Annex 4 - Moving Frame and Whiffletree assembly July 2015 Ankur Agrawal

1291-guide flexure -1260-moving frame assy -countersunk bolts M6 vented – 6qty-(item no.47) -allen key-4, torque wrench to 8.5 N-m

Place flexure on top of 01260 Align 1291 to 1260 with locating pin on 1260

Fasten M6 bolt on flexure

Tighten with torque of 8.5N-m.

Fixture -500

Lift moving frame and place on fixture that 1291 to face downside While putting 1260 on fixture, align y of 1260 on y of table Locate alignment pin of fixture on y side to hole of 1260 Rest 1260 on fixture pad

Align 6 holes of central hub to jack platform. Engage two bolts to hold -1260 with jack platform of fixture.

Take part -1202 , torque wrench – 8 Take part -1202 , torque wrench – 8.5N-m , 11mm crow foot spanner, extensions, spanner- 11mm

Install 1202 on all 3 arms of 1260 Tight using 11mm spanner

Torque all 3 nos of 1202 with torque wrench with value of 8 Torque all 3 nos of 1202 with torque wrench with value of 8.5 N-m with 11mm crow foot spanner

Rotate nook jack clockwise to lower 1260 all the way down

Place whiffletree assy on fixture so that leaf spring faces towards fixture base(ensure 1202 not hit assy) Align 1202 Pivot & central hole on 1251 Visually.

Take 1204, button head cap screw M3 x 4mm (item no.52), M1S-910 -411, 2mm hex allen key

Place 1204 -6qty over actuator holes of casting

Fasten M3 bolts and keep part loose for further alignment.

Place 411 over 1204. Ensure 411 is properly seated over 1204.

Increase height of moving frame to align 1202 to center of 1251 Use counter balance arms to align middle triangle with 1202

Take part -910 -512, 513, spirit bubble level.

Place 512 bush over pocket of 1265 arm of 1260.

Place 512 bush over pocket of 1265 arm of 1260. Align 512 slot long length of arm, ensure 512 is not moving.

Insert pin 513 through to 1221 hole to 512 slot.

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Put bubble level on 1221 center.

Try to adjust bubble level in center by tapping on 1254

Take M3 socket head cap screw (item no. 39), M3 flat washer (item no Take M3 socket head cap screw (item no. 39), M3 flat washer (item no. 40), allen bit (2.5 mm), torque wrench (1 N-m).

Fasten bolt and washer to clamp sheet fixture 1203 with 3nos of holes in each casting of 1260. Tight all bolts with 2.5 allen key from center to outside.

Tight all 6 bolts with torque of 1 N-m form center to outside.

Take following tools: -Zinc hex nut M6 (item no. 44), -flat washer (item no. 42) and -spring washer (item no. 43), -torque wrench with 8.5 N-m.

Place flat washer & spring lock washer over pin 1202 in center of 1251.

Place M6 nut over pin 1202 in center of 1251.

Fasten nut & Tight with torque wrench (8.5 N-m).

Hand tight M16 fixture nut to clamp whiffle tree assy.

Take -910 -00514, torque wrench with 0.75 N-m, 2 mm bit

Put – 514 through hole and leaf spring (1215A2) and -01204.

Tighten M3 button head screw of 1204 with torque of 0.75 N-m.

Remove -514

Remove --411 with tweezers.

Take leaf spring 1215A1, socket head bolt- M4 (item no. 41), M4 washer ( item no. 36), 910 -409, part 1204, Button head M3 (item no. 52), 2mm and 3mm bit, torque wrench with 0.75 N-m and 2.3 N-m.

Place 1204 over 1253 and Fasten with button head. Keep bolts loose for further assy.

Place 1215A1 over center of 1221.

Fasten M4 bolts and washer on leaf spring. Keep leaf spring loose for further assy. Insert spacer in gap of middle triangle and leaf spring to keep leaf spring straight.

Put -411 to hole of 1204 Ensure flange of -411 is butted properly over 1204.

Put -409 passing through center of 1215A1, 1204 and hole of -01260.

Tight both M3 bolts of 1204 with torque of 0.75 N-m.

Tight 4xM4 bolts of leaf spring with torque of 2. 3 N-m Tight 4xM4 bolts of leaf spring with torque of 2.3 N-m. Ensure holding of triangle while tightening.

Remove 409 Remove 409 and 411 using tweezers.

Remove 411 using tweezers.

Take 1270A1-1qty and A2-2qty, M4 washers (item no.36), M4 bolt (item no. 50), allen bit(3mm), torque wrench 2.3 N-m and 5 N-m, 1206, 1207, thin spanner 17mm.

Place 4nos M4 bolt with flat washer over actuator mounting holes on casting using tweezers.

Place 1270A2 from bottom of casting, thread M16 of 1270 passes through 1204 and leaf spring Verify wire orientation of actuator towards opposite of 1221.

Fasten all 4 bolts of actuator.

Carefully tight with torque wrench of 2.3 N-m. Use extended torque wrench and ensure tools will not hit assy

Raise motor to butt flange of 1270 with leaf spring and apply locktite

Place 1207 over M16 thread of 1270.

Carefully insert 17 mm spanner to hold flats of 1270.

CAUTION!!.. Tight nut with 5 N-m, till its end. Ensure spanner and torque wrench are placed one above the other to avoid twisting. Ensure ratchet should go only one click while torquing.

Install 1270 A2 with same procedure as earlier Verify wire orientation of actuator towards opposite of 1221.

Place 1270A1 on 1253 from below. Verify orientation of actuator wire.

Put M4 flat washer, M4 spring lock washer and M4 bolt from below.

Fasten M4 bolts using 3mm hex bit with long extension. Tight M4 bolts using 2.3 N-m Mountz preset torque wrench.

Put bubble level on leaf spring.

Raise 1270 to butt collar of thread M16 on leaf spring.

Raise 1270 to adjust sprit bubble level to center.

Place 1207 and 1206 on M16 threads.

Apply locktite on M16 thread.

Place 17mm spanner to flats of part 1272 of actuator

CAUTION!!.. Tight nut with 5 N-m, till its end. Ensure spanner and torque wrench are placed one above the other to avoid twisting. Ensure ratchet should go only one click while torquing.