R0000728 R0000729 Stroke Assembly Dismantling : Différence entre versions

[version en cours de rédaction][version en cours de rédaction]
 
(3 révisions intermédiaires par le même utilisateur non affichées)
Ligne 4 : Ligne 4 :
 
|Description=<translate>Instructions for refurbishment of R0000728 and R0000729 stroke assemblies using Kit R0000299</translate>
 
|Description=<translate>Instructions for refurbishment of R0000728 and R0000729 stroke assemblies using Kit R0000299</translate>
 
|Categories=Production
 
|Categories=Production
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|Difficulty=Very hard
+
|Difficulty=Hard
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|Duration=8
+
|Duration=3
 
|Duration-type=hour(s)
 
|Duration-type=hour(s)
 
}}
 
}}
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<u>'''Tools / consumables Required'''</u>  
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<u>'''Tools Required'''</u>  
  
  
Ligne 31 : Ligne 31 :
  
 
Degreasing bath  
 
Degreasing bath  
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+
   
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Solvent Fe10
 
−
 
 
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Loctite 243adhesive
 
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Loctite 641 bearing fit
 
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Thixotropic grease
 
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−
 
 
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<u>'''Parts Required'''</u>
 
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Kit R0000299 containing
 
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B0000043 Double Angular bearing 15 I?D 35 O?D 15.9 long rubber seal 3 x 2
 
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B0000105 Double Angular Bearing 15 I/D 35 O/D 15.9 Long x 1
 
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B0000335 3ph Brake motor 2 pole 3000rpm x 1
 
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B0000380 Double Angular Bearing 25 I/D 52 O/D 20.6 Long + rubber seal x 2
 
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D0000059 Damper Bridge x 1
 
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D0000062 Damper Bridge Boss x 2
 
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D0007730 ZX4 V Notch Mk1 Spindle Shaft x1
 
−
 
 
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D0007867 Bevel Gear (Left) x 1
 
−
 
 
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D0007868 Bevel Gear (Right ) x 1
 
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D0007873 Motor Gear x 1
 
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D0007874 Pinion Gear x 1
 
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D0007875 Pinion Shaft x 1
 
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Ligne 78 : Ligne 38 :
 
{{Materials}}
 
{{Materials}}
 
{{EPI}}
 
{{EPI}}
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{{Tuto Step
 
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|Step_Title=<translate>Handing clarification</translate>
 
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|Step_Content=<translate>R0000728 and R0000729 are mirror images to each other
 
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Please inspect pictures to clarify and confirm correct hand to be built
 
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(Supplied unit to be refurbished will always be rebuilt as the same hand )</translate>
 
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|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_075738.png
 
−
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−
|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_075806.png
 
−
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−
}}
 
−
{{Tuto Step
 
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|Step_Title=<translate>Unless otherwise stated</translate>
 
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|Step_Content=<translate>Always use Loctite 243 on all fasteners fitted unless stated different
 
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−
 
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All bearings should be an acceptable fit, with Loctite 641 and FE10 solvent used if required
 
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−
 
−
All fasteners should be marked once finalised</translate>
 
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|Step_Picture_00=R0008013_Clacker_assembly_quality.png
 
−
}}
 
 
{{Tuto Step
 
{{Tuto Step
 
|Step_Title=<translate>Disassembly</translate>
 
|Step_Title=<translate>Disassembly</translate>
Ligne 255 : Ligne 190 :
 
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104252.png
 
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104252.png
 
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 +
}}
 +
{{Tuto Step
 +
|Step_Title=<translate>Disconnect bevel gear</translate>
 +
|Step_Content=<translate>Lock drive flange as shown and remove M5 fastener on end of bevel gear
 +
 +
 +
Machined washer to be reused</translate>
 +
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104533.png
 +
|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104550.png
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|Step_Picture_02=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104556.png
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 +
}}
 +
{{Tuto Step
 +
|Step_Title=<translate>Remove bevel gear</translate>
 +
|Step_Content=<translate>1 Use drift to move bevel gear enough to allow pry bars to be used  underneath
 +
 +
2 Use pry bars to remove gear
 +
 +
 +
3 Key and shim washers to be reused
 +
 +
 +
Bevel gear to be disposed</translate>
 +
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104748.png
 +
|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104801.png
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|Step_Picture_02=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104852.png
 +
|Step_Picture_02_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":0,"top":0,"width":713,"height":751,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":0.84,"scaleY":0.84,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/6/62/R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_104852.png","filters":[]}],"height":632,"width":600}
 +
|Step_Picture_03=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105026.png
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 +
}}
 +
{{Tuto Step
 +
|Step_Title=<translate>Use press to remove blade flange</translate>
 +
|Step_Content=<translate>Press blade flange out of bearing assembly
 +
 +
 +
Spacer between 2 bearings should be reused</translate>
 +
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105324.png
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|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105330.png
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 +
|Step_Picture_02=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105813.png
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}}
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{{Tuto Step
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|Step_Title=<translate>Remove bearing from housing</translate>
 +
|Step_Content=<translate>Remove bearing using drift and dispose of bearing</translate>
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|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105556.png
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|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105603.png
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}}
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{{Tuto Step
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|Step_Title=<translate>Remove bearing housing</translate>
 +
|Step_Content=<translate>Disconnect 4 off M6 countersunk bolts and separate bearing housing from face plate
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 +
 +
Both parts to be reused</translate>
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|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105726.png
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|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_105732.png
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}}
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{{Tuto Step
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|Step_Title=<translate>Remove motor pinion housing</translate>
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|Step_Content=<translate>1 Remove 4 off M6 socket caps as shown
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 +
 +
2 Separate block from motor
 +
 +
 +
Motor pinion housing to be refurbished . Motor and pinion to be disposed</translate>
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|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110021.png
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 +
}}
 +
{{Tuto Step
 +
|Step_Title=<translate>Disposed parts not required</translate>
 +
|Step_Content=<translate></translate>
 +
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110302.png
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|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110323.png
 +
}}
 +
{{Tuto Step
 +
|Step_Title=<translate>Clean and degrease</translate>
 +
|Step_Content=<translate>Clean and degrease parts indicated for rebuild</translate>
 +
|Step_Picture_00=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110646.png
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|Step_Picture_00_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":0,"top":0,"width":1189,"height":699,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":0.5,"scaleY":0.5,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/3/3d/R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110646.png","filters":[]},{"type":"textbox","version":"2.4.6","originX":"center","originY":"center","left":165.69,"top":103.27,"width":47.8,"height":22.6,"fill":"#FF0000","stroke":"#FF0000","strokeWidth":1,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":3.94,"scaleY":3.94,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"text":"X","fontSize":20,"fontWeight":"normal","fontFamily":"sans-serif","fontStyle":"normal","lineHeight":1.16,"underline":false,"overline":false,"linethrough":false,"textAlign":"left","textBackgroundColor":"","charSpacing":0,"minWidth":20,"styles":{} }],"height":353,"width":600}
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|Step_Picture_01=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110431.png
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|Step_Picture_02=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110441.png
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|Step_Picture_03=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110445.png
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|Step_Picture_04=R0000728_R0000729_Stroke_Assembly_Refurbishment_with_R0000299_Kit_Screenshot_2024-06-04_110455.png
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Version actuelle datée du 4 juin 2024 à 11:15

Instructions for refurbishment of R0000728 and R0000729 stroke assemblies using Kit R0000299

Auteur avatarGareth Green | Dernière modification 4/06/2024 par Gareth Green en cours de rédaction

Difficulté
Difficile
Durée
3 heure(s)

Instructions for refurbishment of R0000728 and R0000729 stroke assemblies using Kit R0000299

Difficulté
Difficile
Durée
3 heure(s)

Introduction

Assemblies fitted to MK1 ZX4 will require refurbishment at some point of life cycle.


The following instructions should be followed to ensure that correct assembly and setting are performed


Tools Required


Standard hex key set

Standard spanner set

Double pin saw flange spanner

Drifts and punches

Ballpein hammer

Soft hammer

Degreasing bath



Étape 1 - Disassembly

The stroke assembly must be dismantled in the exact manner stated as many sections can only be removed once mating parts have been extracted


Please use the following steps accurately

R0015338 Bench Assemble Serial Plate caution.png



Étape 2 - Remove blade Guard

Remove M5 socket cap and washer and slide off blade guard


Blade guard to be reused

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 091001.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 091027.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 091033.png


Étape 3 - Remove Blade

use 24mm ring spanner and saw blade pin spanner to remove blade from assembly


Dispose of saw blade and M16 bolt


Keep M16 Washer and blade flange for rebuid

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 092430.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 092439.png


Étape 4 - Remove damper bridge

Remove 2 off m8 fasteners to remove damper bridge and pillars


Dispose of all parts

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 092739.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 092748.png


Étape 5 - Disconnect front blade assembly

1 Rotate blade flange with a 25mm spanner to align 2 off M6 cap heads through access holes

2 Remove 2 off m6 socket cap bolts

3 Rotate blade flange to align second set of M6 socket caps and remove

4 off in total M6 socket caps to be removed

...There are also 4 off M6 countersunk bolts that are accessible through these access holes. These must not be removed

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102054.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102312.png

Étape 6 - Extract front blade assembly

Front assembly can now be extracted from the main housing

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102414.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102439.png


Étape 7 - Extract 2 off shafts

Remove 4 off M8 grubscrews indicated and extract 2 off hardened shafts from main body


Shafts to be refurbished

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102555.png


Étape 8 - Remove hard stop

Use 17mm spanner to remove hard stop as shown


Hard stop to be refurbished

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102747.png



Étape 9 - Remove motor assembly

1 Remove 3 off M8 socket caps indicated


2 Separate as shown . Two components are doweled together, use caution to not damage any faces when separating two parts

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 102844.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103004.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103008.png

Étape 10 - Remove Pinion bolt and shaft bolt

Remove fasteners as shown


Machined washer to be reused

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103146.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103156.png

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103212.png

Étape 11 - Remove drive pinion

Raise pinion shown to allow blocks to be added beneath


Use drift to separate pinion from shaft


Dispose of pinion gear

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103220.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103225.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103436.png


Étape 12 - Remove drive shaft

1 Remove 3 off M6 countersunk bolts shown

2 Remove top cap and keep for refurbishment

3 drive shaft from base to extract assembly from housing

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103657.png

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 103713.png

Étape 13 - Extract shaft from bearing housing

Extract shaft as shown, and remove bearings from housing


Dispose of bearings

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104106.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104113.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104118.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104124.png

Étape 14 - Remove keys from shaft

Remove two off keys from shaft to reuse and dispose f rest of components



Étape 15 - Disconnect bevel gear

Lock drive flange as shown and remove M5 fastener on end of bevel gear


Machined washer to be reused

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104533.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104550.png


Étape 16 - Remove bevel gear

1 Use drift to move bevel gear enough to allow pry bars to be used underneath

2 Use pry bars to remove gear


3 Key and shim washers to be reused


Bevel gear to be disposed

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104748.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 104801.png

Étape 17 - Use press to remove blade flange

Press blade flange out of bearing assembly


Spacer between 2 bearings should be reused

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 105324.png


Étape 18 - Remove bearing from housing

Remove bearing using drift and dispose of bearing

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 105556.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 105603.png


Étape 19 - Remove bearing housing

Disconnect 4 off M6 countersunk bolts and separate bearing housing from face plate


Both parts to be reused

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 105726.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 105732.png


Étape 20 - Remove motor pinion housing

1 Remove 4 off M6 socket caps as shown


2 Separate block from motor


Motor pinion housing to be refurbished . Motor and pinion to be disposed


Étape 21 - Disposed parts not required

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 110302.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 110323.png


Étape 22 - Clean and degrease

Clean and degrease parts indicated for rebuild

R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 110431.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 110441.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 110445.png
R0000728 R0000729 Stroke Assembly Refurbishment with R0000299 Kit Screenshot 2024-06-04 110455.png

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