEDlVH.lS 08' HHGFIVD


RIVHD MOH


Storage T
V Push Off
Bullet Finger
Powder Hopper . or
Storage Hopper l Dlsciarge
l i Over ‘ D
Case Signal Flow 5 FY
Hopper System Hopper
l l J Ident. Rack ___>
. K 5 Tracer Feed Agltate Chg. Feed i 5 .
Tube Hammer _) Blk. Tube i Feed 5 Optmnal .
l_-TsPi_l -——+ PM
i L , T
\ V ,
Feed Chg. H I1I1)SOI;'7da;d Feed ['1 I '
Unit Dial . Check “V”
7 Setthng Wheel
l Sta. 1 Sta. 2 Sta. 3 Sta. 45 Sta. 6 Sta. 7 I
\ \ \ \ \ \ \ ~
Spread
TEE? ~» and —> Dwell -> Pocvgger ~> gg —> -> 13S‘1e1;‘t*t —> 521‘; —> Crimp » Dwell -> Dwell -R Dwell —> Dwell
Detect ' '


l “
L Indicator System Stations J——i I Regis. I
No Case Fed——High or Low Powder Chg. or
No Bullet Fed Will Stop Succeeding Operations
and Operate Trap Door Station 6.


eouenbog sse:>o.|,_.|
[U7]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Product Description

PRODUCT DESCRIPTION
Complete Cartridge
The three component parts of a cartridge, the case, the powder and the
bullet come to the straight line loading machine for assembly.
The case, when received at the loading machine, is complete, as shown in
Fig. 1. The extractor groove has been cut in the case, the primer has been
inserted in the primer pocket and the case has received a 100% inspection
to insure a standard quality of case.
The case dimensions are as follows:
Height of case 2.4793 to 2.4883
Inside diameter of mouth .307 to .3078
The powder used in the manufacture of these cartridges is purchased under
speciﬁcations furnished by the government.
Standard powder charge weights are furnished by the Ballistics Depart-
ment. However, powder varies by volume with the weather and also with
the lot from which it comes. For this reason, after the machine has been
set up with a standard powder charge and the charging block has been
adjusted to hold exactly that particular charge, it may be necessary to
reset the charging block to accommodate another powder charge. This
tendency of the powder to vary in volume necessitates close observation in
the Loading Department and adequate control tests by the Ballistics
Department.
The bullets, when received in the Loading Department, are completely
assembled, as in Fig 2. The -Armor Piercing bullet is composed of four
component parts; a jacket, a lead slug, a steel core, and a base ﬁller cap.
The gilding metal jacket and base ﬁller cap are of 90% copper and 10%
zinc. The lead slug, of 97%% lead and 2%% antimony, is ﬁtted into the
nose of the jacket and acts as a lubricant for the steel core. The steel core
is made from Manganese-Molybdenum steel, ground to speciﬁcations to
insure a perfect ﬁt in the jacket.
The component parts of the Tracer bullet are the jacket, the lead slug, the
tracer powder and the igniter powder. The lead slug is contained in the
nose of the gilding metal jacket; the tracer powder is used in the body,
and the igniter powder in the base of the bullet.
The case mouth is spread, the case receives the correct charge of powder
and the bullet is seated in the case. After the case, powder and bullets
have been assembled, the product is known as a cartridge, see Fig. 3.
The over-all length of the cartridge is 3.301 to 3.3384.
I 42 I
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Inspection

Assembling
of Components
Visual
Inspection
Powder
Inspection
Gage Core
Gages
INSPECTION
The assembling of the components, ease, powder and bullet to make a com-
pleted cartridge on the straight line loading machine must be watched very
closely and the cartridges must be inspected regularly by both the operator
and adjuster. Immediate shut down is imperative whenever the machine
produces defective cartridges.
The cartridges are visually inspected for dents, marks, scratches on case or
bullet, cuts on the bullet, mashed bullet noses, cannelures which extend too
high or are seated too low in the case, and cartridges with too light or no
crimp. At frequent intervals a certain portion of the seated bullets should
be twisted to be sure that they are not loose in the case. Pull tests will be
made at speciﬁed intervals to insure uniform crimping and seating.
The powder detector on the straight line loading machine must be checked
at regular intervals. Powder weights are taken from the machine every
hour and checked against the standards provided by the Ballistics De-
partment.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a cartridge to a gage. A protected location should be used for
storage of gages to prevent their being damaged when not in use.
SNAP LENGTH GAGE
The over-all length of the com-
pleted cartridge is gaged by a
snap length gage, illustrated at
the left. The speciﬁed over-‘all
length of the completed car-
tridge is from 3.301 to 3.3384.


PROFILE GAGE
The proﬁle gage, illustrated at
the right, is used to gage the
alignment of the completed
cartridge. This manual gaging
operation provides a check to
determine whether or not the
case has been damaged in any
way, while the components were
being assembled or loaded.


[43]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Inspection

Gages SINGLE RING
(Cont.) GAGE . . . .
The bullet pomt gage is used at frequent mtervals 1n order
to determine whether the point has been damaged in any
way during the various operations. Speciﬁcations for the
point are as follows: minimum .045 to maximum .050.


The above described inspection methods are those most commonly em-
ployed in Caliber .30 Straight Line Loading. However, other methods may
be developed to maintain the manufacturing standards.
[44]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adjustments
ADJUSTMENTS
Objective To maintain satisfactory production a machine must be adjusted to com-
Cautions
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect the
machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be en-
countered, therefore certain adjustments may be required that have not
been described in this section. A thorough analysis of the trouble will indi-
cate what corrective measures must be taken other than those included in
this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion, or until
the ﬂywheel has stopped.
Inspect the clutch latch rather than the starting button to determine
whether the clutch is disengaged.
Make frequent inspection to determine whether proper and sufficient
lubricant is being pumped to the working tools of the machine.
Adjustments on, or below, the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the adjuster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether all connections
and adjustments are secure.
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments
\-

Case Feed Unit The case feed unit is the mechanism used to push the case from the bottom
of the feed tube into the transfer ﬁngers. The case feed unit is located
between the left end of the machine and station. Adjustment is made by
lengthening or shortening the stroke of the feed bars in the mechanism. It
is necessary to assure proper contact between the case and the transfer
ﬁngers.
Powder
Case Feed
. Dial
Operating
Arm
Agitating
Hammer
Case Feed _
Unit Cover
Adjustment --
Rocker ’
Arm

VIEW OF CASE FEED UNIT ADJUSTMENT
Tool: 1%” wrench.
Procedure: 1. Turn the ﬂywheel until the feed bars are at the end of their forward
stroke.
2. Loosen the lock nut on the operating arm.
3. Turn adjusting nut either forward or backward until the feed bars clear
the guide rail surface approximately V32”.
4. Tighten the lock nut and check the adjustment.
I46]
CALIBER .30 STRAIGHT LINE LOADING MACHINE ‘ Adjustments

Mouth Spread, The short case and no case detector is the tool which contacts the mouth
Short Case and end of each case as it proceeds along the transfer bar. The purpose of this
No Case Detector detector is to actuate a reject mechanism when a short case or a no case is
detected. If this detector does not actuate the reject mechanism when a
short case or no case is passed under this station, the detector should be
adjusted. The detector can be lowered or raised until the contact trigger
will release the indicator paddle on the reject mechanism when a short case
or no case is at the detector station.


../ Cap Screw
Cam Block
/ Indicator Paddle

Cam Finger
H‘ Reset Plate
Cap Screw /'
VIEW OF THE MOUTH SPREAD AND NO CASE DETECTOR STATION
Tools: %” wrench, V16” wrench, 7/8" wrench, screwdriver.
Procedure: 1. Turn the ﬂywheel until the ram is at bottom dead center.
2. Use a V16" wrench to adjust the cam block until the cam ﬁnger kicks the
trigger over.
Tighten the cap screw.
Insert a case in the machine.
Turn the ﬂywheel until the ram is at top dead center.
Use a ‘:?{6" wrench to adjust the reset plate so that the indicator paddle
will not bind on the trigger.
7. Turn the ﬂywheel until the ram is at bottom dead center. Be sure that
the shoulder of the punch rests on the mouth of the case.
8. Use a 7/8" wrench to release the lock nut.
area
[47]
CALIBER .30 STRAIGHT LINE LOADING MAcHINE Adjustments

Charging The charging dial is the assembly that receives the case from the transfer
Dial Alignment ﬁngers and delivers it to a position where the case can be charged. After
the case is charged, the charging dial delivers it to a position where the
transfer bar will pick it up and deliver it to the -next station. The case slots
of the charging dial should be in alignment with the guide rails. Move the
yoke that actuates the charging dial to a position on the transfer bar which
will produce the correct length to the ratchet stroke.
_, Case Slots
cl'I<II'9i"9 Dial Ratchet
3 /A/'- _L‘\ '
f
Pawl
O
l_©I_. 0
Transfer Fingers /
L , ~ -
/ Yoke ' \
Guide Rail


Transfer Bar \ Set Screw
Locking Arm. \\O 1)
Cap Screw Egg; 3 0
Locking Arm MU O
Holding Nut /-/I
DRAWING SHOWING THE CHARGING DIAL ALIGNMENT ADJUSTMENT
Tools: 1%” wrench, 9/16" wrench, screwdriver.
Procedure: 1. Turn the ﬂywheel until the transfer bar is at the end of its left stroke.
2. Hold the locking arm back, and turn the powder dial until the case
slots line up with the guide rails.
3. Use a 9/16” wrench to loosen the two cap screws which hold the yoke
towards the transfer bar. Use a screwdriver to loosen the set screw
on the yoke.
4. Push the yoke towards station 1 until the pawl ﬁts behind the ratchet
tooth.
5. Use a 9/16” wrench to tighten the cap screws which hold the yoke to the
transfer bar. .
6. Use a screwdriver to tighten the set screw ﬁrmly against the yoke.
7. Use an 11/16” wrench to loosen the locking arm holding nut.
8. Set the position of the arm so that it drops into the charging dial
groove when the dial movement is stopped.
9. Use an 1%,” wrench to tighten the lock nut.
10. Turn the ﬂywheel and observe the operation.
[48]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adiustments

Charging Unit The charging unit clutch trip is the mechanism that disengages the charg-
Clutch Trip ing unit clutch when no case or a short case is detected. It is located at
the rear of the machine behind the charging unit. The clutch should auto-
matically keep the charging block unit from operating when no case or a
short case is detected. The operating arm should be set for a .002 to .004
clearance of the conveyor screw, and the clutch lever should be adjusted
until it is in the engaged position.
.--’ Operating Lever


Cap Screw —""’
-—- Powder Block


I Operating Arm
-1?‘
Yoke
Clutch Pins
"-' Collar
' I
VIEW OF THE CHARGING UNIT CLUTCH TRIP ADJUSTMENT
Tool: ‘V16 " wrench.
Turn the ﬂywheel until the operating arm is clear.
Use an 1%" wrench to loosen the cap screw holding the clutch lever.
Raise the operating arm until it clears the conveyor screw worm shaft
approximately .002 to .004.
4. Use an 1%" wrench to tighten the cap screw which holds the clutch
lever.
5. Turn the flywheel until the ball is under the operating arm at top
center.
6. Check to see whether or not the clutch is releasing.
Procedure:
5'-’~".“"!"
[49]
CALIBER .30 STRAIGHT LINE LOADING MACHINE _ Adiustments

Charging The charging block unit is the mechanism that receives the powder charge
Block Unit from the powder hopper and delivers it to the powder funnel over the case.
The movement is actuated by an arm or rod that may be adjusted so that
at the end of its forward stroke the charging block unit is in alignment
with the powder funnel; at the extreme of its backward stroke, the charg-
ing block is in alignment with the powder hopper. To align the charging
block unit properly, loosen the lock nuts on the operating arm and adjust
the operating arm.


Cap Screw
VIEW SHOWING CHARGING BLOCK ADJUSTMENT
Tools: 2732” wrench, adjusting template.
Procedure: 1. Remove the bolts which hold the hopper to the charging block unit
with a 2%” wrench. Raise the hopper clear of the machine with a rope
hoist.
2. Turn the hand wheel to bring the charging block rocker arm to the end
of its backward stroke.
3. Place a template in position in the charging block unit.
I 50 I
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments
~_____—_
Procedure: 4. Loosen the lock nuts on the operating arm with a 2%" wrench.
(cont) 5. Align the rear edge of the valve in the charging block with the rear
edge of the hole in the template by turning the adjusting rod until
proper alignment is attained.
6. Tighten the lock nuts.
7. Turn the hand wheel until the rocker arm of the charging block is at
the end of its forward stroke.
8. Observe whether or not the powder valve is in alignment with the
powder funnel on the charging dial.
Anvil


-— Agitating Hammer
VIEW OF THE CHARGING UNIT
I51]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adiustments

Agitator
Hummer
Powder ,
Hopper
Anvil /
Agituting /.
Hummer


Tools:
Procedure:
The agitator hammer strikes the powder block fourteen times in rapid
succession while the powder valve is receiving powder from the hopper.
The purpose of this agitation is to ﬁll the powder valve evenly and if the
agitator hammer does not strike the powder block ﬁrmly enough to ﬁll
the valve, an adjustment should be made which will increase the tension
on the hammer stroke.


. \\
, \
‘ "7
.".|
* .
VIEW or THE AGITATIN
Lock Nut
3"’ Set Screw


I 0' ‘-I "E
G HAMMER ADJUSTMENT
1%" wrench, %~," wrench, %" wrench, %” wrench.
1.
F*°!°
P‘?
9°.“
Turn the ﬂywheel until the smooth side of the agitating cam is opposite
the hammer pawl.
Use an ll~{6" wrench to loosen the nut on the operating arm stop screw.
Use a 5/16” wrench to set the stop screw to allow the pawl to miss the
smooth part of the ratchet cam.
Tighten the lock nut.
Use a % " wrench to loosen the lock nut on the agitating hammer bear-
ing block stop screw.
Use a %3” wrench to set the bearing block stop screw to allow 564"
clearance between the hammer and the charging block anvil.
Tighten the lock nut.
Operate the machine and observe the operation of the agitating ham-
mer.
I52]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments
Powder The powder valve is the port in the powder charging block which regulates
Valve the charge of powder dropped into the cases. For various reasons, the
capacity of the charging block may have to be changed; i.e., different lots
of powder may require different charges by weight, while atmospheric
conditions may cause powder to vary by volume. The powder should be
agitated lightly with a hammer, as this adjustment is being made.
Agitating
Hammer

VIEW OF THE CHARGE BLOCK
Tools: 2%” wrench, V2" wrench, 1%” wrench.
Procedure: 1. Close the shut-oﬁ valve.
2. Use a 25/32" wrench to loosen the nuts on the hopper clamp bolts and
remove the bolts.
3. Raise the powder hopper with a rope hoist and fasten the rope end.
4. Loosen the two screws on the block cover and remove it.
5. Remove the powder block from the casting and place it on the sur-
face plate.
6. Use a %” wrench to loosen the lock nut on the adjusting screw.
7. Place a correct powder charge in the valve and use a .5--iii” wrench to
turn the set screw on the powder block until the powder is ﬁush with
the top of the block.
8. Tighten the lock nut after the adjustment is made.
9. Replace the powder block in the casting and replace the block cover.
10. Tighten the screws.
l 53 l
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments
Procedure: 11. Lower the hopper to the feed block casting.
(Cont) 12. Replace and tighten the hopper clamp bolts.
13. Replace the powder in the case.
14. Open the shut-off valve.
Note: Steps 3, 4, 5, should be followed in initial setting. They are not
required for minor adjustments while in service.


VIEW OF THE CHARGE BLOCK REMOVED
I54]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments

Powder The powder detector punch, located at station 3 on the ram, enters the
Detector mouth of the case and contacts the powder charge. The detector mechan-
Punch ism is arranged to detect whether there is an undercharge, a correct
charge, or an overcharge in the case. To adjust the punch, raise or lower
it until it allows a correctly charged case to pass, but rejects an overcharged
or undercharged one.


I Connecting Link
7 “‘ Conneciing Pin
If->».— Com Block
re
Com
Fingers
Indicator
Puddle
Trigger
Cop Screw
Reset Plate /
VIEW SHOWING THE POWDER DETECTOR PUNCH ADJUSTMENT
Tools: 7/8" wrench, %” wrench, screwdriver.
Procedure: 1. Turn the ﬂywheel till the ram is at bottom dead center.
2. Insert a correctly charged case in the powder dial.
3. Use a 94%" wrench to adjust the cam block until the cam ﬁnger kicks
the trigger over.
Tighten the cap screw.
Turn the ﬂywheel till the ram is at top dead center.
Use a 911," wrench to adjust the reset plate so that the indicator paddle
will not bind on the trigger.
7. Lower the ram until the bottom of the cam ﬁnger is even with the
top of the trigger lip.
Use a Z/§" wrench to release the lock nut on the punch.
Adjust the punch, either up or down, while the punch is resting on
the powder charge, so that the low charge cam ﬁnger will extend
about 1/-35;" ahead of the high charge cam ﬁnger.
10. Tighten the lock nut. Check the adjustments.
P°.°‘!“
9°90
[55]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adjustments

Buﬂetlnserﬁng
Punch
The bullet inserting punch pushes the bullet from the feed jaws into the
case. The purpose of this punch is to insert the bullet into the case so
that there is a distance of 1/16” between the mouth of the case and the
cannelure of the bullet. If the bullet is being inserted too far or not far
enough, the inserting punch can be raised or lowered in the holder until
the bullet is inserted in the proper distance.


j‘ c.,,. _.,;. ‘ connecting
IE" IT‘ Connécting Pin
Indicator Paddle
' —- Reset Plate
VIEW SHOWING THE BULLET INSERTING PUNCH ADJUSTMENT
TOOIS: %
Procedure: 1.
2.
3.
S-'”P‘!"“‘
’-1'-qd
12.
I-‘F’S°9°.'*1
” wrench, %” wrench, screwdriver.
Turn the ﬂywheel till the ram is at bottom dead center.
Insert a case in the powder dial.
Use a %=," wrench to adjust the cam block until the cam ﬁnger kicks
the trigger over.
Tighten the capscrew.
Turn the ﬂywheel till the ram is at top dead center.
Use a %" wrench to adjust the reset plate so that the indicator paddle
will not bind on the trigger.
Turn the ﬂywheel until the case is under the powder detector punch.
Insert a bullet in the feed jaws.
Turn the ﬂywheel until the bullet is inserted in the mouth of the case.
Use a 7/8” wrench to release the lock nut on the punch.
Raise or lower the inserting punch so that the cannelure on the bullet
is about 1/16” above the mouth of the case and the cam ﬁnger clears
the trigger lip.
Tighten the lock nut in this position and check adjustments.
[56]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adjustments
Bullet Feed Jaws
TOOIS:
Procedure:
The bullet feed jaws convey the bullet from the feed tube to a position
where the inserting punch can insert the bullet into the case. The jaws
must be opened to receive the bullet from the feed tube. An adjustment can
be made on the set screw so that the jaws are opened to receive a bullet each
time they are brought back. An adjustment on the operating arm is made
to align the feed jaws with the feed tube when it is in its receiving position.


2%,)" wrench, 1%,” wrench, his
9°???‘ F‘P°!°!"
10.
11.
Feed
Tube
Feed Jaws
_.-——- Sﬂde
/' Operating Arm
VIEW OF BULLET FEED UNIT
/ PI
wrench, 5/8” wrench, screwdriver.
Turn the ﬂywheel until the feed jaws are under the inserting punch.
Use a 25/3;” wrench to loosen the lock nuts on the operating arm.
Use an 11/16” wrench to release the stop bolt on the back of the feed unit.
Adjust the operating arm until the feed jaws are centered under the
punch.
Use a %” wrench to adjust the stop bolt.
Tighten the lock nut on the stop bolt.
Tighten the lock nuts on the operating arm.
Turn the ﬂywheel until the feed jaws are at the end of their backward
stroke.
Use a %" wrench to release the lock nut on the feed jaw tension ad-
justment.
Use a screwdriver to adjust the jaws so the bullet will enter freely.
Tighten the lock nut.
[57]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments
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DRAWING OF THE BULLET FEED UNIT
[58]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adiusfmenfs

Bullet Feed The cam follower lock of the bullet feed unit is the ratchet-like ﬁnger that
Unit Cam locks the cam follower when the bullet transfer ﬁngers are in the back po-
Follower sition where they receive the bullets. When the detection of a defective
Lock case is made, the steel ball rides on the rear side of the conveyor screw.
The cam follower lock prevents the bullet transfer ﬁngers from delivering
a bullet to the inserting punch until the defective case has passed. If the
cam follower lock does not operate when a detection of a defective case is
made, the operating rod can be adjusted to drop the cam follower far
enough to lock securely.


Tension _______. Operating
Spring / Lever
./ Lock Nuts
Operating
Arm
VIEW OF CAM FOLLOWER LOCK ADJUSTMENT
Tool: %; " wrench.
Procedure: 1. Turn the ﬂywheel until the cam follower rides on the high side of the
cam. Be sure there is no ball under the indicating lever.
2. Use a 9/16" wrench to loosen the lock nut on the operating arm.
3. Turn the adjusting rod until the cam follower lock clears the cam
follower by approximately 1/1/6".
4. Use a 9/f-," wrench to tighten the lock nuts.
I 59 I
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adjustments

Bullet
Seaﬁng
Punch
Bullet Insert _. .
Station \
Powder Detector
Station
TOOIS:
Procedure:
The bullet seating punch presses the bullet down into the case to the
proper depth. The seating depth of the bullet regulates the over-all
length of the cartridges which are being loaded at the machine. This
seating punch can be lowered or raised in the ram, whichever is necessary
to make the cartridge the correct over-all length.


Set Screw
VIEW OF THE BULLET SEATING PUNCH ADJUSTMENT
11/16" wrench, 3 8" wrench.
1.
Place a case with an inserted bullet beneath the seating punch. Turn
the ﬂywheel until the machine is at bottom dead center.
Use an M6" wrench to release the lock nut.
Use a %" wrench to loosen the punch holding screw, thereby allowing
the punch to drop and rest on the bullet.
Use an 11/16” wrench to loosen the lock nut on the adjusting screw.
Use a 3/8” wrench to turn the adjusting screw downward until the
bullet is seated to give the cartridge its proper over-all length.
Tighten the lock nuts.
I 60 I
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments

Trap Door The trap door is the slide that covers the reject tube at station 6. The
purpose of this trap door is to open the case track and allow the rejected
cases to fall into the reject tube, thereby preventing the crimping tool from
acting on a case without a‘ bullet in it. If the trap door does not open far
enough to allow the case to fall into the reject tube, the operating rod can
be lengthened or shortened so that the action of the balls on the rear side
of the conveyor screw will open the mouth of the reject tube sufﬁciently
to allow rejected cases to fall through.


,-—-— Tension Spring
'_— Balance

-'~."~_‘ Lock Nut
Operating
Rod
VIEW OF THE TRAP DOOR ADJUSTMENT
Tool: % " wrench.
Procedure: 1. Turn the ﬂywheel until the ball on the indicator shaft raises the trap
door cam lever to its highest position.
2. Hold the operating rod and use a V2" wrench to loosen the lock nuts.
3. Turn the rod until the trap door is fully open.
4. Tighten the lock nuts. 0
l 61 l
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Ad iustments

Holding Clamps
The holding clamps are the ﬁngers that hold the case securely in a vertical
position at the bullet seating station and at the crimping station. If the
bullet is not being seated in proper alignment with the case or if criss-cross
marks are made on the bullet, the holding clamps are not holding the
cartridge in a vertical position and they will have to be adjusted. This is
accomplished by adjusting the set screws until the cartridge is held in a
vertical position.
Cap Screw
Allen Set
Screw
Allen Set
Screw
=1 ~
B
Tools:
Procedure: 1.


. M _/ Allen Set Screw


VIEW OF THE HOLDING CLAMP ADJUSTMENT
9/16" wrench, 3/16" Allen wrench.
Insert a case in position between the holding clamp and the guide rack
and turn the hand wheel to bring the holding clamps to the end of their
forward stroke.
Use a 9/11;” wrench to loosen the capscrew which holds the clamps in
position.
. Use a 3/1/6" Allen wrench to tighten or loosen the upper and lower ad-
justing screws so that the cases will be held ﬁrmly against the guide
rack.
. Tighten the cap screws.
[62]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments
Crimping The crimping head crimps the mouth of the case into the bullet cannelure.
Head The crimping head located at station 7 should be adjusted so that there is
no excess play between the crimper head and the ram.
Push Rod


/— Spanner Nuts
VIEW OF THE CRIMPING STATION
Tool: Spanner wrench.
Procedure: 1. Release the spanner nuts on the push rod.
2. Adjust the ram up or down to increase or decrease the amount of crimp.
3. Tighten the spanner nuts.
[63]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adiustments

Cartridge
Transfer Ram

TOOIS:
Procedure:
The cartridge transfer ram is the arm that pushes the cartridge from the
inverting wheel into the identiﬁcation rack. This transfer ram must be
adjusted so that its extreme right movement is suﬁicient to push the in-
verted cartridge onto the identiﬁcation rack far enough that, when the
identiﬁcation rack indexes, the cartridge will not jam. The rocker arm can
be adjusted to pivot farther to the right by changing its position on the
actuating rod.
VIEW OF THE TRANSFER RAM ADJUSTMENT
2%" Wrench, %" wrench.
1. Turn the ﬂywheel until the transfer ram is at the extreme of its left
stroke.
2. Use a 2% ” wrench to loosen the rocker arm locking stud on the transfer
ram rocker arm.
3. Move the rocker arm to the left until there is %;" clearance between it
and the safety stop pin.
4. Use a 2142" wrench to tighten the rocker arm locking stud.
I64}
CALIBER .30 STRAIGHT LINE LOADING MACHINE Adjustments

Transfer Ram Tip 1. Use a 5/8" wrench to loosen the lock nut on the transfer ram tip.
2. Turn the tip clockwise or counterclockwise until the tip is 1/8" from the
left side of the inverting wheel.
Note: Always make a complete turn.
Rocker Arm
~/


Cam Follower -,;_\
Barrel Cam / J I _ '.- ’ 5 n ‘W Holding Clamp
REAR VIEW OF THE TRANSFER RAM ADJUSTMENT
[65]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Ad iustments
lnverting Wheel
and Guide Track
Alignment
Lock Nut /-
Operating
Arm ‘
Tools:
Procedure:
The inverting wheel carries the cartridges from the guide track of the
machine to the identiﬁcation rack and at the same time inverts the car-
tridge while it is being carried. The inverting wheel must be in proper align-
ment with the guide track or the transfer bar cannot push the cartridge
from the track onto the inverting wheel. Adjustment on the inverting
wheel can be made by means of a turnbuckle on the operating arm, and by
retiming the eccentric cam which actuates the operating arm.

VIEW OF THE OPERATING ARM
11/is” wrench, 2%" wrench, 5/{I-,” wrench.
1. Turn the ﬂywheel to bring the push rods to top center.
2. Loosen the lock nut on the eccentric cam stud with a 2%” wrench.
3. Drop the operating arm until the inverting wheel ratchet clears the
pawl.
Tighten the lock nut.
Check the position of the inverting wheel alignment by inspecting the
position of the inverting wheel.
Loosen the lock nuts on the operating arm with an 1%” wrench.
Using a 5/16" wrench, lengthen or shorten the operating arm to align
the inverting wheel and the guide rails properly.
9‘?
$9‘
[66]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Ad iustments

Identiﬁcation The identiﬁcation lacquer cup is the small dipper which carries the lacquer
Lacquer Cup up to the bullet in the identiﬁcation rack and deposits the lacquer on
approximately V2" of the tip of the bullet. If the lacquer does not cover
%” on the tip, the lacquer cup must be raised. This adjustment is made
by loosening the holding bolts and raising the arm to which the dipper is
attached.


Cap Screw -""'
Set Screw ---
Tools:
Procedure: 1.
7*?‘


__ Lacquer Cup
VIEW OF THE LACOUER CUP
V2" wrench, screwdriver.
Insert a cartridge in the identiﬁcation rack above the lacquer cup.
Turn the hand wheel to bring the lacquer cup to its highest position.
2. Use a screwdriver to loosen the set screw that holds the cup.
3.
4. Use a %" wrench to loosen the cap screw which holds the cup to the
Set the cup in a level position and tighten the set screws.
slide.
Set the cup in position to lacquer the bullet tip approximately % to V2 ”
from the tip.
Tighten the cap screws.
Operate the machine and observe its operation.
I67]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adjustments

Indicator Worm
Shaft Shear Pin
Replacement
Camshaft
TOOIS:
Procedure:
The shear pin is the safety device which locks the spur gear to the worm
shaft. In the event of a jam in the indicator system, the pin will shear,
thereby preventing damage to the indicator system. When this condition
develops, the pin must be replaced.
a::.'~:'~:
VIEW OF THE FOUR SPUR GEARS
1%" Wrench, %2’' drift punch, hammer.
1. Remove the two oil cups.
2. Use a 1%" wrench to remove the guard.
3. Align the holes in the worm shaft with those in the timing gear.
4. Use a %" drift punch and hammer to remove the broken pin.
5. Install a new shear pin. ‘
6. Replace the guard and oil cups.
Caution: Make sure aligning marks coincide.
[68]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Adjustments
Main Drive Clutch
Procedure:
The main drive clutch is the mechanism through which the power is
transmitted from the motor to the machine. When the clutch begins to
slip and the machine does not operate smoothly, the main drive clutch
should be adjusted to transmit power more evenly.

71." 7 '.,¢.'‘ . -
"i B . . .: ‘ .h_
/~' ~,.
\ AI ‘_. "- ‘
VIEW OF THE MAIN DRIVE CLUTCH
‘III, A -.
..;: A .
1. Release the adjusting pin from the adjustment collar by pulling the
pin out by hand.
2. Turn the adjusting collar clockwise to tighten the clutch or counter-
clockwise to loosen it. Always be sure that the clutch is not adjusted
too tight. Check the adjustment to be sure that the adjusting pin has
seated ﬁrmly in the slot.
[69]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections

Objective
Scratches
on the Case
TROLIBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation
of this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
When making an analysis of the trouble that occurs, always check the
components being fed into the machine before checking for faults on the
machine.
Considerable trouble occurs on this machine because of dirt or loose pow-
der on the track, beneath the charging dial, around the strippers and on
various other parts of the machine. Foreign matter on the track may raise
the case and cause a jam of the machine; powder mixed with oil forms a
gumming substance, which results in sluggish action of moving parts.
Under certain conditions, loose powder will accumulate and possibly
explode.
Because of the above reasons the operator should be cautioned to keep
the machine free of dirt and loose powder. Forced air can be used oc-
casionally to blow the loose powder from the machine.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as it
operates.
Trouble may occur with incorrect powder charge because of atmospheric
conditions or because of achange in the type of powder that is used. To
compensate for atmospheric conditions or a change in powder, it will be
necessary to adjust the charging block to increase or decrease the amount
of powder that enters the case, and it will also be necessary to adjust the
powder detector punch.
Visual inspection reveals scratches on the case.
The cause is: The correction is:
1. In order to eliminate scratching
of the cases, it is necessary to
remove the part of the machine
that has a burr and remove the
burr with ﬁne emery cloth.
1. Scratches on the case are due
to burrs on the holding clamps,
the holding ﬁngers, the transfer
bar ﬁngers or the guide rails.
[70]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections
Scratches
on the Bullet
Scratches in the
Extractor Groove
Visual inspection reveals scratches on the bullet.
The causes are:
1. The holding clamps at the
The corrections are:
1. Adjust the holding clamps so
crimping station do not hold
the cartridge directly beneath
the crimping tool. Criss-cross
marks are produced as the
crimping tool rotates against
the side of the bullet.
. The proﬁle inserting punch is
burred on the inside and causes
burrs on the bullet as it is in-
serted into the case.
. Burrs in the bullet hopper.
. There are burrs in the feed tube
assembly which cause scratches
on the bullet as it passes through
the tubes to the bullet feed
ﬁnger.
The causes are:
1. Burrs on the strippers will cause
scratches in the extractor groove
as the cases are conveyed from
station to station.
that the cartridge sits in a ver-
tical position directly beneath
the crimping tool. Turn on the
power and allow the crimping
tool to be forced to its lowest
position. Loosen the cap screws
on the holding clamp and turn
the adjusting screws on the
holding clamps until the cart-
ridge is held ﬁrmly. Tighten
the cap screw and check the
crimping operation. If the bul-
let is scratched on the side to-
ward the front of the machine,
adjustthebottomholdingclamp
slightly forward. This will tip
the top of the cartridge away
from the side of the crimping
tool. It may be necessary to
readjust several times before
the scratching of the bullet is
eliminated.
. Remove the burr by wrapping
crocus cloth around a pointed
object and turning the crocus
cloth inside the proﬁle inserting
punch.
. Remove the bullets from the
hopper and remove the burrs
from the hopper with ﬁne emery
cloth.
. Remove the burrs from the feed
tube assembly. Wrap a sheet
of ﬁne emery cloth around a rod
and, rotate it inside the feed
tube.
Visual inspection reveals scratches in the extractor groove of the case.
The corrections are:
1. It is necessary to remove the
bolts from the guide rail and
remove the guide rail from the
machine; then remove the burrs
from the stripper with ﬁne em-
ery cloth. Replace the stripper
and the guide rails.
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections

Scratches in the
Extractor Groove
(Cont.)
Crimp Is
Too Low
Crimp Is
Too High
Defective Crimp
Mashed Mouths
2.
The slots in the inverted wheel
are burred or have an accumu-
lation of brass. This will cause
scratches in the extractor groove
as the cartridge passes from the
transfer bar into the inverting
wheel.
2. Remove the slotted sections
from the inverting wheel by re-
moving the screws. Remove
the brass or burrs with ﬁne
emery or crocus cloth.
Visual inspection reveals that the case is being crimped too far down on the
mouth of the case.
The cause is:
1.
The crimping tool is adjusted
too low.
The correction is:
1. Raise the crimping tool by
turning the spanner nuts on the
crimping tool operating rod. It
may be necessary to readjust
several times before accuracy
is attained.
Visual inspection reveals that the crimp is too high on the bullet.
The cause is:
1.
The crimping tool is adjusted
too high. It crimps the bullet
rather than the case.
The correction is:
1. Lower the crimping tool by
turning the spanner nuts on the
crimping tool operating rod. It
may be necessary to test and
readjust the crimping tool sev-
eral times before accuracy is at-
tained.
Visual inspection reveals that the case is not being crimped ﬁrmly around
the cannelured portion of the bullet.
The cause is:
1.
The crimping die is worn and
does not contact the mouth of
the case correctly.
The correction is.
1. Remove the worn die and re-
place with a new or recondi-
tioned one.
Visual inspection reveals that the mouths of the cases are being mashed.
The causes are:
1.
Foreign material on the track
beneath the charging dial raises
the case so that the mouth of
the case remains in the port.
The mouth is mashed as the
charging dial turns.
. The transfer ﬁngers are bent.
The cases are tipped at the
powder detect station. The
powder detect punch hits the
edge of the mouth and mashes
it.
The corrections are:
1. Remove the case that has been
mashed and blow out the for-
eign matter with forced air.
. Remove the mashed case. Re-
move the transfer ﬁngers by
pushing the ﬁngers back and
removing the pin behind the
ﬁngers. Straighten the ﬁnger in
the arbor press. Replace the
ﬁngers. Insert the pin.
[72]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections
Cartridges
Are Bent
Jams at the
Inverting Wheel
Visual inspection reveals that the cartridges are bent.
The cause is:
1.
The holding clamps are not
properly adjusted. They are
not holding the case in a truly
vertical position at the crimp-
ing station. The crimping tool
bends the cartridge at the base
of the bullet during the crim-
ping operation.
The correction is:
1.
Adjust the holding clamps so
that they hold the case in a
truly vertical position beneath
the crimping tool. Loosen the
cap screw on the holding clamps
and turn the adjusting screw
until the cartridge is properly
set. Tighten the capscrew.
Visual inspection reveals a jam of the cartridges at the inverting wheel.
The causes are:
1.
A cartridge becomes wedged in
the opening of the inverting
wheel at the inserting ﬁngers.
This may be due to foreign ma-
terial in the slot or to a bent in-
serting ﬁnger. This jam may
cause the inserting ﬁnger to
break. It may also bend the
guide track and tear off the
stripper.
. The inverting wheel is not prop-
erly adjusted. It is not in posi-
tion to receive the cartridges
from the inserting ﬁnger on the
transfer bar.
. The action of the transfer bar
is not in time with the action of
the inverting wheel. This caus-
es the openings in the inverting
wheel to be in the wrong posi-
tion to receive the cartridges
from the transfer bar inserting
ﬁnger. A jam results when the
inserting ﬁnger attempts to force
the case into the openings in
the inverting wheel.
The corrections are:
1.
[\'.>
Clear the jam by backing up
the transfer bar. It will be
necessary to remove all broken
or defective parts and replace
with new or serviced parts.
. Turn the flywheel till the ram is
at bottom dead center. Re-
lease the lock nut on the end of
the camshaft and turn the ec-
centric until the pawl is behind
the tooth on the ratchet. Tight-
en the lock nut. Align the in-
verting wheel with the guide
rail by either lengthening or
shortening the operating arm at
the turnbuckle.
. Adjust the stroke of the invert-
ing wheel so that the action of
the wheel is in time with the ac-
tion of the transfer bar. Loosen
the nut that connects the in-
verting wheel operating arm
to the eccentric. Change the
position of the arm by moving
it toward or away from the cen-
ter. Tighten the nut. It may
be necessary to change the po-
sition of the arm several times
and check by operating the ma-
chine after each setting until
the correct position is attained.
[73]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections
Jams at
lnverting Wheel
(Cont.)
Cases Are Not
Feeding to
Case Feed Unit
Jam at
Transfer Bar
4. The transfer ram tip is not
properly adjusted. It does not
push the cartridge all the way
into the slot in the identiﬁca-
tion rack. The cartridge be-
comes jammed between the in-
verting wheel and the identiﬁ-
cation rack.
4. Loosen the lock nut on the
transfer ram tip. Turn the tip
out a sufficient amount so that
the cartridge is forced com-
pletely through the opening in
the inverting wheel.
Visual inspection reveals that the cases are not being fed to the case feed
unit.
The causes are:
1.
The belt on the case hopper
paddle wheel is loose. It slips
on the pulley and the paddle
wheel does not carry the cases
to the conveyor belt.
. The hopper is too full and the
paddle wheel stops rotating.
The conveyor belt on the hop-
per is loose. It is not conveying
the cases to the feed tube to be
fed into the magazine.
The corrections are:
1. Remove the belt and remove
the connecting link. Cut off the
small portion of the belt and re-
place the connecting link. Re-
place the belt on the pulleys.
. Remove some of the cases from
the hopper and start the paddle
wheel.
. Tighten the conveyor belt.
Loosen the nut on the conveyor
pulley shaft and move the pul-
ley to the right until the belt is
taut. Tighten the nut on the
shaft.
Visual inspection reveals jams of the cases between the transfer bar and
the feed guide.
The causes are:
1. Powder beneath the case at the
powder detect station tips the
case and causes a jam of the
case as it is moved to the next
station.
. One of the lower transfer bar
ﬁngers of the transfer bar is
bent against the holding ﬁnger.
This causes a jam because the
case becomes wedged between
the transfer bar ﬁngers and the
holding ﬁnger.
The corrections are:
1. Clear the jam and blow the
powder from beneath the trans-
fer bar ﬁngers by using forced
air.
. Clear the jam. It may be nec-
essary to turn the ﬂywheel
counterclockwise to back up
the transfer bar in order to free
the jammed case. Loosen the
capscrew that holds the case
guide and remove the case guide
from the machine. Release the
spring tension on the transfer
bar ﬁnger and lift the pin to re-
lease the ﬁnger from the trans-
fer bar. Straighten the transfer
bar ﬁnger in the arbor press and
put it back onto the transfer
bar. Replace the track guide.
[74]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections

Incorrect Powder
Charge Not
Detected
Low Charge
Bullets Are Not
Being Fed to
Feed Jaws
Gaging reveals that the machine is not rejecting cases of incorrect powder
charge.
The causes are:
1.
The detector punch is not cor-
rectly adjusted. It fails to op-
erate the paddle that pushes
the steel ball to the outside of
the worm conveyor shaft.
The worm conveyor shaft is
dirty. The action of the steel
balls is sluggish. They are not
fed back properly to the inside
of the worm conveyor shaft.
The corrections are:
1. Adjust the detector punch. It
is adjusted as follows: Place a
case which contains the correct
charge at the charging dial.
Turn the hand wheel until the
bottom of the cam ﬁnger on the
detector punch is even with the
top of the trigger lip. Loosen
the lock nut and turn the punch
up or down until the low charge
cam ﬁnger is approximately 1/32 "
ahead of the high charge cam
ﬁnger. Tighten the lock nut.
. Clean the worm conveyor shaft
and the steel balls with a shop
rag and carbon tetrachloride or
some other cleaning ﬂuid.
Visual inspection reveals that the cases are receiving a low powder charge.
The causes are:
1.
The ports on the charging dial
are dirty. Powder sticks in the 9
ports instead of passing freely
to the case.
. The charging block is dirty.
The powder does not fall freely
from the block into the ports.
_ The corrections are:
1. Clean the ports on the charging
dial with a shop rag and carbon
tetrachloride or some other suit-
able cleaning ﬂuid.
. Remove the bolts at the base of
the powder hopper and lift the
hopper from the machine. Re-
move the charging block and
clean thoroughly with a shop
rag and carbon tetrachloride.
Replace the charging block and
replace the hopper.
Visual inspection reveals that the bullets are not‘ being fed to the feed
jaws.
The causes are: The corrections are:
1. Take the belt off of the pulley
by removing the belt connector.
Cut off a small portion of the
belt and connect the ends of the
belt. Place the belt back onto
the pulley.
1. The hopper belt is too loose. It
slips on the hopper pulley.
I75]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections

Bullets Are Not
Being Fed to
Feed Jaws
(Cont.)
Jam at the
Powder Dial
2. Foreign material in the feed
tube stops the flow of the bul-
lets to the feed jaws.
The causes are:
1. The powder dial is out of ad-
justmentand does not line up
with guide rails.
2. The pawl stud has broken loose.
The cases become wedged be-
tween the dial and guide rail.
3. A case becomes jammed be-
neath the charging dial because
of a defective stripper. The
case does not move freely along
the stripper.
2. Remove the feed tubes and re-
move the foreign matter from
inside the tube. Replace the
feed tubes.
Visual inspection reveals that the cases are jammed at the powder dial.
The corrections are:
1. It is necessary to realign the
powder dial with the guide
rails. This is accomplished by
releasing the locking arm and
turning the powder dial until
the case slots are flush with the
guide rail. Then loosen the two
cap screws that hold the yoke
on the transfer bar and move
the yoke toward the left end of
the transfer bar. This will align
the pawl with the ratchet tooth
and give the proper stroke to
powder dial as it indexes. Tight-
en the two capscrews before
turning machine.
. It is necessary to remove the
charging unit on the front of
the machine before the powder
dial can be removed. Take out
the connecting pin from the op-
erating arm and also from the
agitating hammer operating
arm. ' Remove the four cap
screws that hold the charging
unit to the bed of the machine
and set the charging unit on the
ﬂoor. Loosen the two bolts un-
der the machine and remove
the powder dial. Disassemble
the dial and send the pawl unit
to the machine shop. When the
unit is returned, reassemble the
machine.
. Remove the charging unit and
the powder dial as described
above. Disassemble the dial
and remove the defective strip-
per. Replace with a new or
serviced stripper and reassem-
ble the machine.
[76]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Troubles and Corrections
Cases Jam at the Visual inspection reveals that the cases are jamming at the case feed unit.
Case Feed Unit
The causes are: The corrections are:
1. The insert ﬁnger is not properly 1. Turn the flywheel until the
adjusted to feed the cases into feed bars are at the end of their
the transfer bar ﬁngers. Three forward stroke. Release the
cases should remain in the case lock nuts on the operating arm
feed unit and the first of these and adjust until the feed bars
cases should be fed into the clear the feed unit block face
transfer bar ﬁngers. approximately 14/’. Tighten
the lock nuts on the operating
arm in this position.
2. The transfer bar ﬁngers are 2. Remove the transfer bar ﬁn-
bent. The jam occurs as the gers. Push the ﬁnger back and
case is being fed into the trans- release the spring. Remove the
fer bar ﬁngers. pin from behind the ﬁngers and
lift off the top ﬁnger. Remove
the bottom ﬁnger. Straighten
the bent ﬁnger in the arbor
press. Replace the ﬁngers and
insert the pin.
Bullet Seated Gaging reveals that the bullets are being seated too deep into the case.
Too Deep
The causes are: The corrections are:
1. The bullet seating punch is ad- 1. Loosen the lock nut on the seat-
justed so that it pushes the bul- ing punch adjusting screw. Turn
let too far down into the case. the adjusting screw counter-
clockwise to release the pres-
sure on the punch. Loosen the
set screw in the punch holder.
Push the punch up into the
holder against the adjusting
screw. Tighten the set screw
and the lock nut on the ad-
justing screw. It may be neces-
sary to readjust several times
before the proper setting is
attained.
2. Foreign material is sticking to 2. Use a shop towel to clean the
the concave portion of the foreign material from the con-
punch, which results in the bul- cave portion of the punch.
let being forced too far into the
CELSQ.
' [77 l
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Troubles and Corrections
Bullet Is Not
Seated Deep
Enough
Visual inspection or gaging reveals that the bullet is not seated deep
enough into the case.
The cause is: The correction is:
1. Place a cartridge of correct
length beneath the seating
punch. Loosen the set screw in
the punch holder and allow the
punch to drop onto the top of
the bullet. Loosen the lock nut
on the punch adjusting nut and
turn the adjusting nut down in-
to the holder until it contacts
the top of the punch. Tighten
the lock nut on the adjusting
screws and the set screw on the
punch holder.
1. The bullet seating punch is ad-
justed too far up. It does not
force the bullet far enough into
the case.
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Tool Servicing

Objective
Servicing
a New
Punch
TOOL SERVICING
Proper tool servicing is essential to maintain standard quality in assem-
bling the three components to make a completed cartridge. Punches are
costly and great care must be exercised in the servicing of these tools.
While adjusters will not be concerned with tool servicing in the Straight
Line Loading Department, at present, such necessary steps as listed should
be known in event that they may be needed in the future. Adjusters
should be concerned primarily with the removal of small scratches that
appear on the working surfaces of the punches, but they must be careful
when using an abrasive on any tool, not to alter its dimensions materially.
All tools that cannot be corrected by polishing will be returned to the
Tool Department, in exchange for new ones. Under no circumstances will
any attempts be made to straighten bent punches; instead they must be
exchanged for new ones.
Before an abrasive of any kind is applied to a new punch, its dimensions
should be carefully checked with a micrometer or proﬁle gage, and its
working surface should be examined for ﬁnishing, handling marks, or a
lack of polish. A highly polished punch allows better working conditions.

FIG. 1
OVER-ALL VIEW OF SPEED LATHE
[79 l
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Tool Servicing

Servicing
a used
punch
Polishing
Lapping
FIG. 2
CORRECT METHOD OF PLACING PUNCH IN CHUCK
As a punch is used, its working surface wears, accumulating scratches.
Excessive wear is determined by measuring with a micrometer or proﬁle
gage. Obviously, an undersize punch must be replaced with one of ap-
proved dimensions. Scratches, if not too deep, may be removed by polish-
ing. The question of how soon a punch will need polishing can be an-
swered only from experience, since many variable factors enter into the
problem.
Polishing is done with a ﬁne abrasive, for example, crocus cloth. A ﬁnal
operation called draw polishing is done after the chuck is stopped. To
draw-polish a punch, move the abrasive cloth lengthwise over the entire
working surface avoiding rotary motion of the punch or the abrasive.
Continue this ﬁnal operation until all marks are removed and the desired
high polish or mirror like ﬁnish is obtained.
An adjuster will not be required to lap more than .0005 inch from a new
punch. If more than this must be removed to bring the punch to correct
size, it should be returned to the Tool Servicing Department for correc-
tion. Lapping is done with a piece of abrasive cloth wrapped around and
moved back and forth along the axis of the punch as it revolves in the
high speed chuck. If the abrasive were held stationary, deep rings would
be cut into the surface, which would ruin the ﬁnish.
The punch shown in Fig. 2 is correctly chucked. Avoid excessive overhang
of the punch as this is a safety hazard; make sure that the jaws are cor-
rectly set and tightened securely. Do not allow the jaws to grasp the
working surface of the punch.
I801
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Lubrication
Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beaﬂngs
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its hearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding. '
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[81]
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Lubrication
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.*?‘P‘:“?°!°
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.‘qP‘.U‘tI>‘E"°.lQ9
Frequency of lubrication.
I 82 I
CALIBER .30 STRAIGHT LINE LOADING MACHINE
Machine Lubrication
Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
.°°.q.°‘.°‘tP‘9°.l\'>f"
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. I f a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the ﬂoor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
I83]
CALIBER .30 STRAIGHT LINE LOADING MAcHINE Machine Lubrication

LUBRICATION CHART

. . N 0. of Fittings, Frequency of
[lubricant Machine Part Grease Cups, etc. Lubrication Hours
Motor gear head . . . . . . . . Res. 1 wk.
Driveshaft 3 8
Clutch collar 1 8
Clutch . 1 24
Drive gears . 1 1 Wk.
Camshaft . . . . . 3 8
Transfer bar rocker arm cam 1 8
Transfer bar rocker arm roller 1 8
Transfer bar rocker arm pivot bearing 1 8
Transfer bar rocker arm slide bearing 1 8
Transfer bar slide arm (2) 6 8
Connecting rods (5) . . 11 8
Indicating powder throwout assembly 7 8
Bullet insert indicating assembly . 2 8
Holding arm slides (2) 4 8
Case feed unit operating arm 2 8
Case feed unit . . . 6 8
Case hopper countershaft . 2 8
Case hopper drivechain . . 1 1 wk.
MEDIUM OIL Case hopper paddlewheel shaft. . 1 8
. Case hopper conveyor belt drive
(Red Oiler)
gears............ 1 24
Case hopper Conveyor belt drive
shaft . . . . . . . . . 1 8
Case feed check unit operating arm 3 8
Case feed check unit slide bar . 2 8
Rocker arm pivot pins (5) 5 8
Connecting links 10 8
Ram wrist pins (5) 10 8
Ram gibs (10) . . . 8 8
Powder charge operating arm . 1 8
Powder charge rocker arm 2 8
Powder charge agitating hammer
pivot............ 2 8
Powder charge agitating hammer
operating arm . 2 8
Powder dial . . . . . . 1 8
Powder dial yoke and pawl . 2 8
Bullet hopper pin clutch 1 1 wk.
Bullet hopper driveshaft 1 24
Bullet hopper drive gears . 1 24
Bullet hopper proﬁle disc shaft 1 24
Bullet hopper conveyor pulley . 2 24

I84]
CALIBER .30 STRAIGHT LINE LOADING MACHINE Mqghine Lubricqﬁgn
LUBRICATION CHART (Cont.)

I/abricant M achine Part No' of Fittings’ FT(lqU'e./My of
Grease Cups, etc. Lubrzcatzon H ours
Bullet hopper drive belt guide
pulleys . . . . . . . . 4 24
Bullet insert unit operating arm . 2 8
Bullet insert unit rocker arm pivot . 1 8
Bullet insert unit connecting links . 4 8
Bullet insert unit pivot . 2 8
Bullet feed jam pivots . 2 8
Bullet feed check assembly . 2 8
Crimping head. 2 8
Productimeter . . . . 2 1 wk
Crimping unit countershaft . 2 8
Conveyor unit belt guide pulleys 3 8
Identifying unit operating arm 2 8
MI(EII{)e{iU(1)\;[leI(_))IL Inverting wheel rocker arm and paw] 2 8
Inverting wheel shaft bearing . 1 8
Paint cup operating plate gibs . 2 8
Identifying rack bearing 2 8
Identifying rack drive gears . 1 8
Indicating system worm shaft
bearings . . . . . . 3 8
Indicating lever pivots . . . 3 8
Indicating powder throwout assem-
bly operating arm . 2 8
Transfer ram cam . 1 8
Transfer ram follower 1 8
Transfer ram operating shaft 1 8
Transfer ram . 2 8
Timing gear bearings . 2 8


CALIBER .30 STRAIGHT LINE LOADING MACHINE
Index
Adjusting Screw, 35
Adjustment, Agitator Hammer, 52
Bullet Feed Jaws, 57
Bullet Feed Unit Cam Follower
Lock, 59
Bullet Inserting Punch, 56
Bullet Seating Punch, 60
Cartridge Transfer Ram, 64
Case Feed Unit, 46
Charging Block Unit, 50
Charging Dial Alignment, 48
Charging Unit Clutch Trip, 49
Crimping Head, 63
Holding Clamps, 62
Identiﬁcation Lacquer Cup, 67
Indicator Worm Shaft Shear Pin
Replacement, 68
Invertin g Wheel and Guide Track, 66
Main Drive Clutch, 69
Mouth Spread, Short Case and No
Case Detector, 47
Powder Detector Punch, 55
Powder Valve, 58
Transfer Ram Tip, 65
Trap Door, 61
Agitating Hammer, 15
Agitator Hammer Adjustment, 52
Anti-friction Bearings, 81
Barrel Cam, 14
Bullet Feed Jaws Adjustment, 57
Feed Unit Cam Follower Lock
Adjustment, 59
Hopper, 9, 10
Inserting Punch, 37
Inserting Punch, Adjustment, 56
Inserting Tool Holder, 34
Is Not Seated Deep Enough, 78
Overhead Hopper, 39
Seated Too Deep, 77
Seating Punch, 37
Seating Punch Adjustment, 60
Seating Tool Holder, 35
Tube and Feed Check, 39
Bullets Not Being Fed to Feed Jaws, 75
Cam, 18
Finger, 18, 22
Follower Lock Adjustment, 25
Camshaft, 2, 3, 21, 24, 29
Cartridge Inverting, 40
Inverting Wheel, 29
Transfer Ram Adjustment, 64
Cartridges are Bent, 73
Case Feed Unit, 4, 11
Feed Unit Adjustment, 46
Hopper, 5
Overhead Hopper, 38
Paddle Wheel Hopper, 38
Cases Are Not Feeding to Case Feed
Unit, 74
Jam at the Case Feed Unit, 77
Charge Block Removed, 54
Charging Block, 15, 16
Block Unit, Adjustment, 50
Dial Alignment Adjustment, 48
INDEX
Charging Unit, 51
Unit Clutch Trip Adjustment,
49
Clutch, 2
Coil Spring, 32, 33, 34
Conveyor Belt, 5, 38
Shaft, 3
Crimp is Too High, 72
Is Too Low, 72
Crimping Die, 36, 37
Die Housing, 36
Die Tool Holder, 36
Head Adjustment, 63
Defective Crimp, 72
Detector Pin, 32, 33, 34
Die Holder Plate, 36
Driveshaft, 2, 4, 5, 30
Feed Bar, 11
Tube, 5
Tube and Case Feed Unit, 38
Floor Space, 1
Flow Chart, 41
Friction, 81
Gage Care, 43
Gages, 43
Grease, 81
Height, 1
of Case, 42
Hints on Lubrication, 82
Holding Bar, 14
Clamps Adjustment, 62
Hoppers, 1, 3
Identiﬁcation Lacquer Cup
Adjustment, 67
Rack, 30, 40
Identifying System, 4
Incorrect Powder Charge Not
Detected, 75
Indicator System, 38 : -
Worm Shaft Shear Pin Replacement
Adjustment, 68
Inside Diameter of Mouth, 42
Introducing Lubricating Film
Reduces Friction, 81
Inverting Wheel and Guide Track
Alignment Adjustment, 66
Jam at the Powder Dial, 76
At Transfer Bar, 74
Jams at the Inverting Wheel, 73, 74
Lapping, 80
Lock Nut, 35
Low Charge, 75
Lubrication, 81
Chart, 83, 84
Methods, 81
Machine Description, 1
Motor, 1
Main Drive Clutch, Adjustment, 69
Manufacturer, 1
Mashed Mouths, 72
Methods of Getting Lubricant to
Bearing Surface, 82
Mouth Spread and Case Detector
Tool Holder, 32
Mouth Spread and No Case Detector
Punch, 37
Spread, Short Case and No Case
Detector Adjustment, 47
Objective of Tool Servicing, 79
of Troubles and Corrections, 70
Over-all Length of the Cartridge, 42
Paddle Wheel Hopper, 6
Polishing, 80
Powder Charging Dial, 17
Clutch Assembly, 21
Detector Punch, 37
Detector Punch Adjustment, 55
Detector Tool Holder, 33
Hopper, 3, 7
Inspection, 43
Valve Adjustment, 53
Power, 2, 3
Chart, 31
Production, 1
Proﬁle Gage, 43
Punch, 32, 33 34, 35
Ram, 19, 23,21, 26
Rams, 4
Register, 28
Rocker Arm, 11
Scratches in the Extractor
Groove, 71, 72
on the Bullet, 71
on the Case, 70
Selecting a Lubricant for a Given
Bearing, 81
Servicing a New Punch, 79
a Used Punch, 80
Single Ring Gage, 44
Snap Length Gage, 43
Space Ring, 34
Spanner Nut, 36
Spur Gears, 3
Station 1—Mouth Spread and
Case Detector, 38
1—Mouth Spread and Detector,
18, 19
2—Powder Charge, 38, 39
2—Powder Charging, 20, 21
3——Powder Detector, 22, 23, 39
4—Bullet Inserting, 24, 39
5——Bullet Seating, 26, 39
6—Trap Door, 27, 39
7———Crimping, 28, 39, 40
Stripper Plate, 17
Tool Holder Shaft, 32, 33, 34
Tools, 1
Transfer Bar, 4, 11, 12, 20, 28
Bar Fingers, 17
Finger, 22
Fingers, 13, 38
Ram Tip Adjustment, 65
Transmission, 2, 3
Trap Door Adjustment, 61
Visual Inspection, 43
Weight, 1
Worm Conveyor Shaft, 30
Shaft, 3
I86]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Plate Loading
BY
Training Department

Western Cartridge Company
United States Cartridge Company Division
St. Louis Ordnance Plant
St. Louis, Missouri
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch. photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217. Act of March 28,
1940; Public No. 448, 76th Congress, 8rd Session).
II
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description
Bullet and Case Shaking Machines. . . . . . . . . . . . . . . . . . . . . . . . . 2
Charging Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bullet Seating and Crimping Presses . . . . . . . . . . . . . . . . . . . . . . . 11
Identiﬁcation Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tool Holder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjustments
Case and Bullet Shaking Machines. . . . . . . . . . . . . . . . . . . . . . . . 33
Charging Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Powder Detector Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bullet Seating and Crimping Presses . . . . . . . . . . . . . . . . 39
Identiﬁcation Machine . . . . . . . . . . . . . . . . . . . . . . . . . 47
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 58
III
Case Shaking
Machine
1


C\‘°‘ Q'\“9
‘n'\“°
NW’
Inclosed Room Inclosed Room


Bullet Seating Crimping
Machine Machine
4 5


Charge Detector

.\I
Plate Return
Conveyor \


Roller Conveyor
/
Bullet Shaking
Machine
1
Identification
Machine
6
lllllll
llUlllllllll
FLOOR PLAN LAYOUT FOR PLATE LOADING UNIT
AI
CALIBER .30 PLATE LOADING
Catalogue Data
Manufacturer
Machine
Description
Machine
Motor
Type of Feed
Feed Motor
Production
Strokes per
Minute
Tools
Height
Weight
Floor Space
Motor Reducer
Head
Machine
Motor
Motor Reducer
Head
Machine
hdotor
Motor Reducer
Head
Blower Motor
CATALOGUE DATA
E. I. Dupont from Western Cartridge Co. speciﬁ-
cations and design.
4 V-belt drive, motor to ﬂywheel on crankshaft,
crankshaft through connecting rods to ram. Trans-
fer table drive from motor through 4 V-belt
to crankshaft, crankshaft through operating arm
to index mechanism.
3 h.p.; 220—400 volts; 8-phase; 60-cycle; 1775
R.P.M.
Feed table actuated from indexing mechanism.
Transfer table driven from machine motor.
Average 2 plates per minute or 500 cartridges.
Crimping press 21 strokes per plate
Seating press 19 strokes per plate
Piece No.
Seating Punch . . . . . . . . . . . . . . . . . . . . . AA-2
Crimping Collets . . . . . . . . . . . . . . . . . . . AA-1
Over-all, 5 ft.
1500 lbs.
5 ft. x 4 ft.
3 h.p.; 1775 R.P.M.; reduced to output speed of
425.6 revolutions per minute.
SHAKER TABLE MOTOR
1 h.p.; 220-440 volts; 3-phase; 60-cycle; 1750
R.P.M.
1 h.p.; 1750 R.P.M. reduced to output speed of
160 R.P.M.
IDENTIFICATION TABLE
1/4 h.p.; 115 volts; single phase; 60-cycle; 1725
R.P.M.
1/4 h.p.; single phase; gear speed 20 R.P.M.; gear
ratio motor to output speed 86.3.
% h.p.; 115-230 volts; single phase; 60-cycle; 1725
R.P.M.
[ll
CALIBER .30 PLATE LOADING Machine Description
MACHINE DESCRIPTION
Bullet Cr Case Shaking Machine
The Bullet Shaking Machine and the Case Shaking Machine are separate
machines identical in construction and operation. The Bullet Shaking
Machine positions bullets in a bullet plate, and the Case Shaking Machine
positions cases in a case plate. Each machine agitates its plates thereby
permitting the positioning of the component parts in an upright position
in the plates in preparation for their ﬁnal assembly into the completed
cartridge.
Canvas Tube

CALIBER .30 BULLET OR CASE SHAKING MACHINE
[2]
CALIBER .30 PLATE LOADING
Machine Description

Power and
Transmission
V-Belt
Driveshaft

The bullet and case shaking machine, illustrated above, is powered by a
1 h.p. motor through a V-type and a ﬂat type leather belt. The motor
is mounted in the lower frame at the center of the machine. Power is ap-
plied to the motor by a toggle type switch. The two shaker tables are
shaken from side to side, and actuated by an eccentric cam at each end
of the machine. The machine is a double unit driven from a single motor.
;~I
___ Driveshaft
REAR VIEW OF LOWER HALF OF THE MACHINE
The machine is equipped with two driveshafts, one at each end. The
driveshafts are held in a horizontal position by two ﬁtted bearings. A
pulley wheel is mounted at the center of each driveshaft which is con-
nected to the cam operating shaft by ﬂat leather belts. The driveshafts
extend through the rear of the machine frame and are equipped with
V-type pulleys which are connected to the motor by V-type belts.
I3]

CALIBER .30 PLATE LOADING
Machine Description

Cam
Operating Shafts
Cam
Pulley
Motor
The two cam operating shafts are attached, one at each endof the machine
frame. The shafts are held in a horizontal position by brackets which are
bolted to the machine frame. The cam operating pulley is attached to
the back end of the shaft and is connected to the shaker tables by a metal
strap link.
Two pulleys are mounted in the center of the shafts, one is pinned securely
to the shaft while the other is free running. This forms the clutch by which
one unit of the machine may be stopped independently of the other. Each
shaft is equipped with *a hand operated lever which transfers the belts
from one pulley to the other, thus stopping the action of either unit as


desired.

Belt
VIEW OF CLUTCH ASSEMBLY AND CAM

Shaker Table The two shaker tables are actuated from side to side on two steel rods
which run lengthwise of the machine. The two rods extend through, and
are supported by, the endsof the machine frame. The two shaker tables
are supported side by side on the metal rack directly above the bullet bins.
The construction of the machine includes two bullet bins into which the
bullets are fed through a feed chute from an overhead source. The ma-
chine frame forms the side wall of the bins. The bottoms of the bins are
made of sheet metal and are slanted to allow the bullets to ﬂow to the
front of the bins.
l4l

CALIBER .30 PLATE LOADING Machine Description

Shaker Table The bullets are fed into the bins through a feed chute from an overhead
(Cont.) source. '
Two machines of this type are used in this department. One of them seats
the bullets in the plate while the other seats the cases. The two machines
are identical in construction and operation.
Steel Rods
Shaker Table


Canvas
Feed
Tube
Canvas
Feed
Tube
Swﬂch
Case
Pkﬂe
Case
Pkﬂe

.. IQ
FRONT VIEW OF SHAKER PLATE AND SHAKER PLATE RACK
I 5 l
CALIBER .30 PLATE LOADING Machine Description

Charging Machine
The Charging Machine loads the cases with the proper powder charge by
moving the powder hopper back and forth above the mouths of the cases
as the cases are held upright in the case plates.
Powder Hopper
Crankshaft Spur
Gear ~ _- \.
_ Hopper Supporting
Rails
Crank Charging Plate


Hand Lever , _ ..


/
Wooden Table / . A_ - "
:-:- l"-- "r7195 7”’ A I I I . I » l
CALIBER .30 MACHINE CHARGING
Power and The charging machine, illustrated above,-is mounted on a wooden table.
Transmission The machine is manually operated by a crank which moves the powder
hopper back and forth across the charging plate. The crankshaft has a
small spur gear attached to the inner end which meshes with the teeth
on the hopper supporting rails.
I6]
CALIBER .30 PLATE LOADING Machine Description
\

Hopper Supporting
and Guide Rails
Hopper Powder
Depth Micrometer
@-
u
H3. Hﬂtlti
~o
-0
-o
4'
u
»
-
~.
om
-
-
0
Qt
_
Charging Valve

VIEW OF THE POWDER HOPPER AND CHARGING UNIT
Charge Unit The charging plate is made of brass and contains 247 valves which receive
powder from the hopper as it passes over them. The valves are dis-
charged by a lever which aligns the charged valves with the funnels located
directly below. The case plate is held in a horizontal position directly
below the funnels. As the charging plate is aligned with the funnels, the
powder passes from the charged valve through the funnels into the cases.
These units are held in a horizontal position one above the other directly
below the powder hopper. -
CALIBER .30 PLATE LOADING Machine Description

Powder Hopper
Hopper Supporting
Rails
Depth Micrometer Charging Plate
,7 .
-4
-A
-Q
0
0
un-
no
-9
--
so
at
—
0
up
it

VIEW OF THE POWDER HOPPER AND CHARGING PLATE
Powder Hopper The powder hopper is rectangular in shape and is constructed from sheet
brass. The upper end of the hopper is slightly larger than the bottom.
The hopper is ﬁlled with powder from the-upper end. The lower end of the
hopper ﬁts flush against the surface of the charging plate, allowing the
powder to ﬂow from the hopper into the holes of the charging plates.
The hopper supporting rails have machined teeth on the lower surface of
each rail. The two parallel, horizontal rails are supported at each side of
the charging plate by metal stanchions, located at each corner of the plate.
The powder hopper has a metal slide attached to each side which supports
the hopper on the rails. The small spur gears mesh with the teeth of the
rails and drag the hopper back and forth across the charging plate.
l8l
CALIBER .30 PLATE LOADING
Machine Description

Charge Unit
Hand Lever
Powder
Hopper
VIEW SHOWING CHARGE UNIT HAND LEVER
The charge unit hand lever extends forward from the front of the ma-
chine. The hand lever is mounted at its pivotal point by a wrist pin ar-
rangement which allows a freedom of movement from right to left. The
back end of the hand lever is attached to the charging unit by a short
metal link. When the charging unit has been ﬁlled with powder, the hand
lever is pulled forward bringing the charging unit up against the stop
screws thus aligning the holes of the charging unit above the case mouths.
[9]
CALIBER .30 PLATE LOADING Machine Description

Powder
Hopper
S
Hopper Gpeugr
Supportmg
Rail
glharge
Hand ate
Lever
Charge
Unit
Case
Holding
Plate
:19
VIEW SHOWING CASE HOLDING PLATE
Case Holding The case holding plate is inserted beneath the charging plate from the
Plate front side of the machine. When the case holding plate has been properly
positioned, the charging unit is moved diagonally to align the holes of
the charge unit with the case mouths, and to allow the powder to ﬂow
from the charge unit into the cases.
[10]
CALIBER .30 PLATE LOADING Machine Description

Bullet Seating fr Crimping Presses
The Bullet Seating Press seats the bullet to its proper depth in the case,
thus insuring the proper over-all length of the ﬁnished cartridge. A
second Crimping Press equipped with a crimping collet crimps the case
mouth into the bullet cannelure.
The Bullet Seating Press and the Bullet Crimping Press are identical with
the exception of the tools used.
Crimping Tool
' " I / Holders

I


Foot Treaclle .~,'
A
CALIBER .30 CRIMPING PRESS

I 11 l
CALIBER .30 PLATE LOADING
Machine Description

Presses Used in
Loading of Caliber
.30 Cartridges
Power and
Transmission
Ram
There are two presses used in the loading of Caliber .30 cartridges, the
bullet seating press and the crimping press. These two machines are
identical in construction and operation except for the tool used in the ram.
The crimping press uses a series of collets and sleeves which produce the
crimp around the case mouth, securely locking the bullet and case to-
gether. The bullet seating press uses a system of punches which seat the
bullet to the correct depth in the case.
The Crimping Press, designed by Western Cartridge Company and
illustrated on page 11, is powered by a 3 h.p. motor through 4 V-type belts
connecting the motor to the ﬂywheel. The motor is mounted on an ad-
justable bracket at the rear of the machine bed. This bracket allows the
motor to be raised or lowered to give proper tension to the machine belts.
The power to the motor is controlled by a push button type switch.
The ﬂywheel is mounted on the right end of the horizontal crankshaft
and incorporates a rolling key clutch. The clutch is manually operated by
a foot treadle from the front of the machine. The rolling key clutch con-
trols the transmission of power from the ﬂywheel to the crankshaft. The
press is equipped with an automatic mechanism which stops the machine
when the feed plate has reached the end of its travel toward the rear of
the machine. The machine is equipped with a friction type brake which
is synchronized to operate with the clutch. When the clutch is engaged,
the brake is released and vice versa.

FRONT VIEW OF RAM SHOWING SLEEVE TOOL HOLDERS
Crimping Sleeves
The crimping sleeves are held in a straight line across the bottom of the
ram. The collets are held in the collet holding plate and extend through
the collet operating plate. The collet operating bar is attached to the
machine frame and extends across the machine slightly in front of the
ram. As the ram descends, the collet plate strikes against the collet oper-
ating bar forcing the collets up into the collet operating plate. This action
closes the collets around the case mouth producing the necessary crimp.
I121
CALIBER .30 PLATE LOADING
Machine Description

Crankshaft
1
Power and
Transmission
. "7
CALIBER .30 BULLET SEATING PRESS

The Bullet Seating Press, designed by Western Cartridge Company and
illustrated above, is powered by a 3 h.p. motor through 4 V-type belts
connecting the motor to the ﬂywheel. The motor is mounted on an ad-
justable bracket at the rear of the machine bed. This bracket allows the
motor to be raised or lowered to give proper tension to the machine belt.
The power to the motor is controlled by a push button type switch.
[13]
CALIBER .30 PLATE LOADING
Machine Description
Power and
Transmission
(Cont.)
Seating Punches
The ﬂywheel is mounted on the right end of the horizontal crankshaft and
incorporates a rolling key clutch. The clutch is manually operated by a
foot treadle from the front of the machine. The rolling key clutch con-
trols the transmission of power from the ﬂywheel to the crankshaft. The
press is equipped with an automatic mechanism which stops the machine
when the feed plate has reached the end of its travel toward the rear of
the machine. The machine is equipped with a friction type brake which is
synchronized to operate with the clutch. When the clutch is engaged,
the brake is released and vice versa.


Ram
Seating Punches
VIEW OF RAM AND SEATING PUNCHES
The seating punches are held in the punch plate which is held in place
on the bottom surface of the ram by two Allen head set screws. The
punches are slightly smaller in diameter than the holes through which
they ﬁt thus allowing the punches to ﬂoat slightly in the punch plate.
Each punch has a small shoulder which rests against the upper surface of
the punch plate to keep them from dropping through. The punches butt
against the lower surface of the anvil plate as they contact the bullet
noses in the seating process. The anvil plate is held in the lower ram sur-
face in a machined recess whose sides are slightly slanted to conform to
the sides of the anvil plate shouldered section. The punches are raised or
lowered by adjusting the Pitman connecting rods which alters the ram
stroke.
[14]
CALIBER .30 PLATE LOADING Machine Description

Ram
, l Gib
Ram
Seating
Punches
Feed _
Table
’ Table
Gib
Sis
VIEW OF BULLET SEATING FEED TABLE
Feed Table The machine bed is equipped with a feed table into which the case plate
is locked. The feed table has a metal rail at each side which conforms to
the sides of the case plate. The plate is slid into place against a back rail
and locked securely by a latch at the front of the feed table.
The feed table rides back and forth in two V-shaped gibs which are adjust-
able to provide proper guides of the feed table.
Ram --
Crimping Tool ___
Holders
Feed Table ’

VIEW OF THE CRIMPING FEED TABLE
[ 15 I
CALIBER .30 PLATE LOADING Machine Description


Pawl Operating
. Shaft
I
Geared Shaft
VIEW OF THE INDEXING MECHANISM
Indexing A geared shaft is attached to the rear of the feed table and extends
Mechanism back over the rear edge of the machine bed. The plates are manually
placed on the feed table and are fed through the machine to the crimping
collets by means of an indexing mechanism. The geared shaft enters be-
tween two operating pawls which control the indexing movement of the
feed table. The operating pawls are actuated from an eccentric cam wheel
attached to the left end of the crankshaft. An operating arm extends from
the cam to a cross arm which operates the pawl ﬁngers. One pawl located
on the upper side of the gear shaft pushes the shaft one space backward.
As this pawl releases the shaft, the lower pawl engages a tooth on the lower
side of the shaft and holds it in place while the upper pawl returns to en-
gage another tooth.
I16]
CALIBER .30 PLATE LOADING Machine Description


Crankshaft
. I ~
Connecting Rod \ Brake Assembly
M .
Ram Gib u .
Ram
Feed Table
VIEW OF THE BULLET SEATING PRESS SHOWING THE RAM
Ram The ram is actuated through the connecting rods from the crankshaft.
The ram travels in a vertical stroke held in place and guided by gib plates.
The lower surface of the ram is machined to hold the tool plate. The gib
plates are adjustable to provide correct pressure against the ram bearing
surfaces. The two Pitman connecting rods are attached to the ram by
wrist pins. The ram stroke may be lengthened or shortened by adjusting
the Pitman spanner nuts. A secondary plate is attached to the lower sur-
face of the ram which closes the collets around the case mouth to produce
the crimp.
I17]
CALIBER .30 PLATE LOADING Machine Description
Brake and Clutch Brake and Clutch
Assembly Flywheel Assembly
\ I , I

Ram Gib V-Belts
FRONT VIEW OF BRAKE AND REAR VIEW OF BRAKE AND
CLUTCH ASSEMBLY CLUTCH ASSEMBLY
Brake and Clutch The clutch is incorporated in the ﬂywheel and is operated through linkage
from a foot treadle at the front of the machine. The two-shoe brake is
mounted on a bracket between the ﬂywheel and the machine frame.
When the clutch is engaged, the brake is released.
[13]
CALIBER .30 PLATE LOADING Machine Description


Crankshaft /
Ram Gib /
Connecting /
Rods
In 4
"3... ~ ‘
. ,3. .2 !r!‘
I
-.Za'-.-
FRONT VIEW OF BULLET SEATING CRANKSHAFT AND RAMS
Crankshaft The crankshaft is held in a horizontal position above the machine bed.
The crankshaft is supported by, and rotates in, two ﬁtted bearings in the
machine frame. A bearing block is used at the center of the crankshaft
between the crankshaft and the upper machine frame. This block acts .
as a support to the center of the crankshaft.
The cylindrical crankshaft is machined to form two throw bearings. The
ram is connected to, and actuated by, the crankshaft through two Pitman
connecting rods.
The crankshaft extends through the left side of the machine frame and has
an eccentric cam wheel attached.
I191
CALIBER .30 PLATE LOADING
Machine Description

Identification Machine
The Identiﬁcation Machine identiﬁes the Tracer and Armor Piercing
Bullet by applying lacquer (paint) to the tip or nose of each bullet. The
Tracer Bullet is identiﬁed by a red nose, and the Armor Piercing Bullet is
identiﬁed by a black nose.


Driveshcrfgt
CALIBER .30 PLATE LOADING IDENTIFICATION MACHINE
Power and
Transmission
The Plate Loading Identiﬁcation Machine, illustrated above, is powered
by a 1 h.p. motor through an endless chain connecting the motor to the
driveshaft. Power is applied to the motor by a toggle type switch located
on the front side of the machine. Power is applied from the driveshaft
sprocket wheel to the driveshaft by an electrically operated key clutch.
The cartridges are carried through the identifying machine on an endless
conveyor chain driven by the driveshaft over an idler driveshaft at the
opposite end of the machine. The motor is located beneath the conveyor
chains at the left end of the machine. A second % h.p. motor is mounted be-
low the conveyor chains at the center of the machine. This motor operates
an exhaust fan which dries the cartridges as they pass through the machine.
[20]
CALIBER .30 PLATE LOADING
Mochine Description
Guurd Covering
Sprocket Wheel
Solenoid Switch /
Driveshofts
and Clutch


\ Guard Covering
Driveshoﬁ


Ti
’ ‘.6
g 0
.l .1


g.
l I
lea
VIEW OF THE LEFT END OF THE MACHINE


The main driveshaft is held in a horizontal position by two ﬁtted bearings
at the left end of the machine frame. Each end of the driveshaft is equipped
with a sprocket wheel over which the conveyor chains run. The clutch is
actuated by an electric switch attached to the corner of the machine
frame. The clutch mechanism is mounted between the machine frame
and the left chain conveyor sprocket wheel. When the electric button is
pushed, the clutch key is actuated by a solenoid switch which releases the
clutch key, allowing the clutch to engage. The driveshaft makes one
revolution and during that space of time, the clutch key is released by
the solenoid switch and allowed to ride against the driveshaft. As the
driveshaft revolves to its original starting position, the clutch key again
engages the dog on the driveshaft, stopping the driveshaft from turning.
This action is repeated until the plates are broughtthrough the machine.
This procedure allows the operator time to remove the plates and insert
new ones.
The idler driveshaft is held in a horizontal position at the opposite end
of the machine from the main driveshaft. It also is held by, and rotates in,
two ﬁtted bearings. Each end of the idler driveshaft is equipped with a
chain conveyor sprocket wheel.
l21l
CALIBER .30 PLATE LOADING
Machine Description
Exhaust System
Conveyor Chain
Identifying Pan ‘
Identifying Pan

The exhaust fan is mounted at the bottom center of the’ machine and
coupled direct to the exhaust fan motor. Air is drawn through the hoods
of the machine thus exhausting paint fumes and bringing in fresh air
which tends to dry the paint on the identiﬁed cartridges. The entire bed
of the machine with the exception of each end is covered by the hood.
Drying Hood
—- Lever
VIEW SHOWING THE IDENTIFYING PAN AND HOOD
The identifying pan is located at the forward end of the machine at the
open end of the hood. The pan is held between the conveyor chains and is
moved up and down by a hand lever. When the cartridge plates are placed
on the conveyor belts above the pan nose down the lever is pulled for-
ward, raising the pan until the bullet noses are immersed in the identify-
ing lacquer. The identifying pan is raised and lowered by a vertical shaft.
A series of spur teeth is machined along one surface of the shaft near its
lower end. These teeth mesh with the spur teeth of an arm mounted on
one end of a cross-shaft. The cross-shaft is mounted in a horizontal
position below the machine bed and rotates in two ﬁtted bearings. An
arm with an attached weight extends from the center of the cross-shaft
and draws the pan down, after it has been raised by the hand lever. The
hand lever is attached to the end of the cross-shaft and extends upward
in a vertical position to the machine bed along the right side of the ma-
chine frame.
[22]
CALIBER .30 PLATE LOADING Machine Description


l.__ Conveyor
' Chain
Drive
Chain
Motor -" s
VIEW OF MOTOR AND CONVEYOR CHAIN
Chain Conveyor The chain conveyor system is composed of two endless chains which re-
volve around the chain sprockets, actuated by the main driveshaft. The
outside surface of the conveyor chains are equipped with a series of metal
plates into which the cartridge plates fit as they are carried through the
machine.
Conveyor
l_lli‘l
VIEW SHOWING PART or THE convrvon CHAIN
I 23 l
CALIBER .30 PLATE LOADING
Tool Holder Description
TOOL HOLDER DESCRIPTION


Crimping Press
Crimping Collet: The crimping collet is a hollow, cylindrical, steel
shaft. The upper end of the shaft ﬂares outward to form the crimping
collar. The crimping collet is longitudinally split at four evenly
spaced points around the circumference. These splits allow the collet
jaws to close around the case mouth, crimping it securely to the
bullet.
Crimping Tool Plunger: The cylindrical crimping tool plunger is
machined to three diameters. The larger diameter is externally
threaded for insertion into the tool holder clamp nut. The upper end
of the crimping plunger is machined to a diameter small enough for
insertion into the lower end of the crimping collet. The plunger and
collet are held together by a pin inserted in holes machined in the
lower end of the collet and the upper end of the plunger shaft. The
bottom end of the plunger shaft is machined to form a hexagon
headed nut.
Crimping Tool Holder: The cylindrical crimping tool holder is
hollow for the insertion of the collet and plunger shaft. The tool
holder is externally threaded for a distance of one half its over-all
length. The upper end of the tool holder is tapered and machined to
produce a hexagon headed- adjusting nut.
Seating Press: The Seating Press utilizes the Crimping Tool
Plunger and the Crimping Tool Holder described above, but substi-
tutes the Seating Punch, illustrated here, for the Crimping Collet.
Seating Punch: The cylindrical tool steel seating punch is machined _
to three diameters, the largest diameter being at the upper end of the
punch. The smallest diameter of the punch is machined at the lower
end to conform to the point of the bullet nose. The punch is held in
the lower ram by a ﬂat metal plate which is bolted over the heads of
the punch holding them securely- in the ram.
l24l
CALIBER .30 PLATE LOADING
Process Sequence
Case
Overhead Hopper
Case Shaking
Machine and
Transfer Plate
Case Plate and
Holding Plate
Charging Machine
Charge Detector
Bullet
Overhead Hopper
Bullet Shaking
Machine and
Transfer Plate
PROCESS SEQUENCE
Armor Piercing and Ball Cartridges
The cases are fed by gravity from a truck or conveyor into an overhead
hopper and ﬂow down through a pipe past the gate control, into a canvas
tube connected to the end of the feed pipe.
The cases are released from the canvas tube into a container at the base of
the case shaking machine. The transfer plate is placed on the table of the
shaking machine and a rack is placed around it. The cases are taken from
the container and placed by hand on the transfer plate. The plate is agi-
tated and the cases are shaken into the holes in the transfer plate “head
down.” The rack is removed from the transfer plate and the plate is taken
from the shaking machine and placed on a table.
A case plate is placed against the transfer plate and both of the plates are
turned over, allowing the cases to drop into the case plate “mouth down.”
The transfer plate is removed and any of the cases that have dropped
“head down” into the case plate are inverted. A holding plate is placed
across the bottom of the case plate and both of the plates are turned over
and placed onto the roller conveyor. They are pushed along the roller con-
veyor to the charging machine. The case plate and the holding plate are
placed in the machine with the position of the cases “mouth up.”
Propellant powder is contained in the hopper of the charging machine.
The hopper is manually moved across the charging plate, and the holes of
the charging plate are ﬁlled with powder as the hopper is moved from one
end of the plate to the other. The holes of the charging plate are moved -
into line with the mouths of the cases by a manually controlled lever and
the powder drops from the charging plate into the cases. The case plate and
the holding plate are removed from the charging machine and are carried
to the charge detector.
At the charge detector the cases are placed beneath a series of detector
punches. The detector punches are manually lowered until they press
against the powder charge. A high or low charge is detected by the position
of the upper portion of the detector punches as the punches rest against the
powder. The punches are raised and the case plate containing the cases is
removed and placed on a table.
The bullets are fed by gravity from a truck or conveyor into an overhead
hopper and ﬂow down through a pipe past the gate control mto a canvas
tube connected to the end of the feed pipe.
The bullets are released from the canvas tube into a container at the base
of the bullet shaking machine. A transfer plate is placed on the machine
table and a rack is placed around it. The bullets are taken from the con-
tainer and placed on the plate. The plate is agitated and the bullets are
l25l
CALIBER .30 PLATE LOADING
Process Sequence

Bullet Shaking
Machine and
Transfer Plate
(Cont.)
Bullet Plate and
Holding Plate
Assembly of
Bullets and Cases
Bullet
Seating Machine
Crimping Machine
Disposal of Ball
Cartridges
shaken into the holes of the transfer plate “point up.” The rack is removed
from the plate and the excess bullets are allowed to fall back into the
container. The transfer plate is removed from the machine and placed
on a table.
Another transfer plate is placed on the transfer plate that was removed
from the machine and both of the plates are turned over, allowing the
bullets to drop into the second transfer plate “point down.” The ﬁrst
transfer plate is removed and any of the bullets that may have fallen into
the second transfer plate “point up” are inverted.
A bullet plate is placed over the second transfer plate and the holding ‘
plate is placed over the bullet plate. The series of plates is turned over,
allowing the bullets to fall into the bullet plate “base down.” The bullet
plate and the holding plate are carried to a table at which the case plate
containing the charged cases is located.
The bullet plate and holding plate are placed onto the case plate with the
base of the bullets down. The bullet holding plate is removed from beneath
the bullet plate and the base of the bullets is allowed to drop into the
mouth of the cases. The assembly is conveyed over to the seating machine
by a roller conveyor.
The assembly is taken off the conveyor and placed onto the seating ma-
chine table. The table is pushed toward the rear of the machine so that the
row of seating punches is in line with the ﬁrst row of bullets in the bullet
plate. The seating punches descend on the points of the bullets and seat
the ﬁrst row of bullets in the cases. As the punches ascend, the second row
of bullets and cases are mechanically moved in line with the row of seating
punches, and the seating punches descend and seat the second row of
bullets in the cases. This process is repeated until all the bullets have been
properly seated into the cases. The assembly is removed from the seating
machine.
The bullet plate is removed and sent back to be used again, and the case
plate containing the cases with the seated bullets is conveyed on a roller
conveyor to the crimping machine.
The case plate containing cases with the seated bullets is placed on the
crimping machine table. The table is pushed toward the rear of the ma-
chine so that the row of crimping collets are in line with the ﬁrst row of
cartridges. The crimping collets descend over the bullets to the mouth of
the case and crimps cases 1-3-5-7-9-11 & 13 to the cannelure of the bullet
in the ﬁrst row of cartridges. As the crimping tools ascend, the table
moves mechanically to the second row. This brings the crimping tools in
line with the ﬁrst and second rows of cartridges. The crimping tools again
descend and crimp number 2-4-6-8-10 & 12 cartridges in the ﬁrst row and
1-3-5-7-9-11-13 in the second row. This process is continued until the last
row. As the crimping tools descend the last time, number 2-4-6-8-10 & 12
cartridges are crimped.
The case plate containing the cartridges is removed from the machine and
placed on the conveyor. At the end of the conveyor the cartridges are
dropped into a container. The case plate is returned to the case shaking
machine by the roller conveyor.
[26]
CALIBER .30 PLATE LOADING Process Sequence
Identification The Armor Piercing cartridges remain in the plate and the plate is placed
Machine in the identiﬁcation machine so that the cartridges are “point down.” A
pan containing lacquer is raised so that the lacquer is brought up around
the bullet points. The lacquer pan is lowered and the plate containing the
cartridges is mechanically conveyed through the identiﬁcation machine
where the drying of the lacquered points takes place.
A.P. Cartridge At the farther end of the identiﬁcation machine the plate containing the
Disposal cartridges is removed and the cartridges are dropped into a container.
The case holding plate is conveyed back to the bullet shaking machine
by the roller conveyor to be used again.
ONICIVO-I 31V‘Id 08' tI38I'lVD
eouenbeg SS8DOJd
CASES
OVERHEAD HOPPER


IFEED TUBE I
FLOW CHART


BULLET
OVERHEAD HOPPER


I
I CASE PLATE ]e—-
POWDER
CHARGING


POWDER CHARGE
DETECTOR


| FEED RI_I3—E_]

SHAKER I


I BULLET PLATIﬂ


ASSEMBLY OF
BULLETS AND CASES


l SEATEGW


CONTAINER
FOR
BALL CARTRIDGES

I CRIMPING IDENTIFICATIONJ


CONTAINER
FOR
A.P. CARTRIDGES


lszl
CALIBER .30 PLATE LOADING Product Description
__~\
PRODUCT DESCRIPTION
Complete Cartridge
The three component parts of a Caliber .30 Ball and an Armor Piercing
cartridge, the case, the powder, and the bullet come to the Plate Loading
Department for assembly.
The case when received at the Plate Loading Department is complete as
shown in Figure No. 1. The extractor groove has been cut in the case, the
primer has been inserted in the primer pocket and the case has received a
visual inspection to insure a standard quality of the case.
The case dimensions are as follows:
Height of case, 2.4793—2.4883
‘ Inside diameter of the mouth, .3070_.3078
The powder used in the manufacture of these cartridges as shown in
Figure No. 2 is purchased under speciﬁcations furnished by the government.
Standard powder charge weights are furnished by the Ballistics Depart-
ment. However, powder varies by volume with the weather, and also
with the powder lot from which it comes. After the charging machine has
been set up for a standard machine powder charge, it may be necessary
to reset the charging machine to accommodate another powder charge.
This tendency of the powder to vary in volume necessitates close observa-
tion in the Loading Department and adequate control tests by the Ballis-
tics Department.
The bullets, when received in the Plate Loading Department, are com-
pletely assembled, as shown in Figure No. 3. The Armor Piercing bullet
is composed of four component parts; a jacket, a lead slug, a steel core,
and a base ﬁller cap. The gilding metal jacket is of 90% copper and 10%
zinc. The lead slug, of 97 %% lead and 2%% antimony, is ﬁtted into the
nose of the jacket and acts as a lubricant for the steel core. The steel core
is made from manganese-molybdenum steel ground to speciﬁcations to
insure a perfect ﬁt in the jacket. The base ﬁller cap is composed of a gild-
ing metal, 90% copper and 10% zinc. It is formed into a cup shape and
is ﬁtted over the base of the steel core. It is held in place by the base of
the bullet jacket.
The component parts of the Ball bullet are the jacket and the lead core.
The gilding metal jacket is of 90% copper and 10% zinc. The lead core
is made from 97%% lead and 2%% antimony. It is pressed and cut to
speciﬁcations to insure a perfect ﬁt in the jacket.
The case receives the powder charge and the bullet is seated and crimped
into the case. After the case, powder and bullet have been assembled and
crimped, the product is known as a cartridge. See Figure 4.
The over-all length of the cartridge is: 3.301 to 3.3384.
I 29 I

CALIBER .30 PLATE LOADING
Inspection
Assembling
Components
Visual Inspection
Powder Inspection
Goge Core
Gages


INSPECTION
The assembling of the components, case, powder and bullet to make a com-
pleted cartridge on the plate loading machine must be watched very
closely and the cartridge must be inspected regularly by both the operator
and adjuster. Immediate shut-down is imperative whenever the machine
produces defective cartridges.
The cartridges are visually inspected for dents, marks, scratches on case or
bullet, cuts on the bullet, mashed bullet noses, cannelures which extend
too high or are seated too low in the case, and cartridges with too light or
no crimp. At frequent intervals a certain portion of the seated bullets
should be twisted to be sure that they are not loose in the case. Pull tests
will be made at speciﬁed intervals to insure uniform crimping and seating.
The powder detector of the Plate Loading Department must be checked at
regular intervals. Powder weights are taken from the machine every hour
and checked against the standards provided by the Ballistics Department.
Gages are expensive instruments, machined to a ﬁne precision. Improper
use or carelessness in gaging may spring the gage or put a burr on it which
may affect its accuracy. Therefore, force should never be employed in
matching a cartridge to a gage. A protected location should he used for
storage of gages to prevent their damage when not in use.
MICROMETER DEPTH GAGE
If the powder weights are not
.‘ up to standard, the charging
machine is readjusted and
checked with a micrometer
depth gage, illustrated at the
left.
Note: Whenever the charge is
changed, the powder detector
of the Plate Loading Depart-
B ment must also be changed.
SNAP LENGTH GAGE
The over-all length of the com-
pleted cartridge is gaged by a
snap length gage. The speciﬁed
over-all length of the completed
cartridge is from 3.301 to 3.3384. I
[30]
CALIBER T30 PLATE LOADING
Inspection

Gages (Cont.)
Charge Detector
PROFILE GAGE
The proﬁle gage illustrated at
the left is used to gage the
alignment of the completed car-
tridge. This manual gaging op-
eration provides a check to de-
termine whether the case has
been damaged in any way, while
the components were being as-
sembled or loaded.


The charge detector is a manually operated mechanism for inspecting the
powder charge. The case plate containing the charged cases is placed
beneath a series of detector punches which ﬂoat in the punch holding plate.
The punches are lowered into the cases against the powder charge. When
the punch holding plate is brought to its lowest position, the top of the
detector punches should be level with the surface of the punch holder plate
if the powder charge is correct. The punches which are raised above the
level of the plate, indicate a high charge in those respective cases; the
punches which are below the surface of the plate indicate a low charge.


CHARGE DETECTOR
[31]
CALIBER .30 PLATE LOADING
Adjustments
Objective
Cautions
ADJUSTMENTS
To maintain satisfactory production a machine must be adjusted to com-
pensate for the wear of its tools and other working parts, and to meet new
conditions caused by a difference in material. It is necessary to inspect
the machine and components regularly in order that any troubles may be
detected and corrected immediately.
This section of the manual, with its illustrations, photographs, and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence.
It is impossible to predict all of the machine troubles that will be encoun-
tered, therefore certain adjustments may be required that have not been
described in this section. A thorough analysis of the trouble will indicate
what corrective measures must be taken other than those included in this
manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
Adjustments are never to be made while the machine is in motion.
Inspect the clutch latch rather than the starting button to determine
whether or not the clutch is disengaged.
Make frequent inspection to determine whether or not proper and suffi-
cient lubricant is being applied to the working tools of the machine.
Adjustments on or below the ram requires the insertion of a wood block
between the ram and the bedplate to prevent its falling. This block will
avoid damage to the machine tools or injury to the ad juster’s hands,
should the ram fall accidentally.
Examine the machine periodically to determine whether or not all connec-
tions and adjustments are secure.
CALIBER .30 PLATE LOADING Adiusiments
Case 5 Bullet Shaking Machines
Bullet Shaker and The bullet shaker and the case shaker are machines that load the holding
Case Shaker plates. This is the mechanical robot that will load the cases in the holding
plate head down, and the bullets in the bullet plate point up. The amount
of agitation that is developed by the eccentric cam can be increased or
decreased by changing the position of the shaft on the eccentric cam. If
there is too little agitation, the lever should be placed near the outside
circumference; if there is too much agitation, the shaft should be placed
near the center of the cam.
- - Pulleys

VIEW SHOWING CLUTCH AND CAM ASSEMBLY
Tool: 7/8" wrench.
Procedure: 1. Place an empty plate in the machine.
2. Use a %" wrench to loosen the nuts that hold the lever to the eccentric
cam.
3. Move the lever to a place on the eccentric cam that will give the proper
amount of agitation to the plate.
Note: Proper position can only be attained by placing a lot of cases or
bullets on the plate. Operate the machine to see how quickly the plate
will become ﬁlled. The proper position is the one where the plates will
become ﬁlled rapidly.
4. Use a %" wrench to tighten the nuts that hold the lever to the eccentric.
[33]
CALIBER .30 PLATE LOADING
Adjustments
Charging Machine
Charge
Holding Unit


Charging Machine
The charging machine puts the powder charge in the cases. It is designed
to place a charge in 247 cases at one time.
The charge holding unit holds the powder charge until the case holding
plate is placed beneath it. For various reasons the amount of the charge
must be changed. To make this change, adjust the four set screws to
make the charge holding plate thicker or thinner, whichever is necessary.
Lock
— Screws —
ENLARGED VIEW OF A
Case LOCK AND ADJUSTING
“‘ Plate SCREW
SIDE VIEW OF THE CHARGING MACHINE
TOOIS:
Procedure:
%” Allen wrench, screwdriver.
1. Take a few cases that have just been charged from the case holding
plate. Use a weight check to determine whether or not the charge
is too light or too heavy.
2. Use a 5%" Allen wrench to loosen the four lock screws on the charge
holding plate.
_ 3. Use a screwdriver to loosen the four adjusting screws on the charge
holding plate to make the charge lighter. To make the charge heavier,
tighten the four screws.
Note: These screws must be turned an equal amount; this amount can
only be determined by trial and error method. When an adjustment
is made, a few samples of charged cases should be weight checked. If
it is not correct a readjustment must be made until the proper charge
is attained.
4. Use a in, " Allen wrench to tighten the lock screws.


[34]
CALIBER .30 PLATE LOADING Adjustments
Charge The charge holding unit stop screw is the adjustable set screw against
Holding Unit which the charge holding unit is pushed when it is slid into a position
Stop Screw where the powder will drop into the cases in the case holding plate. The
stop screw is adjusted so that the charge holding unit will stop directly
over the mouth of the cases in the case holding plate. This insures com-
plete emptying of the charge into each case.
Charge Plate


\
11/16" Lock Nut
Charge Unit
VIEW SHOWING CHARGE UNIT STOP SCREW
Tools: 1%” wrench, %” wrench.
Procedure: 1. Place the case holding plate in the machine.
2. Use an 1%" wrench to loosen the charge unit stop screw lock nut.
3. Use the hand lever to move the charge holding unit into position where
it delivers the charge to the cases.
4. Use a 1/4" wrench to turn the stop screw until the charge unit can be
stopped in a position where the holes in the charge unit are in line with
the holes in the case holding plate.
5. Use an 1145" wrench to tighten the lock nut.
I 35 I
CALIBER .30 PLATE LOADING
Adjustments

Case Plate
Stop Screw
Tools:
Procedure:
The case plate stop screws are the adjustable set screws which the case
plate contacts when fully inserted into the charging machine. The pur-
pose is to develop a deﬁnite stopping place for the case plate each time it is
inserted into the charging machine.

SIDE VIEW OF THE CHARGING MACHINE
9/16” wrench, 1%" wrench.
1. Place the case plate in the charging machine.
2. Use an 1%” wrench to loosen the lock nut on the adjustable stop
screws.
3. Use a %" wrench to turn the adjustable stop screws until the case
plate is positioned for the charging unit.
4. Use an 1%" wrench to tighten the lock nut.


ENLARGEMENT OF THE
STOP SCREW
I36]
CALIBER .30 PLATE LOADING Adjustments

Powder Hopper The powder hopper contains the powder while it is being carried back and
forth over the charge unit. This hopper has leather edges on the bottom
that contact the charge unit. The ﬁrmness with which these leather
edges contact the charging unit can be controlled by lowering or raising
the four posts that hold the hopper bracket. If the leather edges of the
hopper bind on the charging unit, or if the charging unit is not swept clean
by the leather edges of the hopper, the four posts that hold the hopper
bracket will have to be adjusted.
I Hopper
= 11/4" Lock
Nuts

CHARGING MACHINE

ENLARGEMENT OF THE
POST AND LOCK NUTS
Tool: 11/4 " wrench.
Procedure: 1. Use a 1% ” wrench to loosen the lock nuts on the four posts that hold
the hopper brackets.
2. Use a 11/4 ” wrench to turn the four adjusting nuts on the rods that hold
the hopper bracket until the leather edges of the hopper contact the
surface of the charging unit ﬁrmly enough to sweep the surface clear
of excess powder and yet not ﬁrmly enough to bind.
3. Use a 1%" wrench to tighten the lock nuts.
l 37 l
CALIBER .30 PLATE LOADING
Adjustments

Powder
Detector Unit
Stop
Screw
Tools:
Procedure:
Powder Detector Unit
The powder detector unit is the mechanism that detects whether or not a
case has an undercharge, a correct charge or an overcharge. Whenever a
powder charge is changed, the detector must be changed to accept the new
charge as correct. This is accomplished by adjusting the four stop screws
on the detector plate so that the detector pins are just level with the plate
when detecting cases with the new charge.
1/3" Lock
Nut
Stop
Screw


J)
I 1/2" Lock Pins Indicate PiI-Is Indicate Pins Indicate I/2" Lock Stop
Nut Under Charge Correct Charge Over Charge Nut Screw
CLOSE UP OF THE POWDER DETECTOR UNIT
% " wrench, screwdriver.
1. Place a case plate holder (with cases that have the new charge) under
the detector pins.
Use a 1/Q " wrench to loosen the lock nuts on the four stop screws of the
detector plate. '
Lower the plate into the detecting position.
Use a screwdriver to adjust the stop screws until the pins are ﬂush with
the plate.
Note: Adjust the screws uniformly.
Use a %” wrench to tighten the lock nuts.
I 38 I
CALIBER so PLATE LOADING Adjustments
Bullet Seating 6 Crimping Presses
Bullet Seating Press The bullet seating press is the machine that seats the bullets in the cases.
The adjustments on this machine are identical to those on the bullet
crimping machine, except that the crimping machine has a few extra
adjustments on the crimping tool.
Vertical Gib The gibs are the adjustable track plates on which the ram slides up and
on the Ram down. The purpose of these gibs is to eliminate any unnecessary play in
the ram. If the ram movement is too free and loose, the two adjustable
set screws on each ram should be readjusted until the excess movement
is eliminated.


/ "/16" Lock Nut
I "5-— 5/3" Set Screws
VIEW OF THE RAM GIB
Tools: 5/;” wrench, 1%" wrench, feeler gage, 7/3" wrench.
Procedure: 1. Use an 11/16” wrench to loosen the lock nuts on the gib adjusting set
screws of the ram.
2. Use a %" wrench to loosen the holding studs of each gib on the ram.
3. Use a %" wrench to turn the set screw clockwise until there is a clear-
ance of .002 between the ram and the gib on each side. Check with a
feeler gage.
Note: Turn the set screws uniformly.
Use a 7/8" wrench to tighten the holding studs of each gib.
Use an 11/{6'' wrench to tighten the set screw lock nuts.
Check the adjustment by turning the ﬂywheel by hand until the ram
moves up and down at least one time. Also check the ram movement
for binding in its travel.
99‘?
[39]
CALIBER .30 PLATE LOADING Adiustments
Transfer Table The transfer table movement must be such that the case plate is in align-
Alignment ment with the punches in the ram each time a row of bullets or cartridges
with Tools is moved under the ram. To do this, adjust the turnbuckle on the arm
in Ram that connects the eccentric with the pawl.


Crankshaft /
17/15" Lock Nut
Turnbuckle
17/16” Lock Nut
VIEW SHOWING TRANSFER TABLE ADJUSTMENT
Tool: 1%;," wrench.
Procedure: 1. Place a case plate and bullet plate in the transfer table.
2. Operate the machine manually until the ram is at a position where you
can observe to what extent the second row of bullets are out of align-
ment with the punches.
3. Use a 1'.’-:1/6" wrench to turn the turnbuckle until the transfer table is
moved enough to align the second row of bullets with the punches in
the ram.
Note: If the punches are out of alignment when they enter the bullet
plate, use the turnbuckle adjustment.
4. Use a 1116" wrench to tighten the lock nut.
I 40 I
CALIBER .30 PLATE LOADING Adjustments

Regulate The transfer table movement is actuated by a mechanism which works
Transfer Table from the eccentric on the crankshaft on the ram. The movement of the
Movement transfer table should be in accordance with the distance between the rows
of the openings in the case plate. This is accomplished by placing the
connection on the eccentric at the place where it will develop the desired
amount of movement.
Turn buckle


' 4
_-‘MT
REAR VIEW OF PRESS FRONT VIEW OF PRESS


—-
TOOI: 3/8” wrench.
Procedure: 1. Use a 1% " wrench to loosen the set screws on the eccentric connection.
2. Move the eccentric connection until it will develop enough movement
to the transfer table to move the case plate so that the second row of
holes will assume the same position the ﬁrst row occupied.
3. Use a 9/8" wrench to tighten the set screw on the eccentric.
Note: This is a trial and error adjustment. It must be made, then the
machine must be operated manually to see whether or not it is correct.
It may be necessary to readjust the eccentric connection.
[41]
CALIBER .30 PLATE LOADING Adjustments

Transfer Table The transfer table gibs are the adjustable track plates on which the trans-
Gibs fer table slides back and forth. Their purpose is to adjust the transfer
table so that the case plate, when placed in the transfer table, will be in
alignment with the punches or the crimping tool in the ram. They also
help to eliminate any excess play in the movement of the transfer table.
If the transfer table is out of alignment to the extent that the tools in the
ram do not line up with the case plate, the gib set screws will have to be
readjusted.
Note: The gibs on the ram must be adjusted before this adjustment is
made.
7/8 ‘I
Studs
3/8 If
Rom Set
Screw
Gib
3/ If
Transfer / Sset
Table
Screw
7/8 ‘I
Stud

VIEW SHOWING TRANSFER TABLE AND GIBS
Tools: 7/8” wrench, %” wrench.
Procedure: 1. Use a 7/8" wrench to loosen the holding studs on the transfer table gibs.
2. Place the case plate containing the cases in the transfer table.
3. Turn the ﬂywheel by hand until the ram is near enough to the case
plate to determine what extent the transfer table is out of alignment_
4. Use a % " wrench to turn the adjusting screws on the gibs until the case
plate openings of the ﬁrst row are in alignment with the tools in the ram.
Caution: The set screws on each gib should be turned uniformly. If
necessary, bring the ram down until the tools enter the holes in the
ﬁrst row.
5. When alignment has been attained, the gib should be adjusted so that
there is .002 clearance or enough to allow smooth movement of the
transfer table.
[42]
CALIBER .30 PLATE LOADING Adjustments

Bottom Pawl The bottom pawl is a safety stop for the action of the top pawl. After
Set Screw the action of the top pawl is set, the bottom pawl set screw is adjusted to
hold the pawl approximately 1/16” from the tooth of the ratchet, This
prevents the transfer table from sliding too far each time the top pawl
moves in to a new position.


Geared Shaft —-

11/16" Lock Nut '
3/8" Set Screw /
VIEW OF THE INDEXING MECHANISM
Tools: 1%" wrench, V8" wrench.
Procedure: 1. Operate the machine manually until the top pawl has moved the
transfer table to a new position.
2. Use an 1%” wrench to loosen the bottom pawl set screw lock nut.
3. Use a %" wrench to turn the bottom pawl set screw until the bottom
pawl is placed in a position about M3” from the tooth on the bottom
ratchet.
4. Use an 1%,” wrench to tighten the set screw lock nut.
l 43 l
CALIBER .30 PLATE LOADING Adjustments
Transfer Table The transfer table stop screw is the set screw that is adjusted to hold the
Stop Screw Transfer table in the proper beginning position. This set screw must be
adjusted so that when the ram descends, the tools in the ram are in perfect
alignment with the cartridges in the ﬁrst row of the holding plate.


7/an LOCl( NUT \
1/2" Set Screw --_____
~;"
___'___._,- Geared Shaft
Operating Shaft


VIEW OF THE INDEXING MECHANISM
Tools: 7/8" wrench, 1/2" wrench.
Procedure: 1. Place the case plate and the bullet plate on the conveyor table.
2. Operate the machine manually until the ram has descended to a posi-
tion where you can observe whether or not the ﬁrst row of openings
on the bullet plate are in alignment with the punches in the ram.
3. Use a 7/8" wrench to loosen the stop screw lock nut.
4. Use a 1/2” wrench to turn the stop screws until the ﬁrst row of openings
in the bullet plate are in alignment with the punches in the ram.
Note: To insure perfect alignment, turn the ﬂywheel by hand until
the punches enter the ﬁrst row of openings in the bullet holding plate.
If the punches are out of alignment, adjust the stop screw.
5. Use a 7%” wrench to tighten the lock nut.
[44]
CALIBER .30 PLATE LOADING
Adjustments
Automatic
Clutch Release
Tools:
Procedure:
The automatic clutch release is the mechanism that is tripped when the
transfer table has reached the end of its movement. The clutch release is
actuated by a set screw on the ratchet arm, where it is connected to the
transfer table. This set screw is adjusted so that when the top pawl con-
tacts the last tooth on the ratchet, the transfer table moves ahead. The
set screw contacts the trip lever ﬁrmly enough to trip the clutch, thereby
disengaging it.


/ Geared Shaft
Operating Shaft
VIEW OF THE INDEXING MECHANISM
1%” wrench, %” wrench.
1. Use an 1%” wrench to loosen the clutch lever trip set screw lock nut.
2. Operate the machine manually until the transfer table has been moved
to the last row of cases and the pawl has pushed the last tooth on the
ratchet as far as it will go.
3. Use a 3/8" wrench to turn the clutch lever trip set screw until it con-
tacts the clutch trip ﬁrmly enough to disengage the clutch lever.
4. Use an 1.l'--'{"¢-,” wrench to tighten the lock nut.
[45 l
CALIBER .30 PLATE LOADING Adjustments
Pitman Shims The Pitman connecting rods on the bullet seating press and on the
crimping press are adjustable turnbuckle connections between the ram
and the camshaft. There is a spanner collar on the turnbuckle which acts
as a pressure equalizer between the shims. The purpose of this Pitman
adjustment on the shims is to regulate the depth of the stroke the ram
makes toward the cartridges in the case holding plate. If the bullets are
not being seated in the cases far enough, a shim is placed in each Pitman
of the ram to lower the travel the correct amount. Likewise, if the crimp
is not at the proper place on the case mouth, a shim can be placed in the
Pitman of the ram to lower the depth of the stroke. ,


Crankshaft
Connecting
Rod / - §o:;necting
o
/ \ I '-~. anner
' '-
.' ollar
Spanner _:'~"
Collar _
Ram /
-. IIIIIIIIIII\ll


, 9 ‘
VIEW SHOWING RAM AND CRANKSHAFT
Tool: Spanner pin.
Procedure: 1. Use a spanner pin to turn the spanner collars of the Pitman rods on the
ram counterclockwise in order to loosen the collars enough to place a
shim on the top edge. The thickness of the shim is determined by how
much farther the bullet is to be pushed into the case, or how much the
crimp needs to be lowered.
2. Place the shims in position; use a spanner pin to turn the spanner col-
lars clockwise until they are pressing ﬁrmly against the shims.
[46]
CALIBER .30 PLATE LOADING Adjustments
Identification Machine
Identiﬁcation The identiﬁcation machine places the lacquer on the tip of the bullet.
Machine The pan that delivers the lacquer to the bullets can be moved so that the
nose of the bullet is lacquered about 1/1”.
_ Conveyor Chain
Pan Operatin
Sha t
3/15" Allen . Spanner Collar

VIEW OF THE LACOUER PAN ADJUSTMENT
Tool: %~,” Allen wrench.
Procedure: 1. Use a 3/16” Allen wrench to loosen the set screw on the spanner collar
of the lacquer pan operating rod.
2. Raise or lower the spanner collar to a position where it will allow the
lacquer pan to be raised enough to lacquer the tip of the bullets about
1/4/!I
3. Use a I/K5" Allen wrench to tighten the set screw on the spanner collar.
[47]
CALIBER .30 PLATE LOADING
Troubles and Corrections .
Objective
Bullets Point Down
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation of
these machines. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
When making an analysis of the trouble that occurs, always check the
component being fed into the machine before checking faults on the
machine.
The following troubles can be recognized by visual and gage inspection of
the component, together with constant observation of the machine as it
operates.
Trouble may occur with incorrect powder charge because of atmospheric
conditions or because of a change in the type of powder that is used. To
compensate for atmospheric conditions or a change in powder, it will be
necessary to adjust the charge holding plate to increase or decrease the
amount of powder that enters the case, and it will also be necessary to
adjust the powder detect machine. ‘
BULLET SHAKING MACHINE
Visual inspection reveals that a large percentage of the bullets fall point
down into the holes of the bullet plate.
The cause is:
1. The bullets fall point down because the agitator does not have the
proper stroke.
The corrections are:
1. The stroke of the agitator is corrected by changing the position of the
agitator arm on the eccentric at the end of the driveshaft. Loosen the
nut on the eccentric and move the agitator arm toward or away from
the center of the shaft. The correct position can be determined only by
changing the position and testing the action after each setting until
the desired action is attained.
2. The belt on the agitator shaft is loose. Slipping of the belt causes a
varied stroke of the bullet plate.
3. The belt is tightened by removing the belt and cutting a small portion
from the end of the belt and then connecting the ends of the belt.
[48]
CALIBER .30 PLATE LOADING
Troubles and Corrections
Cases Mouth Down
Cases Jamming
Improper
Powder Charge
Variable
Powder Charge
Visual inspection reveals that a large percentage of the bullets fall mouth
down into the holes of the bullet plate.
The cause is:
1. The cases fall mouth down because the agitator does not have the
proper stroke.
The corrections are:
1. The stroke of the agitator is corrected by changing the position of the
agitator arm on the eccentric at the end of the drive shaft. Loosen the
nut on the eccentric and move the agitator arm toward or away from
the center of the shaft. The correct position can be determined only by
changing the position and testing the action after each setting until the
desired action is attained.
2. The belt on the agitator shaft is loose. Slipping of the belt causes a
varied stroke of the case plate.
3. The belt is tightened by removing it and cutting a small portion from
the end of it and then connecting the ends of the belt.
Visual inspection reveals that the cases are jamming between the center
bar and the plate holder. There is no adjustment that will correct this
condition. It is necessary to remove the jammed case whenever this
occurs.
POWDER CHARGING MACHINE
Inspection reveals that the powder charge is not correct. There is too
much or too little powder contained in the cases.
The cause is:
The charge holding plate is not properly adjusted so that it admits the
correct charge to the cases.
The correction is:
Adjust the charge holding plate. Loosen the four Allen lock screws, two
on each side of the plate and turn the four adjusting screws. The plate
should be raised to increase the charge or lowered to decrease the charge.
Each of the four screws should be turned a like amount in order that the
charge be equal in all of the cases. After the adjustment is made, the Allen
lock screws are tightened.
Inspection reveals that some of the cases are properly charged but some
have an incorrect charge.
The cause is:
1. The charge holding plate is not level; the cases on one side of the plate
are receiving too much powder.
[49]
CALIBER .30 PLATE LOADING
Troubles and Corrections
Variable
Powder Charge
(Cont.)
Bent Cartridges
The corrections are:
1. Adjust the charge holding plate. Loosen the four Allen lock screws
and turn the adjusting screws on the side of the plate where the cases are
receiving the overcharge. Turn those screws to lower the plate so it
will be level. Tighten the Allen lock screws.
2. The holes in the charge holding plate are not in line with the tubes
that lead to the cases. Some of the powder is left at the side of some
of the tubes instead of going down through the tubes.
3. Adjust the charge holding plate in line with the tubes. Push the lever
that actuates the charge holding plate so that it is in position to release
the charge. Loosen the lock nut on the plate adjusting screw. Turn
the adjusting screw until the holes in the plate are in direct line with
the tubes.
BULLET SEATING PRESS
Gaging or visual inspection reveals that the cartridges are bent at the
cannelure of the bullet.
The cause is:
1. The cartridges are bent because the gibs on the plate table are not
correctly adjusted. The bullets are not properly centered beneaththe
seating punches.
The corrections are:
1. Adjust the gibs one in each side of the transfer table, so that the bullets
are centered directly beneath the punches. In order to do this, it is
necessary to remove the Allen screws from the punch holder and re-
move a punch from each end of the ram. Place the alignment punches
in at the ends of the ram. Place a case and bullet in the machine.
Lower the ram until the alignment punches are just above the holes in
the plate. Loosen the bolts that hold the gibs. If the holes in the
plate are to the right of the alignment punches, the gibs must both be
moved to the left. Loosen the gib adjusting screws on the left gib a
fraction of a turn and tighten the adjusting screws on the right gib a
like amount. If the holes in the plate are to the left of the alignment
punches, the procedure is reversed. The gibs are adjusted and read-
justed until the holes in the plate are aligned with the punches. The
plate table must have a free sliding ﬁt after the bolts that hold the gibs
have been tightened. After the proper adjustment has been attained,
replace the alignment punches with the seating punches.
2. The turnbuckle on the transfer table operating rod is not correctly
adjusted. The bullets are not in line with the punches as the plate
travels towards the rear of the machine. Each of the cartridges will
be bent the same amount because each row of cartridges will be out of
line the same degree.
[50]
CALIBER .30 PLATE LOADING
Troubles and Corrections
Bent Cartridges
(Cont.)
Bullets Seated
Too Deep
Bullets
Not Seated
Deep Enough
2. Adjust the turnbuckle on the transfer table operating rod so that the
bullets in the bullet plate are in line with the indented portion of the
seating punches. Before the adjustment is made, a bullet and a case
plate is inserted in place on the machine and the ﬂywheel is turned
until the punches are just -above the bullet points. Loosen the lock
nut and the set screws on the pawl beneath the gear shaft. Loosen the
lock nuts in each side of the turnbuckle on the plate table operating
rod. Turn the turnbuckle until the concave portion of the seating
punches are in line with the bullet points. Tighten the lock nuts
against the turnbuckle. Turn the set screw on the bottom pawl until
the plate table has about %” play. Tighten the lock nut in the set
screw.
3. The operating arm is not correctly located on the eccentric at the end
of the crankshaft. The plate table is not moved the correct amount
with each turn of the crankshaft. This can be detected by observing
the bullets in the bullet plates. If they are not all bent the same
amount, it is probably the adjustment on the eccentric that is not
correct, rather than the turnbuckle adjustment.
4. Adjust the position of the operating arm on the eccentric. Place a
case plate and a bullet plate in the machine. Turn the ﬂywheel until
the ﬁrst row of bullets is seated. Turn the crankshaft and observe
whether the plate table travels too far or not far enough to seat the
next row of bullets properly. Loosen the nut that holds the operating
arm to the eccentric. Turn the set screw and bring the end of the
operating rod toward the center of the shaft to decrease the distance
of the stroke, or toward the end of the eccentric to increase the distance
of the stroke. Tighten the nut that holds the connecting rod to the
eccentric. The adjustment may have to be repeated a number of
times before the correct position of the operating arm on the eccentric
is attained. ‘
Gaging reveals that the bullets are being seated too deep into the case
mouth.
The cause is:
The ram is adjusted so that it carries the punches too far down onto
the bullet points.
The correction is:
Loosen the two spanner nuts on the connecting rod. Remove a shim
from above each spanner nut and tighten the spanner nuts.
Gaging reveals that the bullets are not being seated far enough into the
case mouth. '
The cause is:
The ram is adjusted so that it does not carry the punches far enough
down onto the bullet points.
The correction is:
Loosen the two spanner nuts on the connecting rod. Place a shim
above each of the spanner nuts and tighten the nuts.
I51l
CALIBER .30 PLATE LOADING
Troubles and Corrections

Not All Bullets
Are Correctly
Seated
Scratched
Bullets or
Bent Cartridges
Crimp
Is Too Low
Gaging reveals that the bullets on one side of the plate are seated to the
correct depth but are not seated deep enough on the other side of the
plate.
The cause is:
The punches are not being held level by the connecting rod. The
punches are not forcing the bullets far enough down on one side of the
plate.
The correction is:
Loosen the spanner lock nut on the side of the connecting rod that is
not forcing the punches far enough down. Place a shim above the
spanner nut. Tighten the nut.
CRIMPING PRESS
Visual inspection reveals that the bullets are scratched, or gaging reveals
that the bullet is not in line with the case.
The cause is:
The gibs on the transfer table are not properly adjusted. The bullets
are scratched or the cartridges are bent as the crimping tool comes
down onto the bullet.
The correction is:
Adjust the gibs, one on each side of the transfer table so that the bullets
are centered directly beneath the crimping tools. Place a case plate
_ containing the cases with the bullets beneath the crimping punches.
Lower the ram until the crimping tools are at their lowest point. If
the cases are slanted toward the right from bottom to top, the gibs
must both be moved toward the right. Loosen the bolts that hold the
gibs. Loosen the gib adjusting screws on the right gib. Turn the ad-
justing screws on the left gib until the cases are in an exact vertical
position. Tighten the screws on the right gib until the gibs are snug
against the transfer plate, but not so tight that they prevent the trans-
fer plate from having a free sliding ﬁt. If the cases are slanted toward
the left from bottom to top, the procedure is reversed. Tighten the
nuts that hold the gibs. It may be necessary to readjust several times
before the correct position of the gibs is attained.
Visual inspection reveals that the crimp on the case is below the cannelure.
The cause is:
The ram is being lowered too far down and forces the crimping tool
down past the cannelure of the bullet.
The correction is:
The ram will have to be raised. This is done by loosening the spanner
nuts on the ram and removing a shim from above each of the nuts.
Tighten the spanner nuts. Whenever an adjustment is made on the
ram, the ﬁrmness of the crimp should be examined. The adjustment
of the ram will change the amount that the collet closes on the bullet
case.
[52]
CALIBER .30 PLATE LOADING
Troubles and Corrections

Case Is Not
Sui-Ticiently
Crimped
Visual inspection reveals that the case is not being crimped ﬁrmly around
the bullet.
The cause is:
The crimping tools are not adjusted so that they close 'sufﬁciently on
the case at the cannelure.
The correction is:
Each of the crimping tools can be individually adjusted. Loosen the
Allen screws in the crimping tool holder plate. Turn the nut on top
of the crimping tool slightly to raise the tool. Turn the Crimping
Sleeve clockwise to increase the crimp and counter clockwise to de-
crease the crimp. Tighten the Allen screw. Whenever the crimping
tools are adjusted, the location of the crimp should be checked.
CALIBER .30 PLATE LOADING
_ Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Beoﬁngs
MACHINE LUBRICATION
The efficiency of all machines depends, to a great extent, upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefficiency is friction. Friction as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬁat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable microscopic
hills and valleys. When the jagged hills and valleys of two engaging bear-
ing surfaces come together, their meshing resists the sliding of one over
the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types
of lubrication needed in industry. Lubricating grease is a compound
of petroleum oil and soap.
2. Vegetable oils and animal oils are mixed with petroleum oils for many
applications
8. Graphite-tannin is a mixture used with water, oil, or grease for lubri-
cation. Its use is limited.
4. Graphite powder is used for lubrication on the charging unit.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
I54}
CALIBER .30 PLATE LOADING
Machine Lubrication
Selecting a
Lubricant
for a Given
Beaﬁng
Grease
Graphite
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
Dampness of surroundings.
\"S3°.¢"t‘>‘.°°.l\°l"‘
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speed, an oil is not required to have
the adhesiveness that is needed at low speeds. Instead, it must have high
ﬂuidity in order to ﬂow quickly through the small clearances that are
found in high speed bearings and thereby maintain an adequate lubricating
ﬁlm.
As the load on a shaft or slide increases, the oil used must be correspond-
ingly heavier in body. A heavy oil has low ﬂuidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few well-chosen, good quality lubricants each of which
will answer several different purposes.
The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
Graphite is used in preference to oil or grease on the powder charging unit.
Graphite is a dry lubricant and prevents the powder from sticking to vari-
ous parts of the machine. If oil or grease were used, it would mix with
loose powder and form a gummy substance.
There are many ways of getting the lubricant to the bearing surface. The
method used depends to a great extent upon:
Design of bearing.
Weight or speed of the shaft.
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
Frequency of lubrication.
:Q9>.¢"rl>.°°.l\°!-‘
I55]
CALIBER .30 PLATE LOADING
Machine Lubrication
Methods of
Getting
Lubricant
to Bearing
Surface
Hints on
Lubrication
ﬁ
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
1. Simple oil hole.
Bottle oiler.
. Ring oiler.
. Plain oil cups.
. Wick feed cups.
2
3
4
5. Drop feed cups.
6
7. Mechanical, force feed, central lubricating system.
8
. Splash feed system.
Grease is’ applied to bearing surfaces through several different devices:
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrica-
tion.”
Carry a wiping rag with you when you oil or grease. Wipe the cup or ﬁt-
ting before you open the cup or apply the grease gun. Also wipe the oiler
spout or grease nozzle. Applications of lubricants are necessarily frequent.
If a little dirt is allowed to enter the ﬁtting each time, it can cause a lot
of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the floor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times, except when
the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way into a
grease barrel can easily be forced into a bearing and cause the machine
to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think that
it should be changed, take it up with your supervisor.
I56]
CALIBER .30 PLATE LOADING Machine Lubrication

LUBRICATION CHART


, . N 0. of Fittings, Frequency of
Lubmcam Machzne Part Grease Cups, etc. I/ubrication Hours
CASE SHAKER
LIGHT GREASE Four Driveshafts
Eight Bearings . . . . . . . . . 8 Alemites 4
MEDIUM OIL Two shaker arm eccentrics . . . . 2 Res. 4
GRAPHITE AND
LIGHT GREASE Plate Slide Bars . . .
Bullet Shaker—same as above .
Powdered Graphite
on all moving parts Powder Charging Fixture—All Brass 4
Seating Press
LIGHT OIL Plate table . . . . . . . . . . . 2 O. C. 4
LIGHT OIL Main bearings crankshaft . . . . . 2 O. C. 4
LIGHT GREASE Rod bearings crankshaft . . . . . 2 Alemites 4
LIGHT GREASE Vertical gibs . . . . . . . . . . 2 Alemites 4
LIGHT GREASE Ram wrist pin bearing . . . . . . 2 Alemites 4
LIGHT OIL Turnbuckle driving arm and eccentric 5 Res. 8
Crimping Press
Same as Seating Press, with the excep-
tion that collets and sleeves are
brushed sparingly with light oil—%;”
round brush being used for applying. Approx. 2
Plate Loading—Identiﬁcation Unit
LIGHT OIL Driveshaft for endless chain . . 2 O. C 8
LIGHT OIL Idler shaft for endless chain . 2 O. C 8
LIGHT OIL Lift shaft for lacquer reservoir . . 4 O. C 8


CALIBER .30 PLATE LOADING
Index
A.P. Cartridge Disposal, 27
Adjustment, Automatic Clutch
Release, 45
Bottom Pawl Set Screw, 43
Bullet Shaker and Case Shaker, 33
Case Plate Stop Screw, 26
Charge Holding Unit, 34
Charge Holding Unit Stop Screw,
35
Identiﬁcation Machine, 47
Pitman Shims, 46
Powder Detector Unit, 38
Powder Hopper, 37
Regulate Transfer Table
Movement, 41
Transfer Table Alignment With
Tools in Ram, 40
Transfer Table Gibs, 42
Transfer Table Stop Screw, 44
Vertical Gib on the Ram, 39
Anti-friction Bearings, 54
Anvil Plate, 14
Assembly of Bullets and Cases, 26
Automatic Clutch Release
Adjustment, 45
Bent Cartridges, 50, 51
Blower Motor, 1
Bottom Pawl Set Screw
Adjustment, 43
Brake, 18
and Clutch Assembly, 18
Bullet and Case Shaking Machine, 2
Overhead Hopper, 25
Plate and Holding Plate, 26
Seated Too Deep, 51
Seating and Crimping Presses,
11, 39
Seating Machine, 26
Seating Press, 13, 17, 50
Seating Transfer Table, 15
Shaker and Case Shaker
Adjustment, 33
Shaking Machine, 25, 26, 48
Bullets Not Seated Deep Enough, 51
Point Down, 48
Cam Operating Shafts, 4
Case and Bullet Shaking Machine, 33
Dimensions, 29
Holding Plate, 10
Is Not Sufﬁciently Crimped, 53
Mouth Down, 49
Overhead Hopper, 25
Plate, 25
Plate Stop Screw Adjustment, 36
Shaking Machine, 25
Cases Jamming, 49
INDEX
Charge Detector, 25, 31
Holding Unit Adjustment, 34
Holding Unit Stop Screw
Adjustment, 35
Unit Hand Lever, 9
Charging Machine, 6, 25, 34. 37
Plate, 6, 7, 8
Clutch, 12, 14, 18, 21
Collet Operating Plate, 12
Component Parts, 29
Conveyor Belts, 22
Chain, 23
Crankshaft, 6, 16, 19
Crimp Is Too Low, 52
Crimping Collet, 24
Collets, 12
Machine, 26
Press, 12, 52
Press Lubrication Press, 57
Tool Holder, 24
Tool Plunger, 24
Transfer Table, 15
Disposal of Ball Cartridges, 26
Driveshaft, 3, 20, 21
Drying Hood, 22
Eccentric Cam Wheel, 19
Exhaust System, 22
Feed Motor, 1
Floor Space, 1
Flow Chart, 28
Flywheel, 12, 13, 14, 18
Friction, 54
Gage Care, 30
Gages, 30
Gib Plates, 17
Graphite, 55
Grease, 55
Height, 1
of Case, 29
Hints on Lubrication, 56
Holding Plate, 25
Identiﬁcation Machine, 20, 27, 47
Machine Adjustment, 47
Table, 1
Identifying Pan, 22
Improper Powder Charge, 49
Indexing Mechanism, 16
Inside Diameter of Mouth, 29
Introducing Lubricating Film
‘Reduces Friction, 54
Lubrication, 54
Chart, 57
Methods, 55
Machine Bed, 13
Description, 1
Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 56
Micrometer Depth Gage, 30
Motor, 2, 23
Reducer Head, 1
Not All Bullets Are Correctly
Seated, 52
Object of Troubles and
Corrections, 48
Pawl, 16
Pitman Shims Adjustment, 46
Plate Loading—Identiﬁcation Unit
Lubrication Chart, 57
Loading Machine, 20
Powder Charging Machine, 49
Detector Unit Adjustment, 38
Hopper, 7, 8
Hopper Adjustment, 37
Inspection, 30
Power, 2, 6, 12, 13, 14, 20
Production, 1
Proﬁle Gage, 31
Ram, 14, 17, 19
Regulate Transfer Table Movement,
Adjustment, 41
Scratched Bullets or Bent
Cartridges, 52
Seating Press Lubrication Chart, 57
Punch, 24
Punches, 14
Selecting a Lubricant For a Given
Bearing, 55
Shaker, 2
Table Motor, 1
Tables, 4, 5
Snap Length Gage, 30
Spanner Nuts, 17
Spur Gears, 8
Strokes per Minute, 1
Toggle Type Switch, 2, 20
Tools, 1
Transfer Plate, 25, 26
Table, 15
Table Alignment With Tools in
Ram Adjustment, 40
Table Gibs Adjustment, 42
Table Stop Screw Adjustment, 44
Transmission, 2, 6, 12, 13, 14, 20
Type of Feed, 1
Variable Powder Charge, 49, 50
Vertical Gib on the Ram
Adjustment, 39
Visual Inspection, 30
V-type Pulleys, 3
Weight, 1
I58]
TRAINING MANUAL
for Adjusters of Production Machines for
SMALL ARMS AMMUNITION
Caliber .30
Gage and Weigh
BY
Training Department
Western Cartridge Company
United States Cartridge Company Division

St. Louis Ordnance Plant
St. Louis, Missouri .
December, 1941
United States Government Contract
W-ORD-481, Title II
PREFACE
An original series of training manuals, pertaining to the adjustments of
Caliber .30 and Caliber .50 cartridge manufacturing machines, was developed
from notes and sketches made by Western Cartridge Company personnel
while in training at Frankford Arsenal early in 1941, and later completed
by them while serving as Chief Instructors in the Training Department of
Western Cartridge Company.
All manuals of the original series have been completely revised in order
to eliminate errors and to incorporate changes in machine design. Special
attention and care has been given to standardizing the terminology for the
machines and machine parts used in the manufacture of small arms ammu-
nition. Photographic illustrations have been freely substituted for draw-
ings and sketches of machine parts, tools, and components. Tables of
contents have been generally rearranged, and much important informa-
tion added. Speciﬁcations have been included wherever possible, but they
are as of this date and are subject to change.
All of the manuals contain basic information needed by machine ad-
justers to solve processing problems in which the machine, its tools, and
its products are factors. The manuals were written primarily to serve as
instructional aids and as reference material for adjuster trainees.
This manual, one of the revised series, has been reviewed by a staff of
production advisers who have approved it as being applicable to the
machines speciﬁed under Catalogue Data.
The following law regarding conﬁdential material holds for these
manuals:
“Whoever, being instructed with or having lawful possession or
control of any document, writing, code book, signal book,
sketch, photograph, photographic negative, blueprint, plan,
map, model, note, or information relating to the National De-
fense, through gross negligence permits the same to be removed
from its proper place of custody or delivered to anyone in viola-
tion of his trust or to be lost, stolen, abstracted, or destroyed,
shall be punished by imprisonment for not more than ten years
and may, at the discretion of the court, be ﬁned not more than
$10,000.”
(June 5, 1917, C30, Title 1, Sec. 1; 40 Stat. 217 . Act of March 28,
1940; Public No. 443, 76th Congress, 3rd Session).
II
MANUAL CORRECTlONS—CALIBER .30 GAGE AND WEIGH
LOCATION ERROR CORRECTION
Pages 30, 31 and Head to shoulder length shown incorrectly Arrow should run from the lowest point on
82-Fig the case to a point midway on the
shoulder
Page 5./,—Pr0c
N 0. 8 1/2 the diameter below the test disc hole %” above the test disc hole
TABLE OF CONTENTS
PAGE
Catalogue Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Description .6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gage Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Process Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubles and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
III

CALIBER .30 GAGE AND WEIGH MACHINE
IV
CALIBER .30 GAGE AND WEIGH Catalogue Data

‘ CATALOGUE DATA
Manufacturer Waterbury Farrel Foundry and Machine Co.,
Waterbury, Conn.
Machine Automatic multi-station inspection machine. Belt
Description drive motor to clutch pulley.
Machine Motor Gear head; % h.p.; 3 phase; 60 cycles; 440 volts;
1725 R.P.M.
Type of Feed Manual
Production 57 per minute
Gages Body or proﬁle gage
Height 5 ft. 10 in.
Weight 3000 lbs.
Floor Space 6 ft. 5 in. x 4 ft. 9 in.
CALIBER .30 GAGE AND WEIGH
Machine Description

Feed
Hopper
Safety
Inserting
Finger
Transfer
Bar
Flywheel
Belt
Power and
Transmission
MACHINE DESCRIPTION
Weighing
Platform
Secondary
Bed
Rocker
Arm
Rocker
Arm
Shaft
Reject
Boxes
CALIBER .30 GAGE AND WEIGH MACHINE
The Waterbury Farrel gage and weigh machine, illustrated above, is
powered by a 3/4 h.p. motor through a ﬂat-type belt to the ﬂywheel. The
motor is mounted beneath the left rear corner of the machine frame on a
hinged platform which allows proper adjustment of the belt tension. The
motor is controlled through a push-button type switch.
The ﬂywheel is mounted to the back end of the main driveshaft and in-
corporates a single disc, double face type clutch. The clutch is controlled,
through linkage, from a manually operated clutch lever mounted above
the index dial. The clutch, when disengaged, allows the machine parts to
stop independently of the ﬂywheel and motor. The clutch lever can be
automatically tripped to stop the machine by a clutch lever tripper which
is actuated by the safety inserting ﬁnger when a faulty proﬁle is encoun-
tered.
The brakes employed on this machine are two small constant friction brake
bands, one on the rear end of the indexing dial shaft and one immediately
behind the ﬂywheel. When the clutch is disengaged the machine friction
plus the constant pressure brakes stops all machine action.
[2]
CALIBER .30 GAGE AND WEIGH
Machine Description
Feed Mechanism
Inserting Finger
Indexing Dial
Seating Post
Transfer Table
Transfer Bar
The feed mechanism consists of a triangular hopper mounted above the
feed bar. The cartridges are manually placed into the feed hopper with the
bullet nose pointing toward the indexing dial. The cartridges ﬂow by
gravity to the opening at the end of the inclined feed hopper bottom. The
feed bar channel receives the cartridge and moves forward to position the
cartridge between the indexing dial gage and the inserting ﬁnger. The
inserting ﬁnger moves forward to push the cartridge from the feed bar
channel into the indexing dial.
The inserting ﬁnger is attached to the upper rack. The lower rack is actu-
ated through a rocker arm from a cam on the main driveshaft. The lower
rack actuates the upper rack through a reciprocating fan gear. The insert-
ing ﬁnger has a secondary ﬁnger attached which moves forward with the
inserting ﬁnger to detect a cartridge which might not have been ejected by
the ejecting stem. The inserting ﬁnger moves forward, pushing the car-
tridge from the feed bar channel into the indexing dial.
The indexing dial is mounted on the forward end of a horizontal cross-
shaft. The cross-shaft is held by, and rotates in, a housing which is bolted
to the front side of the machine bed. The indexing dial faces the right side
of the machine and contains six evenly spaced gages at positions near its
outer circumference. The indexing dial is actuated by a Geneva mechan-
ism which is actuated from the main driveshaft.
The seating post consists of a tapered plate which is bolted to the upper
end of the rocker arm from which it is actuated. The rocker arm is bent at
right angles and mounted at the bend of the rocker arm to the machine bed
by a wrist pin arrangement which allows a free swing of the arm. From
the opposite end of the rocker arm a twenty pound weight is suspended
which causes the tapered plate to seat each cartridge ﬁrmly in the gage as
the indexing dial rotates.
The transfer table is mounted on the machine bed and extends from the
indexing dial across the machine bed to the back of the machine. The
transfer table incorporates the gaging stations and the reject stations. As
the cartridges are fed through the transfer table by the transfer bar, they
are held at each station by the holding blocks. The holding blocks are
actuated through linkage to rise as the transfer bar moves the cartridge
from one station to another. As the transfer bar moves back for another
cartridge, the holding blocks descend, holding the cartridges in place at the
various stations.
When a faulty cartridge is indicated, the release gates are allowed to open
and the cartridge falls into a reject box below the machine bed. The good
cartridges pass from the end of the transfer table onto an inclined platform
leading to the beam scale.
The transfer bar is held in position directly above the transfer table. The
transfer bar consists of two rails held apart by a bearing block at each end.
The transfer bar is actuated through linkage from an eccentric cam on the
main driveshaft. The transfer bar rails are notched on the bottom edges to
ﬁt over each case as it is carried from one station to another. The transfer
[3]
CALIBER .30 GAGE AND WEIGH
Machine Description

Transfer Bar (Cont.)
Primary Movement
Secondary
Movement
Main Driveshaft
Driveshaft
Ball Conveyor
Shaft
Upper and Lower
Gear Rack
Eiecting Rod
bar moves the cartridges through the various stations in the transfer table
and out onto the beam scale.
The primary movement bed is mounted in a gib arrangement and extends
from a position slightly in front of the indexing dial to the rear of the
machine bed. The gib arrangement allows the primary movement bed to
move to and from the gaging stations in the transfer table. The primary
movement bed carries the gage rods and stems and is actuated in its back
and forth movement, through linkage, from an eccentric cam on the cam-
shaft.
The secondary movement bed is held in a gib arrangement immediately
behind the primary movement bed. The secondary movement bed carries
the gaging discs and is actuated through linkage from the camshaft.
The main driveshaft is held by, and rotates in, three main bearings in a
horizontal position below the machine bed. The driveshaft extends from
the left to the right of the machine. The flywheel and clutch are mounted
to the driveshaft which extends through the machine frame at the left of
the machine. The driveshaft also incorporates the cam operating the
Geneva mechanism and the eccentric cams operating the various machine
parts.
The driveshaft is held by, and rotates in, three bearings in a horizontal
position below the machine bed. The driveshaft extends along the right
side of the machine. The driveshaft is driven by a 45° spiral gear and
45° mating spiral gear from the driveshaft. The driveshaft consists of ec-
centric cams and sprocket gears which operate the various machine parts.
The ball conveyor shaft is held by, and rotates in, two bearings. The con-
veyor shaft extends along the right edge of the secondary movement bed
and conveys the balls past the various kicker levers. When the gage rods
indicate a faulty cartridge, the kicker lever pushes the ball from the front
edge of the conveyor shaft to the rear edge. As the balls travel down the
rear edge of the conveyor shaft, they actuate the mechanism which opens
the release gates in the transfer table, and the faulty cartridge drops in the
reject box.
The lower rack is mounted in a horizontal track at the left side of the
indexing dial. The rack is actuated by a rocker arm, which is attached
to the machine bed by a wrist pin arrangement which allows a free swing
of the arm. The upper end of the rocker arm is connected to the lower
rack by a short link which absorbs the increased length of the rocker
arm as it passes through the arc of its stroke. Gear teeth are cut on the
inner face of the rack which mesh with the teeth of the reciprocating fan
gear to drive the upper rack. The upper rack is actuated from the lower
rack through the fan gear in a reciprocating motion. The lower rack
carries the ejecting rod and the upper rack carries the inserting ﬁnger.
The ejecting rod is held in a housing which is fastened to the machine
bed at the back side of the indexing dial. The ejecting rod housing aligns
the ejecting rod with the gage holes as the cartridges arrive at the eject-
l4l
CALIBER .30 GAGE AND WEIGH Machine Description

Eiecting Rod (Cont.) ing station. The ejecting rod is mounted to, and actuated by, the lower
rack. The ejecting rod travels forward to eject the cartridge from the
indexing dial onto the transfer table.
Weighing Platform The weighing platform is mounted on a vertical shaft which extends
through the machine bed at the right of the transfer table. The weigh-
ing platform consists of a series of arms which are evenly spaced around
a hub which is mounted rigidly to the upper end of the vertical shaft
and is held by the shaft about one foot above the machine bed. The last
operation of gaging and weighing is completed on the beam scales
which check for light weight cartridges.


__ Feed
Hopper
l __ Fan
l Gear
Weighing
Platform ‘*3
'; ~~'r'r
la
Relecf I .- Clutch
Container _;
if
- Belt
Discharge Table l Back
Plate
Weighing _ Weight
Platform / R
?g;‘;; | . ~_M....
Reject
CALIBER .30 GAGE AND WEIGH MACHINE
[5]
CALIBER .30 GAGE AND WEIGH
Machine Description
Transfer Bar ,
Rocker Arms
Feed Slide Rocker
Feed Mechanism


l -,;;'.'- jg;
"l“
S1 . .
i “ " Feed Bar
4 I,
n~
\-
Arm
FEED MECHANISM
The feed hopper is a triangular shaped box, mounted above the feed bar
with the hypotenuse of the box as the bottom side. The cartridges ﬂow
by gravity down the bottom of the feed hopper to an opening which feeds
them into the channel of the feed bar. The feed bar, actuated by a rocker
arm, moves forward to position the cartridge between the indexing dial
and the inserting ﬁnger. The feed bar rocker arm is attached to the
left front of the machine by a wrist pin arrangement which allows a free
swing of the rocker arm. The rocker arm has a horizontal arm attached
which follows the eccentric cam on the camshaft. The upper end of the
rocker arm is attached to the feed bar.
I6]
CALIBER .30 GAGE AND WEIGH
Machine Description
Feed Bo:
Safety Inserting
Finger
Detecting Finger
Transfer Bar
Inserting Finger

VIEW OF INSERTING FINGER
The inserting ﬁnger is mounted on the forward end of the ﬁnger shaft.
The ﬁnger shaft is mounted on the upper rack, which is actuated by the
reciprocating fan gear. The inserting ﬁnger pushes the cartridge from
the feed bar channel into the indexing dial at the ﬁrst position. The
second or detecting ﬁnger contacts the gage opening immediately follow-
ing the gage at the ﬁrst position. The detecting ﬁnger will automatically
stop the machine if the cartridge is not ejected onto the transfer table.
[7]
CALIBER .30 GAGE AND WEIGH
Machine Description

Ball Conveyor
Bumper
Pad
Eccentric £
Cams
Shaft


The ball conveyor shaft extends along the front edge of the secondary
movement bed. The conveyor shaft has a spiral ﬂuted track machined
around its circumference which conveys the steel balls along the front
of the kicker -levers. When the gage stem and rod indicate a faulty case,
the kicker lever actuated by a kicker rod, transfers the steel ball to the
rear side of the ﬂuted track. As the ball travels along the track, it passes
beneath a bumper pad which opens the release gates, dropping the faulty
case in the reject tube.
Ball
—— Conveyor
Shall
hm
'!'T~.,’.»,f';g,Ir-. aw» ._
F_ ' '_->¢ . . v x
_ Geneva
Mechanism
PARTIAL VIEW OF GENEVA MECHANIsM
[8 I
CALIBER .:-I0 GAGE AND WEIGH Machine Description
:

Index Dial
Inserting Finger
Spur Gear
Detecting Finger -——-
Gage
Transfer Bar
\
. 1"%_
'
VIEW SHOWING INDEXING DIAL
Indexing Dial The indexing dial is mounted on the forward end of the horizontal cross-
shaft. The indexing dial is held on the cross-shaft by a spanner nut.
A spur gear is mounted around the circumference at the rear face of the
dial. The spur gear meshes with a lower spur gear which is held on a
stud shaft in the machine bed. The rear side of the lower spur gear is
equipped with six evenly spaced ﬁngers which are contacted by a specially
designed cam. This cam and a mating spur gear is known as a Geneva
mechanism; it is used to rotate the indexing dial through the six move-
ments. The cartridges are ejected from the indexing dial by the ejecting
rod which pushes the cartridges from the dial onto the transfer table.
[#1
CALIBER .30 GAGE AND WEIGH Machine Description
_ Gage
_v —- Index Dial


Spur Gear
Seating Post
VIEW SHOWING SEATING POST
Seating Post The seating post is held in a vertical position next to the indexing dial
just below the insert position. A tapered plate is bolted to the seating
post between the post and dial. As the dial rotates, pressure is brought
to bear against each cartridge head which ﬁrmly seats the cartridge in
the gage. The seating post rocker arm is bent at a right angle and
mounted to the machine bed by a wrist pin arrangement which allows a
free swing of the seating post. The horizontal end of the rocker arm is
equipped with a twenty pound weight which exerts a pressure against
the cartridge heads.
[10]
CALIBER .30 GAGE AND WEIGH
Machine Description

Transfer Table The transfer table extends from the indexing dial to the back of the
Rocker
Arm
machine bed. The transfer table incorporates the gaging and rejecting
stations. In the length over-all station, the cartridge is pushed against
a solid back plate. At the primer seating depth station the cartridgeis pushed
against a collar by a weighted back plate, which limits the maximum push
of the gage rod against the primer to twelve pounds. The other stations
are provided with spring tension back plates. The primer seating depth
back plate is controlled by a steel cable which extends over the left edge
of the machine bed on a bronze pulley. A twelve pound weight is attached
to the lower end of the steel cable. As the cartridges pass from the trans-
fer table, they are counted by the counter before they drop onto an in-
clined platform, thence to the beam scale.

VIEW SHOWING TRANSFER TABLE AND GAGING STATIONS
I11]
CALIBER .30 GAGE AND WEIGH
Machine Description
Back Plate
Controlling
Mechanism
Transfer Bar

VIEW OF THE BACK PLATE
The transfer bar is held in position by two bearing blocks which fit into
slots at each end of the transfer bar. The lower edge of the transfer bar
rails are notched to ﬁt the cartridges as they are moved from one station
to another.
Two rocker arms are connected by a cross-shaft, the front end of which
is connected to _a vertical rocker arm, held by a wrist pin arrangement
to the front end of the machine frame. This rocker arm forms a right
angle at its pivotal point, and its lower end extends inside the machine
frame to contact an eccentric cam which provides the necessary motive
power to the transfer bar through two rocker arms. The two rocker arms
connected by the cross-shaft hold the bearing blocks on which the transfer
bar rides. These rocker arms are held to the machine bed by a wrist pin
arrangement which allows them to swing freely.
The transfer bar is moved up and down by means of a second vertical
rocker arm which is mounted to the front of the machine frame in the
same manner as the ﬁrst. The second vertical rocker arm has a horizontal
arm attached below its pivotal point which extends into an eccentric cam
on the driveshaft. This cam provides the back and forth motion of the
transfer bar. Actuated by the two rocker arms from the eccentric cams,
the transfer bar travels in a rectangular reciprocating motion which moves
the cartridges from station to station through the transfer table.
[12]
CALIBER .30 GAGE AND WEIGH Machine Description


Index __ ,. ,__ Transfer
Dial . - Bar
Gage "’
__ Primary
Bed
Gage
. . _ ‘ Disc
Gage _ *1 I ._ ' . ‘T . ,- _ " -' 1 ‘ W Y ‘ Holder
. “ . .>,. __ - - ., ‘ , V ,, ‘ . H "M? I ‘A V ,-, $1. .\ _ " M ‘ ' ' Bed y
.-_sp -4-» J I i ' ' Rocker
" Arm
Rocker
Arm
VIEW SHOWING MOVEMENT BEDS
Primary Movement The primary movement bed is actuated back and forth in the gibs which
Bed support it, by means of a rocker arm and cross-shaft. The cross-shaft
extends horizontally across the machine bed at the rear of the primary
movement bed. The cross-shaft is held by, and rocks in, two ﬁtted bear-
ings. The cross-shaft is connected to the primary bed by short strap
links which compensate for the increased length of the rocker arm’s stroke
as it passes through an arc. The rocker arm is attached by its upper
end to the center of the cross-shaft. The lower end of the rocker arm
has a cam roller attached which rides on the face of an eccentric cam on
the camshaft. The primary movement bed carries the gage rods and
stems.
I13]
CALIBER .30 GAGE AND WEIGH
Machine Description
Rocker
Rocker
Amm __
Shaﬂ
Secondary
Movement
Bed

VIEW SHOWING MOVEMENT BEDS
The secondary movement bed is actuated back and forth in the gibs
which support it, by means of a rocker arm and cross-shaft. The cross-
shaft is mounted in a horizontal position along the right of the machine
bed. The cross-shaft is held by, and rocks in, two ﬁtted bearings. The
cross-shaft is connected to the secondary movement bed by short strap
links which compensate for the increased length of the rocker arm’s stroke
as it passes through an arc. The upper end of the rocker arm is attached
to the center of the cross-shaft. The lower end of the rocker arm has a
cam roller attached, which rides against the face of an eccentric cam on
the camshaft. The secondary movement bed carries the gaging discs.
[14]
CALIBER .30 GAGE AND WEIGH Machine Description


‘U
@ 3
Z
Eccentric Cams Cylindrical Barrel Cam
Geneva Cam


I Eccentric Cams
O
O
Sprocket Wheel
Sprocket Wheel

SKETCH SHOWING DRIVE AND CAMSHAFT
Main Driveshaft The main driveshaft consists of the feed mechanism cam, the Geneva
I mechanism cam, the eccentric cam which operates the vertical stroke of
the transfer bar, and the eccentric cam which operates the horizontal
stroke. The driveshaft is belt driven from the motor through a single
disc type clutch. The clutch is manually operated to start and stop the
machine. The driveshaft is held by three bearings in a horizontal posi-
tion below the machine bed. The driveshaft extends from the left of
the machine to the right.
[15]
CALIBER .30 GAGE AND WEIGH Machine Description
Driveshaft The driveshaft is held in a horizontal position below the right edge of
the machine frame. The driveshaft consists of three eccentric cams
which operate the primary and secondary movement beds, and the hold-
ing block over the transfer bar. A sprocket gear is attached at a point
near the right end of the camshaft. The ball conveyor shaft is chain
driven from this sprocket. The driven shaft is driven through 45° spiral
gears from the driveshaft. A sprocket gear is also attached at the right
end of the driven shaft, that through another sprocket gear and a chain
drives a set of bevel gears that drive the beam scale.


_ Gage
Primary__ Rod
Bed
Secondary g_ ‘~‘ -
Bed :'- r-~~ ‘ 2 " ‘ _. F, Conveyor
‘ . ‘ - \ _ .\ .. \ - ‘ ‘ >. _ l i I , _' Steel/A ' ' l‘ ‘ ' l " ~~ Balls ' ~ ' > ' ' ‘ I 4 .
Rocker
Arm
Rocker
-— Arm
Shaft


VIEW OF MOVEMENT BEDS AND BALL CONVEYOR SHAFT
I16]
CALIBER .30 GAGE AND WEIGH
Machine Description

Inserting
Finger
Detecting
Finger
Spur
Gear
Index
Dial
Geneva
Mechanism
Upper and Lower
Gear Rack

UPPER AND LOWER GEAR RACK
The lower rack is mounted in a horizontal track at the rear side of the
indexing dial. The rack is actuated by a rocker arm, which is attached
to the machine bed by a wrist pin arrangement, which allows a free swing
of the arm. The upper end of the rocker arm is connected to the lower
rack by a short link which compensates for the increased length of the
rocker arm stroke as it passes through an arc. The lower end of the
rocker arm has a cam roller attached which follows in the track of a barrel
cam on the driveshaft. Gear teeth are cut on the inner surface of the
rack which mesh with the teeth of a reciprocating fan gear to drive the
upper rack. The fan gear is mounted on a stud shaft which deviates
slightly from a vertical position to allow the fan gear teeth to mesh with
the upper and lower rack. The two racks travel in a reciprocating motion
actuated by the fan gear. The upper rack carries the inserting ﬁnger and
the lower rack carries the ejecting rod. The ejecting rod moves forward
to push the cartridges from the indexing dial onto the transfer table.
[17]
CALIBER .30 GAGE AND WEIGH Machine Description

__ Bevel
Gear

VIEW OF BEAM SCALE DRIVE ASSEMBLY
Beam Scale Drive The weighing platform consists of a spoked wheel mounted on a hub.
The hub is securely fastened to the vertical driveshaft. The driveshaft
extends through a bearing in the machine bed and has a bevel gear
mounted to the lower end. A cross-shaft is held in a hearing which is
bolted to the underneath side of the machine bed. Attached to one end
of the cross-shaft is a bevel gear which meshes with the bevel gear on the
driveshaft. A sprocket wheel is attached to the opposite end of the cross-
shaft and is chain driven from a sprocket on the camshaft.
I13]
CALIBER .30 GAGE AND WEIGH
Machine Description

Beam Scales
Balance
weight \ ‘ I I
The beam scales are suspended from the spoked wheel between arms by
a pivot arrangement. The beam rod is threaded from the pivot point
to the end which is in contact with the cam at the hub of the wheel.
A circular weight is threaded on the beam rod to balance a cartridge of
correct weight. The outer end of the beam rod is equipped with a small
V-shaped pan which receives the cartridge from the transfer table. The
inner end of the beam rod travels in a cam track which narrows to the
diameter of the beam rod as the cartridge is received from the indexing
dial. This arrangement holds the receiving pan of each beam scale steady
as the cartridge rolls onto the pan. As the wheel rotates, the cam track -
becomes wider which allows the beam scale to pivot if there is a light
weight cartridge on the weighing pan. If the cartridge weighs less than
the weight on the inner end of the beam rod, the cartridge will be knocked
from the pan into a scrap container for light cartridges. If the cartridge
is of the correct weight, it will pass below the ﬁrst ﬁxed button and be
carried around the wheel until the cartridge strikes the second ﬁxed but-
ton which pushes it from the pan into the container of good cartridges.


B ' \\
eam ‘\ " e .,
ScaIe\ ‘ ' Reject
1 "' Container
Pivot
Points T“ ._ Arms


VIEW OF BEAM SCALE ASSEMBLY WITH CARTRIDGES ON THE PANS. ONE
OF THE PANS IS IN A RAISED POSITION INDICATING A LIGHT CARTRIDGE
I19]
CALIBER .30 GAGE AND WEIGH Machine Description


Second
Fixed
Discharge
“1 Table
One of
the Light
Cartridges -___
Being
Rejected
First
-—-- Fixed
Rel“t Button
Container
VIEW SHOWING A LIGHT CARTRIDGE BEING PUSHED OFF OF THE PAN INTO
THE REJECT CONTAINER
I20]
CALIBER .30 GAGE AND WEIGH Gage Description

GAGE DESCRIPTION
The gage and weigh machine checks the cartridge for proﬁle, over-all
length, head-to-shoulder length, extractor groove depth, primer seating
depth, head diameter of case, head thickness of case, and weight.
Bullet Neck and Body
Alignment Shoulder Profile Threaded
Gage Holder Gage Gage Gage Nut


INDEXING DIAL GAGE ASSEMBLY
Indexing Dial Gage Assembly: The indexing dial gage assembly con-
sists of a gage holder, which is threaded into the indexing dial, a bullet
alignment gage inserted into the gage holder, neck and shoulder gages,
and a body proﬁle gage which ﬁts into the gage holder. The gages are
made of hardened steel and are held in the holder by an externally
threaded nut which is threaded into the gage holder.
The cartridge is inserted into the dial gage by a safety inserting ﬁnger.
If the cartridge does not enter completely into the gage because of a de-
fective proﬁle, the safety inserting ﬁnger will act to raise the clutch lever
bumper which automatically trips the clutch lever and disengages the
clutch. The defective cartridge must then be removed manually before
the machine can again be placed into operation.
[21]
CALIBER .30 GAGE AND WEIGH Gage Description


Disc Disc Knurled
Gage Holder Gage Gage Holder N ut


Disc Gage: The disc gage is a circular, ﬂat, hardened steel washer,
beveled on the outside edge, with a hole drilled through the center. The
disc gage is held against the gage holder by an internally threaded nut
which ﬁts into the holder. The holder is threaded at the front and has
a shaft-like portion which ﬁts into a housing mounted on the secondary
movement bed of the machine. A pin, protruding from the holder shaft
through a slot in the housing, keeps the disc holder from turning but al-
lows it to move in a horizontal position.
If the cartridge is of the correct head-to-shoulder length, the gage rod
plunger will slide into the hole in the gage disc when the disc holder is
moved forward. If the head-to-shoulder length is too long or too short,
the gage rod plunger will be forced against the side of the disc gage and
will force the disc holder back. The back end of the disc holder pushes
against a kicker lever which transfers the detector ball to the rear side
of the conveyor screw. The conveyor screw carries the steel ball beneath
the bumper pads which in turn open the release gate. The gaging discs
may be replaced with discs which will allow cases of various speciﬁed
lengths to pass.
[221
CALIBER .30 GAGE AND WEIGH
Gage Description
-h~_~
Cone
Beaﬂng


Lock Nut
Thrust Nut
Gage
Stern
GAGE ROD ASSEMBLY
Gage Rod and Stem Assembly: The assembly is used at the ﬁrst,
second, fourth and sixth gaging stations. The assembly consists of a stem
rod, stem button, stem bushing and a thrust collar and nut. The gage
rod consists of cone bearings, adjustment plate and stem plunger. The
gage rod and stem rod are held on the primary bed by the gage rod and
stem block. The stem, which is held in the primary movement block
by a thrust nut, actuates a gage rod. The gage rod is mounted between
two female pivot bearings. The male pivot bearings and an adjustable
plate are contained on the gage rod. The adjustable plate is held against
the shoulder of the stem. The stem, forced back by the forward action
of the primary block, presses against the gage rod adjustable plate and
pivots the gage rod. At the same time the disc gage holder moves toward
the gage rod plunger.
[23]
CALIBER .30 GAGE AND WEIGH Gage Description
_________——___—_—__—_f__—-———————


GAGE ROD ASSEMBLY
Gage Rod: The gage rod is mounted on the forward edge of the transfer
table by two cone bearings which allow the gage rod to pivot. The gage
rod lifting plate is attached to the upper surface of the primary movement
bed. The gage rod has a shoulder machined on its lower surface which
rides on the roller of the lifting plate. The gage rod is equipped with
a caliper blade which ﬁts into the extractor groove on the case when it
arrives at the gaging station. As the primary bed moves forward, the
gage rod contacts the extractor groove of the case. If the extractor
groove is within speciﬁcations, the gage rod enters into the gage disc as
the secondary movement bed travels forward. If the extractor groove is
not within speciﬁcations, the gage rod will strike against the gage disc,
causing the gage disc to contact the kicker lever transferring the steel
ball to the rear side of the conveyor screw. The conveyor screw carries
the steel ball beneath the bumper pad which in turn opens the release
gate: The gage rods are used at stations 3 and 5.
I24]
CALIBER .30 GAGE AND WEIGH Gage Description

Reject Rod
1
T Bushing 3‘-L“,
If’ "l‘=____'___“'___T"'““‘:°‘*'T' .
Release Gate


Spﬁng
REJECT ROD DISASSEMBLED FROM MACHINE
Rejecting Rod Assembly: The rejecting rod assembly, illustrated above,
is used at every station on the transfer table. The rejecting rod extends
from the release gates to the lower edge of the bumper pads. The steel
balls carried along by the conveyor shaft actuate the bumper pads. This
motion is transmitted through the rejecting rods to the release gates which
open and drop the case into a reject box.
[25]
CALIBER .30 GAGE AND WEIGH
Process Sequence
lncﬁned Feed
Hopper
Feed Bar
Indexing Dial
Position I
Inserting and
Detecting
Position 2
Seaﬁng
Position 3
Station I
Gage, Head and
Shoulder Length
Position 4
Eject to Transfer
Table, Transfer
Bar and Holding
Block
Position 5
Position 6
PROCESS SEQUENCE
The cartridges are manually fed into the hopper in a horizontal position,
with the bullet end facing the left. The cartridges slide down the hopper,
over a ﬁber agitator into the feed throat which allows one at a time to
rest in the feed bar channel.
As the feed bar moves back, the cartridge drops into the feed bar channel.
The feed bar conveys the cartridge forward and holds it in alignment
between the inserting ﬁnger and one of the gages in the indexing dial.
The indexing dial has six identical gages mounted at equal spaces around
the dial near the circumference. The indexing dial conveys the cartridges
through each of the six positions as follows:
The inserting ﬁnger pushes the cartridge from the feed bar channel into
the proﬁle gage of the indexing dial. If the cartridge does not ﬁt properly
in the gage, the machine will stop and the operator will remove the car-
tridge with a manually operated ejecting rod. The detector ﬁnger also
moves into the proﬁle gage at position 6 and if there is a cartridge present,
the detector will stop the machine before the gage reaches the inserting
position. '
At position 2, the cartridge is seated ﬁrmly in the gage by the pressure
of the seating post.
As the primary Etfld secondary gaging mechanism move in, the button of
the gaging stem contacts the head of the cartridge to gage the head-to-
shoulder length. If the cartridge is too long or too short, the reject
mechanism will open the release gates on the transfer table and the
cartridge will fall through the ﬁrst reject opening into a box under the
machine. This reject mechanism operates the same at all of the gaging
stations of the transfer table, which has six reject openings and tubes
leading to six separate boxes. The primary and secondary gaging mecha-
nism operates in the same manner at all stations.
At position 4 the cartridge is ejected from the gage by the ejecting rod
onto the transfer table, where it is held by a weight action stripper. The
transfer bar then advances the cartridge from one station to the next,
through ﬁve more gaging stations along the transfer table. A holding
block holds the cartridge ﬁrmly in place while the gaging occurs. There
is a release gate between the stations and between succeeding stations
to discharge defective cartridges.
After the cartridge is ejected from the gage, the indexing dial indexes to
position 5. No operation occurs at this position.
This is the last position of the dial. Here the safety detecting device
stops the machine if a cartridge is present in the dial.
I26]
CALIBER .30 GAGE AND WEIGH
Process Sequence
Position 7
Station 2
Gage Over-all
Length
Position 8
Station 3
Gage Cannelure
Diameter
Position 9, Station 4
Gage, Primer Depth.
Detect for Inverted
or No Primer
Position IO
Station 5
Gage, Head
Diameter
Position ll
Station 6
Gage, Head
Thickness
Position I2
Inspection
The cartridge is pressed against the stationary back plate, and gaged for
over-all length, by the button of the gaging stem. The holding block
moves up and the transfer bar conveys the cartridge to the second re-
lease gate, and then to position 8.
The head of the cartridge is pressed against the front guide plate by a
spring tension back plate, and is gaged for extractor groove diameter by
the lower movable caliper blade and the stationary upper caliper blade.
The holding block moves up and the transfer bar conveys the cartridge
to the third release gate, then to position 9.
The head of the cartridge is held against the adjustable thrust collar
by the weight pressure back plate. The cartridge is gaged for primer
seating depth. Inverted or no primer is detected by the gaging stem.
The holding block moves up, and the transfer bar moves the cartridge
to the fourth release gate, and then to position 10.
The head of the cartridge is pressed against the front guide plate by the
spring pressure back plate. The cartridge head diameter is gaged between
the stationary upper caliper blade by the adjustable lower caliper blade.
The holding block moves up and the transfer bar conveys the cartridge
to the ﬁfth release gate and then to position 11.
The spring pressure back plate holds the cartridge forward as it lines up
between the upper and lower stationary blades. Pressure is released and
the gaging stem button pushes the head of the cartridge against the two
blades to gage for head thickness. The holding block moves up, and the
transfer bar conveys the cartridge to the sixth release gate then past the
counter, down a slide to the beam scale pan at position 12.
At this position the cartridges are weighed for light weight. The beam
scales are timed to have the pan ready for each cartridge as it comes down
the slide. The beam scale rotates counterclockwise, conveying the car-
tridges past the two ﬁxed buttons. If the cartridge is light weight, the
pan will rise and the cartridge will be pushed off the pan by the ﬁrst
ﬁxed button, into the discharge box. Cartridges of correct weight will
pass under this arm, to the second ﬁxed button, which pushes the car-
tridges from the pan onto a table where they roll off into a safety box.
At frequent intervals, one cartridge that has passed through all of the gages
and is supposed to be perfect, is gaged by hand to check the adjustments
of the machine. The rejected cartridges which fall through the release
gates are also checked by hand to make sure that only bad cartridges are
being rejected. All cartridges rejected for being underweight are scrapped.
All other rejected cartridges are run through the machine a second time.
If they are rejected the second time, they are gaged by hand and are
scrapped if they fail to meet speciﬁcations. If they pass this hand inspec-
tion, they are sent to the Inspection Department before being packed.
Each lot of good cartridges is sampled by the Inspection Department.
If any defective cartridges are found, the whole lot will have to be run
through the machine a second time. Particular care must be taken to
keep the machine in perfect adjustment at all times.
[27]
CALIBER .30 GAGE AND WEIGH Process Sequence


FLOW CHART
Cartridges are fed manually into the hopper in a hori- Power is furnished by a
zontal position, bullet end facing the left. Cartridges 3/J,-h.p. motor, through re-
slide down the hopper, over a ﬁbre agitator, into the duction gear, ﬂat leather
throat of the hopper which allows one at a time to fall belt, ﬂywheel and clutch
into feed bar channel. from camshaft.
Feed Bar Feed bar is actuated
After receiving the cartridge in the channel the feed through rocker arm, cam
bar moves forward, carrying the cartridge to a position follower and cam on drive-
in alignment with one of the six gages in the indexing shaft.
dial and the safety inserting ﬁnger.
Safety inserting ﬁnger is
actuated through rocker
Position 1 1 arm reciprocating fan gear
At this position the safety inserting ﬁnger moves in L and rocker arm cam on
pushing the cartridge from the feed bar channel into the driveshaft.
proﬁle gage. Dial moves the cartridge to position 2.


Indexing dial is actuated
through Geneva action.


Position 2
At this position the cartridge is seated ﬁrmly in the
gage by the seating post. The dial moves the cartridge
to position 3.


Position 9; Station 4
At this station the cartridge is gaged for primer seating
depth. Holding block then moves up and the transfer
bar moves the cartridge to the fourth release gate, then


to position 10. '


Position 10; Station 5
At this station the cartridge is gaged for head diameter.
Holding block moves up and the transfer bar moves the
cartridge to the ﬁfth release gate, then to position 11.


Position 11; Station 6
At this station the cartridge is gaged for head thick-
ness. Holding block moves up and the transfer bar
moves the cartridge to the sixth release gate, then past
the counter, down an inclined platform, to the beam
scale pan.


l
[28]
CALIBER .30 GAGE AND WEIGH Process Sequence

FLOW CHART (Cont.)

Position 12
At this position cartridges are weighed for light weight.
Beam scales are timed to have a pan ready for each car-
tridge as it comes down the inclined platform. The beam


scale rotates counterclockwise, carrying the pans past Beam scale is actuated
the two ﬁxed buttons. If the cartridge on the pan is through bevel gear, pinion
light weight, the pan will rise and the cartridge will be gear, sprocket, chain and
pushed off the pan, by the ﬁrst ﬁxed button, into the sprocket on driven shaft.

discharge box. Cartridges that are of the correct weight,
will pass under this button, to the second ﬁxed button,
which pushes the cartridges from the pan onto a table,
to a safety box.


Position 3; Station 1
At this station the cartridge 1s gaged for length from
head-to-shoulder. The dial moves the cartridge to posi-


tion 4.


Push out punch is actuat-
ed through rocker arm and


cylindrical cam on drive-
Position 4 Shaft.
At this position the cartridge is ejected from the gage


by the push out punch, onto the transfer table where it

is held by a weight action stripper. The transfer bar
then advances the cartridge from station to station —~
along the transfer table. A holding block holds the car-
Transfer bar is actuated
-— through two rocker arms
from cams on driveshaft.


tridge ﬁrmly in place while the gaging occurs. There is a
release gate after this station and after each succeeding
gaging station to discharge a cartridge.

Holding block is actuated


—— through rocker arm from
cam on driveshaft.


Position 7; Station 2
At this station the cartridge is gaged for over-all
length. Holding block moves up and the transfer bar
moves the cartridge to the second release gate and then
to position 8.


Position 8; Station 3
At this station the cartridge is gaged for extractor
groove diameter. Holding block moves up and the
transfer bar moves the cartridge to the third release
gate, then to position 9.


[29]
CALIBER .30 GAGE AND WEIGH
Product Description

‘
~ PRODUCT DESCRIPTION

<———— Nose of Bullet


/’
,/.::s
as’:
/’»t~t~:t
;:~:~a
/:o.o‘d$ Bullet Jacket
/,¢‘o.u
i/$.;.:.:,-; Lead Slug
:-~:~:~:~¢
r:::~:~:~:.;:
‘?*”‘*‘~%§ Tracer Mix
Mouth ‘ 5
C of s E Knurled Cannelure
ase
'5
‘I \ Crimp
I5
0 \
I
If --a{- Neck
/I
/r t
/5 r, \
I g-, r y Shoulder
if ’ r" 5 '
’ \ . .
lgnrtor MIX
I
3’
_“i
T?
§ _ Propellant
O ' Powder
'5
E’
3 4- Body of Case
3
.0
_:
o
$
$2
.6
o
o
I
Web Thickness
/ Flash Hole
Anvil
,.'.‘.'-C I _ kPrimer Mixture
%§— K Extractor Groove
§7’II,v7/Ci/ 1 P '
, 3 , _. _ nmer
P


l——— Head l‘%__’l___,__.-Primer Poclcet
CALIBER .30 TRACER CARTRIDGE SCALED
TO ONE AND ONE-HALF TIMES ACTUAL SIZE
The Caliber .30 Tracer cartridge, as it appears at the
gage and weigh machine, is shown in the cross-sec-
tional drawing at the left.
The Caliber .30 Tracer bullet is composed of a gilding
metal jacket, a lead slug, backed by a charge of pyro-
technic (tracer) powder, and an igniter powder charge
which is contained in the base of the bullet. The
tracer powder is ﬁred by the igniter charge which is
ignited by the propellant powder.
The bullet is seated in the mouth and extends into the
neck of the case. The mouth of the case is crimped
into the cannelure of the bullet. The tip of the bullet
is painted red for identiﬁcation.
If the head-to-shoulder dimensions fail to meet speci-
ﬁcations, the cartridge may fail to chamber, or if it
chambers, may fail to function properly or to extract.
The body of the case contains the propellant powder
which is ignited by the ﬂash from the primer, and
which in burning creates sufficient pressure to dis-
patch the bullet on its ﬂight.
The extractor groove is a cannelure cut around the
head of the cartridge case. Its purpose is to facilitate
the extraction of the ﬁred case.
The primer pocket is a cavity in the case head which
contains the primer. When the primer is struck, the
primer mixture detonates and its ﬂash through the
ﬂash hole ignites the propellant powder. It is im-
portant that the primer be seated deep enough not to
be ﬂush with the case head.
[30]
CALIBER .30 GAGE AND WEIGH
Product Description
Nose of Bullet

Lead Ball
Jacket
French Cannelure
Crimp
Neck
Shoulder
__ Propellant
Powder
Over-all Length


'5
Q r=— Body of Case
3
B
2
=
.2
m
52
.6
3
I Web Thickness
/ Flash Hole
Anvil
Foil
_ _ Primer Mixture
I W ' I Extractor Groove
I /
F _‘_‘ Primer
|<_ I 1 Primer Pocket


L Head
CAL. 30 BALL CARTRIDGE SCALED TO ONE
AND ONE-HALF TIMES ACTUAL SIZE
The Caliber .30 Ball cartridge, as it appears at the
gage and weigh machine, is shown in the cross-sec-
tional drawing at the left.
The caliber .30 Ball bullet is composed of a gilding
metal jacket and a lead core. The bullet is seated in
the mouth and extends into the neck of the cartridge
case. The mouth of the case is crimped into the
knurled cannelure on the bullet.
If the head-to-shoulder dimensions of the cartridge
fail to meet specifications, the cartridge may fail to
chamber in the gun, or if it chambers, may fail to
function properly or to extract.
The body of the case contains the propellant powder
which is ignited by the ﬂash from the primer, and
which in burning creates sufﬁcient pressure to dis-
patch the bullet on its flight.
The extractor groove is a cannelure cut around the
head of the cartridge case. Its purpose is to facilitate
the extraction of the ﬁred case.
The primer pocket is a cavity in the case head which
contains the primer. When the primer is struck, the
primer mixture explodes and its ﬂash ignites the pro-
pellant powder. It is important that the primer be
seated deep enough not to be flush with the case head.
I31]
CALIBER .30 GAGE AND WEIGH
Product Description


Ll
I

Nose of Bullet
, /
Lead T-Shot
/1'/it
‘.9 Bullet Jacket
//,2
’ ‘E-' — Steel Core
r%?
I I
/ I Knurled Cannelure
I
// French Cannelure
5 I .
.~| Crrmp
Q’ }\
:2 A
it A
s‘ A
\ Ch Neck
V lh
-‘?~ A
5 5\ déﬁk\ Shoulder
~ ‘.>‘\\\‘\:)”~\ B F'lI C
\ ase I er ap
If \ Base of Bullet
if W
s \ - Propellant Powder


Over-all Length
Head-to-Shoulder Length
—at—
F
Head
S -
I. ‘l. 3. A. " ._-_I
it '-~," '- ‘ l(,,0,
W. '2. - '3 -" 1'-= TC
. ~ I. <Bodyo ase
. “;_ 5-‘ C
I I
' /Web Thickness
- /Flash Hole
/Anvil
I-ii/Foil
Primer Mixture
" jg. t t G
'~ . '0 xrac or roove
yg ;¢\\ .
;\Mu"\\ Pnmer
\ -----I-A-z.\
W Primer Pocket
CALIBER .30 A.P. CARTRIDGE——SCALED
TO ONE AND ONE-HALF TIMES
The Caliber .30 Armor Piercing cartridge as it ap-
pears at the gage and weigh machine is shown in the
cross-sectional drawing at the left.
The Caliber .30 Armor Piercing bullet is composed of
a gilding metal jacket, a lead “T”-shot, a steel core
and a gilding metal base ﬁller cap. The bullet is
seated in the mouth and extends into the neck of the
cartridge case. The mouth of the case is crimped into
the French canhelure on the bullet. For the purpose
of identiﬁcation, the Armor Piercing bullet has a
knurled cannelure ahead of the French cannelure,
and the tip of the bullet is painted black.
If the head-to-shoulder dimensions of the cartridge
fail to meet speciﬁcations, the cartridge may fail to
chamber in the gun, or if it chambers, may fail to
function properly or to extract.
The body of the case contains the propellant powder
which is ignited by the ﬂash from the primer, and
which in burning creates sufficient pressure to dis-
patch the bullet on its ﬂight.
The extractor groove is a cannelure cut around the
head of the cartridge case. Its purpose is to facilitate
the extraction of the ﬁred case.
The primer pocket is a cavity in the case head which
contains the primer. When the primer is struck, the
primer mixture detonates and its ﬂash ignites the
propellant powder. It is important that the primer
be seated deep enough not to be ﬂush with the case
head.
ACTUAL
SIZE
CALIBER .30 GAGE AND WEIGH
Inspection
Machine Gaging
Gage Care
INSPECTION
The caliber .30 gage and weigh machine is manually fed. As the cartridges
are placed on the feed slide by the operator they are inspected for dents
and scratches. The machine utilizes six, (6) gaging stations which gage
the cartridges in regard to the following dimensions:
Head-to-shoulder length of case and proﬁle of cartridge.
Over-all length of cartridge.
Extractor groove.
Primer seating depth.
Head diameter of case.
Head thickness of case.
.°‘.°‘:‘>‘.°°.l\"!-‘
In addition to the dimensional gages, the machine’s weighing platform
will detect and eject all cartridges which have a ﬁve grain or more light
powder charge.
Individual metal containers or boxes are so located beneath the machine
to receive the rejected cases. Each box is numbered and should be placed
in its proper location.
Box N o. 1: Short or long head-to-shoulder length.
Box No. 2: Short or long over-all length.
Box No. 3: Deep or shallow extractor groove.
Box No. 4: High or deep seated primers.
Box No. 5: Large or small head diameter.
Box No. 6: Thick or thin head.
All cartridges ejected from stations one to six inclusive are again run
through the machine in order to determine the accuracy of the machine
and further to salvage any cartridges which may have been rejected be-
cause of the inaccuracy of the machine.
Any cartridges rejected from the beam scales for a supposedly light powder
charge must be weighed on a grain weight balance before they can be
scrapped.
At frequent intervals during the day’s production the cartridges are gaged
with the following hand gages. Gages are expensive instruments machined
to a ﬁne precision. Improper use, or carelessness in gaging, may spring
the gage or put a burr on it which may affect its accuracy. Therefore, force
should never be employed in matching a case to a gage. A protected loca-
tion should be used for storage of gages to prevent their damage when not
in use. The most accurate checks are made when the cases are cool since
heat causes expansion of the metal and results in a temporary variation
in the case size.
[33]
CALIBER .30 GAGE AND WEIGH
Inspection


Gages PROFILE AND ALIGNMENT GAGE
_ 3 H Y I‘ The proﬁle alignment gage checks
__- A ~' . the alignment of the bullet and
~50 B A L L -‘M__-“-_ =1 case and also checks the proﬁle of
AC E R C T C‘ L I‘ ‘ the cartridge.
4'”-3i;E “F ls."-..“7
SNAP GAGE (OVER-ALL LENGTH)
The length of the case is checked
with a snap length gage. The
case must enter the “go” step
and must not enter the “no go”
step.
SNAP GAGE
(Extractor
Groove)
The extractor groove is checked by use of the snap U “go” and “no go" extractor groove gage. The groove “' must enter the “go” step and must not enter the . _
“no go” step. *
DIAL INDICATOR GAGE
(Primer Depth)
The primer depth is checked by a dial indicator
gage. The case is set below the dial indicator and
the pin -of the gage rests on the primer. The dial
indicates the depth the primer is seated.
> TWIN RING GAGE (HEAD DIAMETER)
The head diameter of the
case is checked by use of a
twin ring gage. The head
must enter the “go” hole and
must not enter the “no go”
hole.
SNAP GAGE
(Head Thickn ess)
. ._ ... , -- -N
. _ j , , _ ._ _. u . < y~i.s
. . . .. ._,
- . . ._ EC.
The head thickness of the case is checked by the use
of a head thickness gage. The case head must enter
the “go” slot and must not enter the “no go” slot.
[34]
CALIBER .30 GAGE AND WEIGH
Adjustments
ADJUSTMENTS
Objective To maintain satisfactory gaging, this machine must be inspected period-
Cautions
ically. The cartridges gaged by this machine must be hand gaged to check
the accuracy of the machine.
This section of the manual, with its illustrations, photographs and pro-
cedures, contains the necessary information relative to the adjustments
normally required. The order in which these adjustments are arranged is
not necessarily the preferred sequence. It is impossible to predict all the
machine troubles that will be encountered; therefore certain adjustments
may be required that have not been described in this section. Thorough
analysis of the troubles will indicate what corrective measures must be
taken other than those included in this manual.
Adjustments and repairs requiring special equipment and knowledge
should be referred to the Maintenance Department.
The machine and surrounding ﬂoor space must be free from foreign mat-
ter at all times.
Before making an adjustment, the clutch must be disengaged, the motor
and power turned off.
In order to insure proper adjustment of the machine and the alignment of
its tools, always operate the machine by hand before turning on the power.
When the adjustments have been completed, make sure that there are no
tools or rags on the safety inserting ﬁnger, feed bar channel, indexing dial,
primary or secondary movement, beam scales, upper and lower rack, fan
gear, camshafts, transfer bar, transfer table or any of the moving parts.
Check the feed bar, seating post, guide plate, stem buttons, and inserting
ﬁnger to see that they are clear of the indexing dial. Be sure all guards are
in place, Allen screws on the indexing dial tight and the lock nuts on the
beam scale balance weight are locked.
Inspect the machine periodically during the day’s run to determine
whether or not all connections and adjustments are secure.
CALIBER .30 GAGE AND WEIGH
Adjustments

Primary Stop
Screws
Primary Movement
Bed

Secondary Movement
The primary stop screws are the screws against which the primary move-
ment bed bumps in its movement towards the indexing dial. The pur-
pose of the stop screws is to develop a positive and accurate stopping place
for the primary movement bed each time it travels toward the indexing
dial and transfer table to gage the cartridges. If the primary movement
bed does not bump the primary stop screws, the cartridges will not be
gaged accurately. _
Bed
Enlargement of
Primary Stop Screw
VIEW OF PRIMARY AND SECONDARY MOVEMENT BEDS
Tools:
Procedure:
1%" wrench, %" wrench, 134" wrench.
1. Remove the clutch guard.
2. Use a 13/4" wrench to turn the camshaft until primary movement is
at the extreme end of its forward movement.
3. Use a 1%” wrench to loosen lock nuts on primary movement stop
screws.
4. Use a 3 8" wrench to turn the Stop screws clockwise until they touch
stops on the frame of the machine.
Note: When adjusting set screws, push the primary movement bed
away from the indexing dial and transfer bar. This will eliminate
any play in the primary movement.
5. Use a 1%" wrench to tighten the lock nut on the primary movement
stop screws.
6. Replace the clutch guard.


I 36 I
CALIBER .30 GAGE AND WEIGH
Adjustments

Conveyor Screw
Timing

VIEW SHOWING LOCATION OF IDLER PULLEY
TOOIS:
Procedure:
The conveyor screw is a long steel shaft on the under side of the machine
beneath the gage disc assembly, which has a fluted spiral on it from one
end to the other. When this conveyor screw turns, steel balls are guided
along the shaft by the ﬂuted spiral. The purpose of these steel balls is to
aid in ejecting a rejected cartridge. When a defective cartridge is detected,
the kicker lever kicks the ball over to the other side of the conveyor
screw. The ball is guided by the ﬂuted spiral under a bumper pad which
the ball raises. The bumper pad opens a release gate which permits the
cartridge on the transfer table to drop into the reject chute.
Kicker
Plate
Idler
Pulley
Gage
Rod
Gage Disc
Timing H H
0 er
Chain
Steel
Ball
Kicker
Lever
Conveyor
Camshaft
Screw
Sprocket
VIEW OF CONVEYOR SCREW SHAFT
3%” wrench, 1%” wrench.
1. Use a 1%” wrench to turn the camshaft until the gage rod plunger
comes in contact with the working discs of all stations.
2. Use a I}-4” wrench to loosen the idler wheel stud; lower the idler wheel.
3. Remove the timing chain from the sprocket and turn the conveyor
screw forward until the kicker lever lines up with the ball on the con-
veyor screw ﬂute nearest the kicker lever.
4. Replace the timing chain on the sprocket and reset the idler wheel.
5. Use a E3/1” wrench to tighten the lock nut.
6. To check the adjustment, operate the machine and observe the action
of the conveyor screw.
l37l
CALIBER .30 GAGE AND WEIGH
Adjustments

Safety Inserting
and Detecting
Finger
Safety Inserting
Finger
Tools:
Procedure:
The safety inserting ﬁnger is a small arm with a button on the end of it.
It passes down the feed bar channel and slides the cartridges into the in-
dexing dial, and stops the machine in the event that the cartridge will not
enter the gage completely. The detecting ﬁnger is much the same as the in-
serting ﬁnger in shape. Its purpose is to detect whether or not there is a car-
tridge in the gage just before the gage reaches the position where the in-
serting ﬁnger inserts the next cartridge. The detecting ﬁnger is a safety
device which stops the machine if it detects a cartridge in the gage at
position 6. If the inserting ﬁnger fails to insert a cartridge properly in the
indexing dial, the machine will jam. If the detecting ﬁnger fails to detect
a cartridge in position 6, the cartridge may be detonated by the next car-
tridge which is inserted at ﬁrst position. Both the inserting ﬁnger and de-
tecting ﬁnger are held on the shaft that actuates them by a trunnion con-
nection. The trunnion can be moved to different positions on the shaft.
These positions govern the distances the ﬁngers travel towards the in-
dexing dial. The detector ﬁnger has an additional adjustment of two set
screws that enable the detecting ﬁnger to extend farther than the inserting
ﬁnger. The detecting ﬁnger can extend into a gage while the inserting
ﬁnger barely reaches the gage.
Transfer Bar
VIEW OF SAFETY INSERTING ‘AND DETECTING FINGER
1~°/4" wrench, 11/16” wrench, %-3" Allen wrench, 3/8” wrench.
1. Insert the head-to-shoulder test plug in the gage in position 1 of the
indexing dial.
I38]
CALIBER .30 GAGE AND WEIGH
Ad iustments

Procedure: 2.
(Cont.)
Safety Inserting
Finger
Transfer Bar
3.
HOP‘
Use a 1 3/4” wrench to turn the camshaft over until the inserting ﬁnger
has reached its maximum forward thrust toward the indexing dial.
Use a 1%” wrench to loosen the lock nut on the inserting ﬁnger
trunnion.
Use a %" wrench to loosen the inserting ﬁnger set screw and push the
trunnion forward until the inserting ﬁnger button contacts the test
plug ﬁrmly.
Use a %" wrench to tighten the set screw.
Use a 11/{6” wrench to tighten the lock nut on the inserting ﬁnger.
Use a V32" Allen wrench to loosen the front adjusting screw of the de-
tecting ﬁnger.
Use a 9/32” Allen wrench to turn the back adjusting screw until the
detecting ﬁnger button is about I-I/5" in the gage in the indexing dial
at position 6.
Remove the test plug from the gage in position 1.
Insert a cartridge in the gage at position 5. Engage the clutch lever;
use 1%" wrench to turn the camshaft over at machine speed and as
the test plug reaches position 6, observe whether or not the clutch
lever is tripped. If it is, engage the clutch lever and continue turning
the camshaft until the test plug passes the ﬁrst position. Check to
see whether or not the inserting ﬁnger contacts the head of the test
plug but does not trip the safety feature.


I \ Allen Set Screws
Detecting Finger
CLOSE-UP OF SAFETY INSERTING AND DETECTING FINGER
l 39 l
CALIBER .30 GAGE AND WEIGH Adjustments

Gage Rod Cone The gage rod is suspended between two female adjustable bearings and
Bearings has two adjustable cone bearings. The male parts of the cone bearings
are on the gage rod. The female bearings can be adjusted to create the
desired tension on the male parts of the gage rod. By loosening one ad-
justment screw of the female bearing and tightening the adjustment screw
of the other female bearing, the gage rod can be centered horizontally in
the hole of the gaging disc.


‘ _ . ~ ,
I ',. 1,
' - ' 2
z
7!- Gage Disc
“ ‘€- Gage Rod
Lock Screws ..__l ‘
CLO5E-UP OF GAGE ROD ASSEMBLY
Tools: -'/16" wrench, 2" screwdriver.
(Have the primary movement forward and the secondary movement %
the way forward.)
Procedure: 1. Use a 2" screwdriver to loosen the lock screws on the female parts of
the cone bearing.
2. Use a %" wrench to turn the adjusting screws toward each other until
the desired pressure is exerted on the male part on the gage rod.
Note: To center the gage rod, loosen the screw on the side to which
the gage rod must be moved; then tighten the other adjusting screw
the same amount. This process is repeated until the gage rod is
centered. .
3. Use a 2” screwdriver to tighten the lock screws, and to lock the female
parts of the cone bearing in their position.
[40]
CALIBER .30 GAGE AND WEIGH
Adjustments
Centering Agitator
Cover and Stem
Bushing


Gage Rod —
Agitator Cover I
Thrust Nut /
and Lock Nut
The agitator cover and the stem bushing bring the gage rod into a position
where the rod will center the test disc when the stem is acting upon the
mean test plug in the indexing dial.
The agitator cover is an adjustable plate which is fastened to the gage
rod. It is held by two screws; the screw holes are slotted to allow the
agitator cover to be adjusted to different positions. Besides the slotted
holes which permit an adjustment, the gage rod plunger has an adjustable
set screw which contacts the end of the agitator cover. This set screw is
used in making the adjustment and the two screws in the agitator cover
are used to lock the plate ﬁrmly.
The stem bushing is the sleeve through which the gage stem slides. It is
contained in the housing on the primary movement bed, and can be ad-
justed to different positions in the housing. The thrust adjusting nut of
the stem bushing can change the distance that the gage stem travels to-
wards the indexing dial as much as 1/Z".
CLOSE~UP or GAGE ROD ASSEMBLY
[41 l
CALIBER .30 GAGE AND WEIGH
Adjustments
Tools:
Procedure:
a
'/16” wrench, 7/8" wrench, 34" wrench, 3" screwdriver, 3/32” Allen wrench.
1.
P
$°9°.‘\l.°‘.°‘
10.
11.
Put in test disc. (Primary movement is forward and secondary move-
ment is 1%; way forward).
Use a 3" screwdriver to loosen the lock screws on the agitator cover
of station 1. '
Use a "/16" wrench to loosen the thumb adjusting screw lock nut.
Turn the thumb adjusting screw clockwise or counterclockwise to
center the agitator cover slots in relation to the two lock screws.
Tighten the two lock screws with a 3" screwdriver.
Tighten the thumb adjusting screw lock nut with a 7/16" wrench.
Loosen the stem bushing lock screw with a V32” Allen wrench.
Loosen the lock nut on the thrust adjusting nut with a %" wrench.
Use a %" wrench to turn the thrust nut clockwise or counterclock-
wise until the top of the plunger lines up with the outer circle of the
test disc.
Tighten the stem bushing Allen screw with a V32” Allen wrench.
Tighten the thrust adjusting lock nut with a 7/8" wrench.
I42]
CALIBER .30 GAGE AND WEIGH Adjustments

Feed Bar The feed bar is the carrier plate with a channel on the right end, into
which a cartridge can ride. It is located beneath the inclined feed slide.
The feed bar is actuated by a rocker arm and moves forward from the
mouth of the feed slide to a position where an inserting ﬁnger can slide
through the channel and insert the cartridge in the channel into the index-
ing dial. If the inserting ﬁnger strikes the edge of the channel, the feed
bar is out of adjustment. An adjustment nut on the rocker arm spring
connection governs the length of the rocker arm's stroke forward. A
safety stop screw prevents the feed bar from going too far in its travel.


‘_ Hopper
O Box
7/ I!
Adjustirig \
Nut
__ Feed
778" Lock Bu’
Nut
5/16” Allen _
Screw I’. _
Feed
__ Bar
Rocker
1I/15" Nut Arm
VIEW SHOWING FEED BAR ADJUSTMENT
Tools: 1%" wrench, 114;” wrench, £1/is” Allen wrench, 7/3" wrench, feeler gage,
%" wrench.
Procedure: 1. Remove the feed bar guard and the safety stop screw guard.
2. Use a 1%" wrench to turn the camshaft until the inserting ﬁnger has
moved all the way out and has again traveled about 1/2 its full forward
movement toward the indexing dial.
3 Use a 1%" wrench to loosen the safety stop screw lock nut.
4. Use a %" Allen wrench to turn the safety stop screw clockwise into
the feed bar housing two complete turns.
5. Use a V8" wrench to loosen the feed bar adjusting lock nut.
6. Use a 7 8" wrench to turn the feed bar adjusting nut until the feed bar
channel is in line with the inserting ﬁnger button.
[43]
CALIBER .30 GAGE AND WEIGH
Adiustments
7. Use a %” wrench to tighten the feed bar adjusting lock nut.
8. Use a 5/16" wrench to turn feed bar safety stop screw until a .004”
10.
clearance exists between the safety stop screw and the shoulder on
the feed bar housing.
Check clearance with a feeler gage and use 11/16” wrench to tighten
feed bar safety screw lock nut.
Replace the feed bar guard.
[44]
CALIBER .30 GAGE AND WEIGH
Adjustments

Setting of Gage The gages of the indexing dial are identical and must extend from the in-
dexing dial uniformly. They are all contained in an individual holder
which is adjustable. One gage must be set, and the rest of the gages are
adjusted to conform to that particular one. The gage holder is threaded
on the outside and screws into the openings in the indexing dial. When the
Allen set screws on the outside circumference of the indexing dial are
tightened, they lock the gage holders in position.


TOOIS:
Procedure:
'- Gage
~. Indexing Dial
Seating Post
VIEW OF INDEXING DIAL ASSEMBLY
%" Allen wrench, 1%" wrench, alignment tool, speed wrench, mean
head-to-shoulder test plug.
1.
2.
Remove the clutch guard.
Place the mean head-to-shoulder test plug in gage 1 in the indexing
dial and .375 test disc in head-to-shoulder gaging station.
Use a 1/4" Allen wrench to loosen the Allen set screw, holding the
gage holder in the indexing dial.
Use a 1% ” wrench to turn the machine over until gage 1 reaches the
third position of the indexing dial, the primary movement forward,
and the secondary movement 1/2 way forward toward the indexing dial.
Use the gage holder speed wrench to turn the gage holder of gage 1
clockwise or counterclockwise in the indexing dial until the gage rod
plunger centers in the test disc hole.
Check the adjustment by ﬂipping the gage rod with the ﬁnger tips
while holding the test disc back with the other hand, then release.
Use a 1% " wrench to turn the machine over until the test cartridge
is ejected from gage 1 at the fourth position. Retrieve the test plug,
then turn the camshaft until gage 1 has reached the sixth position.
[45]

CALIBER .30 GAGE AND WEIGH
Adjustments

Procedure: 8.
(Cont.)
ll.
12.
13.
14.
15.
REAR VIEW OF INDEXING DIAL
Use a %" Allen wrench to lock the gage holder of gage 1 in the index-
ing dial by tightening the gage holder set screw.
Note: Before adjusting the remaining gages, adjust the seating post.
(Refer to seating post adjustment.)
Insert the mean head-to-shoulder test plug in gage 1.
Use a 134" wrench to turn camshaft until gage 1 is in third position.
Observe whether or not the gage rod plunger centers the test disc hole.
If not, loosen the lock screws of the agitator cover of ﬁrst gaging
station. Use a 7/15" wrench to loosen the adjusting screw lock nut and
turn the screw until the gage rod plunger centers the test disc hole.
Tighten screws and thumb screw lock nut.
Use a 13/4 ” wrench to turn the camshaft until the test plug is ejected
from gage 1 at the fourth position. Then continue to turn the cam-
shaft until gage 2 is in position where the test plug can be inserted.
Use a 14 " wrench to loosen the Allen set screw in gage 2.
Use a 1%" wrench to turn the camshaft until gage 2 is in the third
position of the indexing dial, and the secondary movement is half
way forward toward the indexing dial.
Note: Repeat the same procedure on gage 2 that was followed on
gage 1 in steps Nos. 5, 6 and 7. Follow the same procedure for
gages 3, 4, 5, and 6 that was used on gage 2.
Replace the clutch guard.
Check adjustments by operating the machine and checking each gage
with mean head-to-shoulder test plug. Observe whether or not the
gage rod centers the test disc hole.
[46]
CALIBER .30 GAGE AND WEIGH Adjustments
___~__V‘—
Seating Post The seating post is a tapered steel plate and is located on one end of a
rocker arm which carries a weight on its other end. The purpose of this
seating post is to seat all cartridges in the indexing dial uniformly. The
seating post rocker arm bumps against an adjustable shaft that is fastened
to the machine. This bumping takes place when the indexing dial rotates
a gage past the seating post.

_ Index Dial
Q
Adjustment ‘ I » , ; Shaft _ ~ - ~ ~ If‘,
“ Seating Post
VIEW OF SEATING POST
Tools: ,4" wrench, 7/8” wrench, IA" wrench, feeler gage.
Procedure: Place the head-to-shoulder test plug with the minimum head in gage 1.
1
1
2. Remove the clutch guard.
3
Use a 1%" wrench to turn the camshaft until gage 1 is in the second
position.
4. Use a 7/8" wrench to loosen the seating post adjusting shaft lock nut.
I 47 I
CALIBER .30 GAGE AND WEIGH Adjustments

Procedure: 5. Relieve the weight on the seating post; use a %" wrench to turn the
(Cont.) adjusting shaft until a clearance of .004" exists between the end of the
adjustable shaft and the seating post check with a feeler gage.
6. Use a 1%" wrench to turn the camshaft until the test plug is ejected
from gage 1 at the fourth position of the indexing dial.
7. Replace the clutch guard.

— CLOSE-UP SHOWING SEATING POST LOCK NUT
I48]
CALIBER .30 GAGE AND WEIGH Adjustments

Over-all Length This gaging station gages the over-all length of the cartridge. The gaging
Gaging Station mechanism must be adjusted to pass the mean over-all length test plug
and reject the maximum and minimum over-all length test plugs. This
over-all length gage is the ﬁrst station on the left of the transfer table.


_ Indexing
Transfer __3 Dial
Bar “‘*"‘ .~ ..
Over-all Primo
Length " Bed
Gaging
Station
> Secondary
Q .
VIEW OF PRIMARY AND SECONDARY BED
Tools: .375 test disc, 3” screwdriver, %" wrench, ~34” wrench, 7/16" wrench, %”
Allen wrench, 1%" wrench, mean test plug.
Procedure: 1. Insert the mean test plug and the .375 test disc at second station.
2. Use a 3” screwdriver to loosen the locking screws on the agitator
cover on the second gaging station.
Loosen the thumb adjusting screw lock nut with a l/16" wrench.
3
4. Loosen the stem bushing Allen screw with a %2'’ Allen wrench.
5. Loosen the thrust adjusting lock nut with a 7/8" wrench.
6
. Turn the thumb adjusting screw in or out until the gage rod plunger
centers the test disc hole.
7. Tighten the agitator cover lock screws with a 3” screwdriver.
8. Tighten the thumb screw lock nut with a I/1%” wrench.
I49 I
CALIBER .30 GAGE AND WEIGH Adjustments

Procedure: 9. Use a 34" wrench to turn the thrust nut in or out until a clearance of
(Cont.) .025" exists between the stem holder and bushing. Check with a
feeler gage.
10. Tighten the stem bushing lock screw with a V32” Allen wrench.
11. Tighten the thrust adjusting lock nut with a 7/8” wrench.
Gage Rod Agitator Cover


VIEW OF ONE OF THE GAGING ASSEMBLIES
[50]
CALIBER .30 GAGE AND WEIGH
Adjustments
Primer Depth
G
siii
Gage
TOOIS:
Procedure:
The primer must be seated a certain depth below the level of the head
of the case. This depth is gaged at the primer depth station known as
fourth gaging station. The adjustments are identical to the second gaging
station with an additional adjustment on a weight tension back plate.

PRIMER DEPTH GAGING STATION
.375 test disc, 3" screwdriver, %” wrench, %" wrench, '/15” wrench, 342”
Allen wrench, 134 " wrench, minimum test plug.
1. The fourth gaging station is adjusted in the same manner with but one
exception, namely, an adjustment on the weight tension back plate.
2. Replace the mean test plug with a minimum over-all length test plug.
3. Use a 9/16" wrench to loosen the weight tension tie rod lock nut; turn
the tie rod adjusting stop nut clockwise, until about V16” clearance
exists between the bronze bushing and the adjusting stop nut.
[51]
CALIBER .30 GAGE AND WEIGH Adjustments

Head Thickness The head thickness is checked at this gaging station. This station is
Gaging Station adjusted to reject minimum and maximum test plugs and to pass the
mean test plug. It is known as the sixth station. To adjust, follow the
same procedure as for second gaging station.
Gage Disc Gage Disc
Gage Rod E”
Agitator Cover
LOCl( Nut Q’!
Thrust Nut Lower Caliper
Blade Screws


- ‘ Upper Caliper
Blade Screws
4
HEAD THICKNESS HEAD DIAMETER
STATION STATION
[52]
CALIBER .30 GAGE AND WEIGH Adjustments
Extractor Groove The depth of the extractor groove of the cartridge is checked at this gag-
Diameter Gaging ing station. It is known as third gaging station. An adjustment can be
Station made on the caliper blades that gage the extractor groove depth. These
blades are set so that the mean test plug causes the gage rod plunger to
center the test disc hole and will reject maximum and minimum test plugs.
If the gage rod plunger does not reject the maximum and minimum test
plugs, an adjustment is needed.
Upper
Caliper
, I ' >'=
Blade “ I 1'“ .
a
screw; M
g


" S 1" ' I_ ‘ I 5 : Upper
Lower J 1 _, , Y 1, Cali er
Caliper Y , . ' — Blacre
Blade ' Allen
Screws Screws
Gage
Rod
., ¢¢¢¢ ' .
EXTRACTOR GROOVE DIAMETER GAGING STATION
Tools: '/15” wrench, screwdriver, .375 test plug, mean test plug, %” Allen wrench,
feeler gage, 134" wrench.
Procedure: 1. Use a 1%" wrench to turn the camshaft until the secondary move-
ment is far enough forward so that the gage rod touches the disc.
2. Place a .375 test disc at the third station; also a mean plug.
3. Use a 7/16" wrench to loosen the lifting plate and push it back as far
as possible.
4. Use a %2” Allen wrench to loosen the upper caliper blade screws.
5. Use a screwdriver to loosen the upper caliper blade screw and turn
the lock screw until the upper blade is at its highest position.
6. With a 7/15” wrench, loosen slightly the cap screws holding the gage
rod cone bearing housing.
7. With a screwdriver, loosen the lower caliper blade lock screw.
l 53 l
CALIBER .30 GAGE AND WEIGH Adjustments
Procedure: 8. Turn the lower caliper adjusting screw with a screwdriver while ap-
(Cont.) plying hand pressure on the holding block until the gage rod plunger
is V2 the diameter below the test disc hole. Remove the pressure
from the holding block. Tighten the lock screw.
9. With a 31/6” wrench tighten the cap screws holding the gage rod cone
bearing housing.
10. With a 3” screwdriver, loosen the upper caliper adjusting screw and
tighten the lock screw until the gage rod plunger centers the test
disc hole. Tighten the adjusting screw until a slight drag is felt; then
alternately tighten the adjusting screw and lock screw.
11. Tighten the upper caliper lock screws with a %2'’ Allen wrench.
12. Remove the mean plug.
Head Diameter This gaging station is the place where the head diameter is checked, and
Gaging Station is known as station 5. This station is adjusted to reject the maximum
and minimum test plugs but to pass mean test plugs. To adjust this sta-
tion, follow the same procedure as for third gaging station.


Q
Thrust Nut
Lower Caliper
Blade Screws

i Upper Caliper
- Blade Screws


HEAD THICKNESS HEAD DIAMETER
STATION STATION
I54]
CALIBER .30 GAGE AND WEIGH
Adjustments

Reject Rod
1' Bushing
Spring
Reject Rods
Procedure: 1.
1!’
Tools:
The reject rod opens the release gate of the gaging station where the
cartridge failed to pass inspection. These rods must be adjusted so that
when rejection occurs, the release gate will be opened in time to allow the
rejected cartridge to slip from the transfer table into the reject tube.
Reject rods must also allow the release gate to close completely after re-
jection takes place. There is a reject rod for every gaging station.
Loch Nut
Reject Rod
VIEW SHOWING REJECT RODS
13/4" wrench, 1/2” wrench.
Use a 1%” wrench to turn the camshaft by hand until the steel balls
on the conveyor screw are directly under the bumper pads.
2. Use a 1/2" wrench to loosen the lock nut on the reject rods at the brass
T bushing on each station.
3. Turn the reject rod by hand on each station clockwise to open the re-
lease gates.
4. Open the release gates by the above procedure until they are ﬂush
with the guide plate; then turn }/8 of a turn more for positive release.
Use a V2” wrench to tighten the lock nut on all six reject rods.
Check for accuracy.
we
Release Gate

Spring Rod
==_===-'===="""“_ """"'-3"‘
REJECT ROD DISASSEMBLED FROM MACHINE
[55]
CALIBER .30 GAGE AND WEIGH Adjustments

Beam Scale Cone The beam scales have a cone bearing which is adjustable, and each scale
Beating is balanced between two ﬁngers. The male points of the bearings are on
the beam of the scale and the female parts are on the adjusting screws
which extend through the ﬁngers, between which the beam scale balances.
The adjusting screws can be extended until the desired pressure is exerted
on the male points of the beam scale. The beam scale can be centered
between the two ﬁngers by adjusting tne two female bearing screws in
relation to each other.
Cam


V , ‘_ 5/16" Lock Nuts
__ 1 4" Adjusting
crews
Beam Scale — ~,,
-;
N
6'-,
V
<§' -
.1; ,
.r ‘I
.
BEAM SCALE ASSEMBLY
Tools: 1/4" wrench, %” wrench.
Procedure: 1. Use a 5/16" wrench to loosen the lock nuts on the two adjusting screws
which extend through the ﬁngers, between which the beam scale
balances.
2. Use a 54'’ wrench to turn the adjusting screws toward each other until
the desired pressure is exerted on the male points of the beam scale.
Note: To adjust these screws, center the beam scale between the two
supporting ﬁngers by extending the screws equally from the ﬁngers.
3. Use 9. %” wrench to tighten the lock nut.
l 56 l
CALIBER .30 GAGE AND WEIGH Adjustments
Balancing Beam The beam scale consists of an oscillating beam with a pan for holding
Scales cartridges attached to one end of the beam, and an adjustable balancing
weight attached to the other end. The weight platform contains eighteen
such beam scales and is located at the right of the machine. The adjust-
able balance weight can be set for cartridges of different weight.
<1
i-* ‘D
1
' ’ .0 Balance Weight


Balance Weight f
5/16" Lock Nut /
. *- 5/16” Lock Nut
Beam Scale
Beam Scale
Pan _______
BEAM SCALE ASSEMBLIES
Tools: '%;," wrench, light weight test plug.
Procedure: 1. Place a light weight cartridge in the pan of the beam scale and use a
5/16” wrench to loosen the lock nut.
2. Turn the balance weight until the pan, when released from a low posi-
tion, will rise slowly and ﬁrmly to a high position.
3. Use a 7/16” wrench to tighten the lock nut.
[57]

CALIBER .30 GAGE AND WEIGH
Adjustments

Clutch
Clutch Yoke
-_-r
Pin
Tools:
Procedure:
The clutch is a mechanism by which power transmission to the camshaft
is controlled. It is located at the rear end of the camshaft. The clutch
has an adjustable yoke that enables the gripping disc to be brought more
ﬁrmly against the ﬂywheel. If the clutch slips, the camshaft will not turn.
If the clutch is too tight, it will not disengage when the clutch lever is
tripped.

CLOSE-UP OF CLUTCH ASSEMBLY
Screwdriver, pair of pliers.
1. Engage the clutch lever to see whether the clutch is too loose or too
tight; if too tight, the lever will tend to hang; if too loose, it will have
too free a movement.
2. Pull the clutch yoke pin out with the pliers. Use a screwdriver to turn
the yoke until the proper tension is felt on the clutch lever. Be sure
the yoke pin locks in a slot.

Note: When the clutch begins to slip, do not make an adjustment
immediately; let the clutch become quite loose. If it is adjusted as
soon as it develops a mild form of slippage, it will not release readily.
[58]
CALIBER .30 GAGE AND WEIGH
Troubles and Corrections
Objective
Cartridges Jammed
' at the Bottom
of Hopper
Clutch is being
Disengaged
TROUBLES AND CORRECTIONS
The adjuster will encounter many troubles and defects in the operation
of this machine. It is impossible to anticipate all the problems that may
confront an adjuster, but the production troubles that most commonly
occur, their causes and corrections are listed below.
The following troubles can be recognized by visual and gage inspection
of the cartridge, together with constant observation of the machine as it
operates.
Accumulation of brass, dirt, dried lacquer and other foreign matter causes
considerable machine trouble. Foreign matter on the stem buttons results
in the rejection of good cartridges; foreign matter on the beam scale cam
prevents the beam scale from functioning properly. For the above reas-
ons, it is necessary to clean the parts of the machine periodically. The
operator should be taught to clean the trap door periodically to prevent an
accumulation of foreign matter in the gages.
Visual inspection reveals that the cartridges are jamming between the
feed bar channel and the slot at the bottom of the hopper.
The causes are: The corrections are:
1. The feed bar channel is not in
line with the opening at the
bottom of the hopper.
1.‘ Remove the cases from the hop-
per and adjust the feed bar
channel. Loosen the lock nut
and turn the adjusting nut until
the feed bar is in line with the
opening at the bottom of the
hopper.
2. The inserting ﬁnger is pulling . Occasionally remove the dirt
the cartridges partly out of the from the inserting ﬁnger with
dial gage. This is caused by the rags and carbon tetrachloride.
lacquer on the primer.
3. The cartridges have been im- . Remove the cartridges from the
properly placed into the hopper.
hopper and place them back in-
to the hopper in the correct
position.
Visual inspection reveals that the clutch has been disengaged by the
clutch trip mechanism.
The causes are:
1.
There is a cartridge in the feed
bar channel with the head
forced against the dial gage.
The corrections are:
1. Remove the cartridge from the
feed bar channel and check the
position of the cartridges in the
hopper.
[59]
CALIBER .30 GAGE AND WEIGH
Troubles and Corrections

Clutch is being
Disengaged
(Cont.)
Correct Head-to-
Shoulder Cartridges
Rejected
The causes are:
N)
. The inserting ﬁnger is not prop-
erly adjusted. It trips the
clutch lever when the cartridge
is properly seated.
. Dirt in the proﬁle gage pre-
vents the cartridge from being
completely inserted into the
dial gage.
. The proﬁle of the cartridge is
not correct.
The corrections are:
2. Adjust the
inserting ﬁnger.
Loosen the lock screw. Slide
the trunnion so that the insert-
ing ﬁnger just contacts the car-
tridge seated in the proﬁle gage.
Tighten the lock screw.
Clean the proﬁle gage with a
brush soaked with carbon tetra-
chloride.
Remove the cartridge from the
proﬁle gage and place it in the
proﬁle reject container.
Gaging reveals that correct head-to-shoulder length cartridges are being
rejected and short head-to-shoulder length cartridges are not rejected.
The causes‘are:
1.
2.
3.
4.
5.
There is dirt on the head-to-
shoulder stem button.
There is dirt in the proﬁle gage.
Stem is not adjusted properly.
Seating post is adjusted too far
from the indexing dial.
The cone bearings on the gage
rod are too tight preventing the
gage rod -from functioning prop-
erly.
The corrections are:
1.
Clean the stem button with a
rag and cleaning ﬂuid.
. Clean the proﬁle gage with a
brush and cleaning ﬂuid.
. Adjust the stem at the ﬁrst sta-
tion. Insert a mean head-to-
shoulder test plug; loosen the
screws on the agitator cover
and turn the adjusting screw
until the gage rod plunger cen-
ters the gage disc. Tighten the
screws on the agitator cover.
Adjust the seating post closer
to the dial gage. Insert a mini-
mum test plug in the proﬁle
gage and turn the indexing dial
until the test plug is in the cen-
ter of the seating post. Loosen
the lock nut and turn hexagon
rod so a clearance of .004" ex-
ists between the seating post
and the arm. Tighten the lock
nut.
. Loosen the set screws holding
the female bearings and turn
bearing adjusting screws until
the gage rod pivots freely.
Tighten the set screws.
[60]
CALIBER .30 GAGE AND WEIGH
Troubles and Corrections
Nicks on Shoulder
of Cartridge
Scratches on the
Head of Cartridge
Correct Primer
Depths Rejected
Fails to Reject
Light Cartridge
Visual inspection reveals nicks on the shoulder of the cartridge.
The cause is: The correction is:
1. Adjust the channel in line with
the dial gage. Loosen the nuts
on the channel adjusting rod
and turn the adjusting nut un-
til the channel is in line with
the dial gage. Tighten the lock
nut.
1. The feed bar channel is not in
line with the dial gage.
Visual inspection reveals that there are scratches on the head of the
cartridge.
The causes are: The corrections are:
1. The seating post is burred and
scratches the head of the car-
1. Remove the seating post by re-
moving the screw that holds it
tridge as the cartridge is being
moved by the indexing dial.
. There is an excessive accumu-
lation of brass on the seating
post.
in place, and remove the burr
with a ﬁne grade of emery
cloth.
. Remove the seating post and
clean with ﬁne emery cloth.
Remove the screw on the seat-
ing post arm and lift out the
seating post.
Gaging reveals that cartridges of correct primer depth are being rejected,
but cartridges of incorrect primer depth are not being rejected.
The corrections are:
1. Clean the stem bottom with a
rag and carbon tetrachloride or
some other cleaning ﬂuid.
The causes are:
1. There is dirt on the primer
depth stem bottom.
2. Station is not adjusted proper- 2. Place a test plug at the primer
ly. depth station and adjust the
gage rod. Loosen the screws on
the agitator cover and turn the
adjusting screw until gage rod
plunger is centered in the gage
disc.
Gaging reveals that themachine fails to reject light cartridges, but may
be rejecting correct weight cartridges at the ﬁrst ﬁxed button.
The causes are: The corrections are:
1. Dirt on the cylindrical cam pre-
vents the beam scales from rid-
ing on the cam.
1. Clean the cylindrical cam with
a brush or cloth and use carbon
tetrachloride.
I61]
CALIBER .30 GAGE AND WEIGH Troubles and Corrections
Fails to Reject The causes are: The corrections are:
Llghl Cartridges 2. Tight hearings on the beam 2. Loosen the lock nut on the
(Cont) scales ' I
prevent the beam scales beam scale bearing screw. Turn
from functioning properly. the bearing screw until the
beam scale pivots freely.
3. Beam scale is not adjusted 3. Place a light cartridge on the
properly. scale, loosen the lock nut and
adjust the weight on the scale
until the pan rises.
CALIBER .30 GAGE AND WEIGH
Machine Lubrication

Friction
Introducing
Lubricating
Film Reduces
Friction
Lubrication
Anti-friction
Bearings
MACHINE LUBRICATION
The efficiency of every machine depends to a great extent upon the ability
of its bearings to:
1. Withstand excessive wear.
2. Operate with low maintenance costs.
3. Operate without excessive power loss.
A major cause of inefﬁciency is friction. Friction, as far as we are con-
cerned here, is the force that resists the sliding of one surface over another.
It makes no difference whether these surfaces are ﬂat or curved.
When highly ground bearing surfaces are greatly magniﬁed, it is found
that they are not smooth at all but are made up of innumerable micro-
scopic hills and valleys. When the jagged hills and valleys of two engaging
bearing surfaces come together, their meshing resists the sliding of one
over the other.
By introducing a lubricating ﬁlm between the bearing surfaces, they are
separated sufficiently to allow easy sliding.
Liquid friction is substituted for solid friction which reduces the resisting
force, because the resisting force of liquid friction is much less than the
resisting force of solid friction. Friction cannot be eliminated, but it can
be minimized by using a lubricant.
The most important lubricants are:
1. Petroleum oils and greases. Petroleum oil or crude oil is a mineral oil
that is pumped from the earth. By various degrees of reﬁning, oils of
different properties are obtained for the thousands of different types of
lubrication needed in industry. Lubricating grease is a compound of
petroleum oil and soap.
2. Vegetable oils andanimal oils are mixed with petroleum oils for many
applications.
3. Graphite—tannin is a mixture used with water, oil, or grease for
lubrication. Its use is limited.
By using ball or roller bearings, we substitute rolling friction for sliding
friction, and thereby reduce the resistance to the small amount of friction
caused by contact of the balls with their cages and races, and the liquid
friction of their lubricant. Lubricants are used in anti-friction bearings
to protect the highly polished balls or rollers from rust and corrosion and
to reduce friction between the moving parts.
[63]
CALIBER .30 GAGE AND WEIGH
Machine Lubrication
Selecting a
Lubricant for a
Given Bearing
Grease
Lubrication
Methods
Some of the factors that govern the selection of a lubricant are:
1. Speed of the shaft or slide.
Load on the shaft or slide.
Opportunities for leakage from the bearing.
Constant or intermittent operation.
Cleanliness of surroundings.
Temperature of surroundings.
.*S”P‘F‘9°l“
Dampness of surroundings.
At normal temperatures lighter bodied oils should be used as the speed of
the shaft or slide increases. At higher speeds, an oil is not required to
have the adhesiveness that is needed at low speeds. Instead, it must have
high ﬂuidity in order to ﬂow quickly through the small clearances that
are found in high speed bearings and thereby maintain an adequate
lubricating ﬁlm.
As the load on a shaft or slide increases. the oil used must be correspond-
ingly heavier in body. A heavy oil has low fluidity, high viscosity, high
resistance to leakage and great adhesiveness. The high adhesive power
makes up for the lack of ﬂuidity in maintaining the oil ﬁlm. The high
ﬁlm strength of heavy oils is necessary to withstand heavy shock loads.
Grease is used in preference to oil when certain operating conditions are
found:
1. Mechanical design allows grit and dirt to get into lubricated areas.
2. Mechanical design would allow excessive oil leakage.
3. Application is infrequent and hazardous.
4. Operating speed is low and pressure is heavy.
It is desirable where possible, to standardize the lubricants for a certain
plant to include a few, well-chosen good quality lubricants each of which-
will answer several different purposes.
. The United States Cartridge Company has standardized its needs so that
less than ten different kinds of oils and greases are used.
There are many ways of getting the lubricant to the bearing surface.
The method used depends to a great extent upon:
1. Design of bearing.
Weight or speed of the shaft.‘
Normal leakage.
Size of bearing.
Surroundings.
Accessibility of bearing.
.q.°°.o‘t‘>‘.°°.l\°
Frequency of lubrication.
I64]
CALIBER .30 GAGE AND WEIGH
Machine Lubrication

Methods of
Getting
Lubricant to
Bearing Surface
Hints on
Lubrication
Consideration of these and other factors help to determine the method
that is to be used to lubricate a given bearing. Some of these methods are:
Simple oil hole.
Bottle oiler.
Ring oiler.
Plain oil cups.
Drop feed cups.
Wick feed cups.
Mechanical, force feed, central lubricating system.
9°.‘Q.°°$"t‘>.°°.N!"
Splash feed system.
Grease is applied to bearing surfaces through several different devices.
1. Screw down cups.
2. Compression cups.
3. Pressure guns and patented ﬁttings.
4. Mechanical lubricators.
5. Grease packing.
A systematic control of all lubrication is important. Lubrication must be
done periodically and lubrication cups kept ﬁlled with lubricant.
Excess oil on and about the machine is not a sign of a properly lubricated
machine; it shows poor workmanship. Evidence of good lubrication is
usually shown internally, not externally.
Follow lubrication charts carefully to determine frequency and type of
lubrication. A “must” in the mind of a good mechanic is “good lubrication”.
Carry a wiping rag with you when you oil or grease. Wipe the cup or
ﬁtting before you open the cup or apply the grease gun. Also wipe the
oiler spout or grease nozzle. Applications of lubricants are necessarily
frequent. If a little dirt is allowed to enter the ﬁtting each time, it can
cause a lot of trouble.
Don’t lay a grease gun down in a dirty place. Never lay it on the floor.
A grease gun should be in one of two places; in its rack or in the hands
of the oiler.
The grease barrel should be kept tightly covered at all times—except
when the gun is being ﬁlled. A speck of abrasive dirt that ﬁnds its way
into a grease barrel can easily be forced into a bearing and cause the
machine to be shut down for days.
Do not deviate from lubrication procedures without authority. Lubrica-
tion engineers have speciﬁed lubrication for each spot. If you think
that it should be changed, take it up with your supervisor.
[65]
CALIBER .30 GAGE AND WEIGH
Machine Lubrication
LU BRICATION CHART

Imbricant
Machine Part
N 0. of Fittings,
Grease Cups, etc.
Frequency of
Lubrication H ours

LIGHT GREASE
(Blue Gun)
Clutch collar
24
MEDIUM OIL
(Red Oiler)
Spiral gears on driveshaft .
Gear head motor
Res.
Res.
1 wk.
1 wk.

LIGHT OIL
(Brown Oiler)
Continued on
Next Page

Clutch . . . .
Clutch lever assembly
Main driveshaft .
Driveshaft
Cam follower rollers .
Weighing unit drive chain
Weighing unit drive gears
Weighing unit drive chain idler
Weighing unit main shaft .
Scale beam pivots .
Scale beam rollers .
Barrel cam follower pivot .
Sliding bearing or positive gear
Reciprocating fan gear bearing
Follower gear and positive gear
Gibs.
Safety inserting ﬁnger pivot points .
Dial shaft
Indexing dial gear .
Geneva wheel . . . . . . .
Main shaft 3 cam rocker arm and
driven assembly .
Main shaft 4 cam rocker arm
driven assembly .
Transfer bar . . . . . .
Magazine feed mechanism . . . .
Main shaft 5 cam rocker arm an
driven assembly . . . . . . .
Driveshaft ﬁrst cam rocker shaft .
Rocker arm connecting link pivots .
Secondary movement slides .
Driveshaft second cam rocker shaft .
Rocker arm connecting link pivots .
Primary movement slides .
Kicker levers
Gaging stations .
o O
and
I-* I-‘O0
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I—*l-—‘
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24
1 wk.
24
24
24
1 wk.
24
24
24
1 wk.
00 oooooooooooooooooor-A
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CALIBER .30 GAGE AND WEIGH Machine Lubrication

LUBRICATION CHART (Cont.)


. . N 0. of Fittings, Frequency of
Lubricant Machine Part Grease Cups, etc. Lubrication Hours
Roller bearings . . . . . . . . . 2 24
Ball conveying screw shaft bearings 2 8
Ball conveying screw shaft chain 1 1 wk.
Reject rod housing 18 24
Release gates . . . . . . . . . . 6 24
LIGHT QIL Drive shaft third cam rocker pivots . 3 24
(Brown Oller) . . .
(C t ) Llftlng houslng shaft . . . . 2 24
on ' Lifting housing gate . . 2 1 wk.
Holding blocks . . . . . . . . . 11 24
Primer depth weight tension assem-
bly . . . 8 24
Countershaft . . . . . . . 1 1 wk.
Hand pushout assembly . . . . . 3 1 wk.


CALIBER .30 GAGE AND WEIGH
Index
Adjustment, Balancing Beam
Scales, 57
Beam Scale Cone Bearing, 56
Centering Agitator Cover, 41
Clutch, 58
Conveyor Screw Timing, 37
Detecting Finger, 38
Extractor Groove Diameter
Gaging Station, 53
Feed Bar, 43
Gage Rod Cone Bearing, 40
Head Diameter Gaging Station, 54
Head Thickness Gaging Station, 52
Over-all Length Gaging Station, 49
Primary Stop Screw, 36
Primer Depth, 51
Reject Rods, 55
Safety Inserting Finger, 38
Seating Post, 47
Setting of Gage, 45
Stem Bushing, 41
Alignment Gage, 34
Anti-friction Bearings, 63
Anvil, 30, 31, 32
Balancing Beam Scales Adjustment,
57
Ball Conveyor Shaft, 4, 8, 16
Beam Scale, 11, 16, 19
Scale Cone Bearing Adjustment,
56
Scale Drive, 18
Brake, 2
Bullet Alignment Gage, 21
Cam, 12, 15
Camshaft, 6, 13, 14, 16, 18
Cannelure, 31, 32
Cartridges Jammed at Bottom of
Hopper, 59
Centering Agitator Cover
Adjustment, 41
Clutch, 2, 4, 15
Adjustment, 58
Disengaged, 59
Lever, 2
Conveyor Screw, 22
Screw Timing Adjustment, 37
Correct Head-to-Shoulder
Cartridges Rejected, 60
Primer Depths Rejected, 61
Cross-shaft, 3, 9, 12, 13, 14, 18
Detect, 26
Detecting Finger, 7
Finger Adjustment, 38
Dial Indicator Gage, 34
Disc Gage, 22
Driveshaft, 2, 3, 4, 15, 16, 18
Eccentric Cam, 4
Ejecting Rod, 4, 5, 17
Stem, 3
Extractor Groove, 24, 30, 31
INDEX
Extractor Groove Diameter Gaging
Station Adjustment, 53
Fails to Reject Light Cartridge, 61
Fan Gear, 17
Feed Bar, 3, 6, 26, 28
Bar Adjustment, 43
Bar Channel, 3
Hopper, 6
Mechanism, 3, 6
Finger Shaft, 7
Flash Hole, 30, 31, 32
Floor Space, 1
Flow Chart, 28, 29
Flywheel, 2, 4
Foil, 30, 31, 32
Friction, 63
Gage, 1
Care, 33
Rod Assembly, 23, 24
Rod Cone Bearing Adjustment, 40
Stem, 8
Stem Assembly, 23
Gaging, 33
Assembly, 50
Gear Teeth, 17
Geneva Mechanism, 3, 4, 9
Grease, 64
Head, 30
Diameter Gaging Station
Adjustment, 54
Thickness Gaging Station
Adjustment, 52
Height, 1
Inclined Feed Hopper, 26
Indexing Dial, 3, 7, 9, 10, 11, 17, 26
Dial Gage Assembly, 21
Insert, 26
Inserting Finger, 3, 4, 7
Inspection, 27
Kicker Lever, 4
Rod, 8
Lead Slug, 30
Lower Gear Rack, 4, 17
Rack, 3
Lubricating Film, 63
Lubrication, 63
Chart, 66, 67
Hints on, 65
Methods, 64
Machine Motor, 1
Manufacturer, 1
Methods of Getting Lubricant to
Bearing Surface, 65
Motor, 2
Mouth, 30
Neck, 30, 31, 32
Nicks on Shoulder of Cartridge, 61
Nose, 30, 31, 32
Over-all Length Gaging Station
Adjustment, 49
Position 1—26, 28
2—26, 28
3—26, 29
4—26, 29
5—26
6—26
7-27, 29
8-27, 29
9—27, 28
10—27, 28
11—27, 28
12—27, 29
Power, 2
Primary Movement Bed, 4, 13
Stop Screw Adjustment, 36
Primer, 31
Depth Adjustment, 51
Pocket, 30, 32
Production, 1
Proﬁle Gage, 34
Propellant Powder, 31, 32
Reject Box, 3
Container, 20
Rods Adjustment, 55
Station, 11
Tube, 8
Rejecting Rod Assembly, 25
Release Gate, 3
Rocker Arm, 3, 6, 12, 13, 14, 17
Safety Inserting Finger, 2, 21
Inserting Finger Adjustment, 38
Scratches on Head of Cartridge, 61
Seating, 26
Post, 3, 10
Post Adjustment, 47
Secondary Movement Bed, 4, 8, 14
Selecting a Lubricant, 64
Setting of Gage Adjustment, 45
Shoulder, 30, 31, 32
Snap Gage, 34
Spur Gear, 9
Station 1-26, 29
2—27, 29
3—27, 29
4-27, 28
5—27, 28
6—27, 28
Steel Core, 32
Stem Bushing Adjustment, 41
Switch, 2
Transfer Bar, 3, 4, 12
Table, 3, 4, 5, 11, 12, 17
Transmission, 2
Twin Ring Gage, 34
Type of Feed, 1
Upper Gear Rack, 4, 17
Rack, 3
Weighing Pan, 19
Platform, 5
Weight, 1
[68]
DATE DUE

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