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's HW1000 Procedure

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YOU NEED TO DO THIS AT THE START OF EACH BUILD.

Unit Content

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O_PEO_1 – Bevel Gear 95 Topics
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Session Content
0% Complete 0/95 Steps
A.1.1- Check security and the condition of machine cover, write any inspection notes in the notes section and click save.
A.1.2 – Open the crank handle access door, insert the crank handle and carry out safe manual isolation.
A.1.3 Perform a manual function test, ensuring there is input to output movement, remove the crank handle.
A.1.4 – Remove machine cover, using correct manual handling techniques and place it in the safe area.
A.1.5 – Check the security of gearbox cover, clean if dirty, and release (but do not remove fully) the 3 captive screws on the gearbox cover.
A.1.6 – Remove and inspect the cover, clean the underside if dirty, and place the cover in a the safe area.
A.1.7 – Identify main components shown in Diagram 001
A.1.8 – Re-insert the crank handle and perform another manual function test, looking for any obvious problems with the machine, visually inspect the machine components, whilst turning the crank handle. Write any inspection notes in the notes section and click save.
A1.9 – Set the machine to its mid position and remove the crank handle.
B.0.0 – Tool list, write any missing tools in the notes section and click save.
B.0.1 – Identify the conduit, proof mark the conduit and remove the 2 saddle clamps.
B.0.2 – Lift the conduit & wiring loom away from the equipment and place in the safe area.
B.0.3 – Inspect the saddle clamps / fixings and refit into their respective positions, write any inspection notes in the notes section and click save.
B.1.1 – Disconnect wiring loom spade connections (or plug) at motor connection block Do Not remove the motor connection block.
B.1.2 – Proof-mark the motor position against the gearbox frame.
B.1.3 – Place the 2 Angle Iron Chocks on the workbench where you will place the motor.
B.1.4 – Select the Wooden Dowel and place beneath the motor to act as a support roller.
B.1.4 – Using a ½” AF Spanner OR A 1/4 WW Spanner, release the 2 nuts, on each side of the motor flange.
B.1.5 – Remove the 2 nuts, flat and spring washers and place to one side, then release the nut at the top of the motor flange
B.1.6 – Ensuring the motor is supported by the previously placed wooden dowl, remove top nut and washers and place to one side.
B.1.7 – Hold the motor securely and using the wooden dowl as an aid move the motor away from the gearbox sub frame until it comes clear of the studs.
B.1.8 – Lift the motor from the machine using correct manual handling techniques and place in the safe area on the work bench using Angle Iron Chocks, to prevent it rolling off the bench.
B.1.9 – Refit the 3 nuts and flat washers onto the gearbox frame studs.
B.1.10 – Return the finished tools back to the designated locations, write any missing or damaged tools in the notes section and click save.
B.1.11 – Visually Inspect – Motor flange / gearbox sub frame Interface – burrs / debris between faces, write any inspection notes in the notes section and click save.
B.1.12 – Visually Inspect – Inspection cover – security and condition, write any inspection notes in the notes section and click save.
B.1.13 – Visually Inspect – Motor body / power connection block condition, write any inspection notes in the notes section and click save.
B.1.14 – Visually Inspect – Motor drive gear – burrs / unusual wear to gear teeth, write any inspection notes in the notes section and click save.
B.1.15 – Visually inspect – Motor fixings, write any inspection notes in the notes section and click save.
B.2.1 – Visually inspect the gearbox sub-assembly fixings, write any inspection notes in the notes section and click save.
B.2.2 – Diagonally proof mark the 2 Machined Bolts of the 4 bolts, which hold the gearbox sub frame to the machine chassis.
B.2.3 – Using a 7/16” Whitworth Socket. Diagonally release the 4 bolts one turn, to remove any stored energy.
B.2.4 – When satisfied it is safe to do so and there is no apparent preload on the gearbox, remove the 4 bolts with the spring and flat washers, and place to one side.
B.2.5 – Carefully slide the gearbox away from the bevel gear assembly until enough room is created to lift the gearbox from the machine chassis.
B.2.6 – With the help from a colleague (if required) and using correct handling techniques, lift the gearbox from the machine and place onto the work bench.
B.2.7 – Inspect the bolts and washers, checking that the machined bolts were in the correct location, write any inspection notes in the notes section and click save.
B.2.8 – Re-proof mark bolts if necessary and refit into their respective holes on the chassis.
B.2.9.1 – Visually inspect the parts again for signs of damage and wear and note down in the notes section and click save.
B.2.9.2 – Return the finished tools back to the designated locations.
B.3.1 – Visually inspect the Bevel Gear Sub-assembly fixings, write any inspection notes in the notes section and click save.
B.3.2 – Place the Wooden Blocks slightly apart on the work bench, in the correct configuration to support the Bevel Gear Sub-assembly.
B.3.3 – Using a 1 7/8” AF Socket and 3/4” Drive T-bar, release the bevel gear Philidas nut.
B.3.4 – Undo the nut until it is no longer held by its lock and rotates freely.
B.3.5 – Diagonally proof mark the 2 machined bolts of the 4 bolts which hold the bevel gear casting to the points machine housing.
B.3.6 – Using a 7/16” Whitworth Socket. Diagonally release the 4 bolts one turn, to remove any stored energy.
B.3.7 – When satisfied it is safe to do so and there is no apparent preload on the bevel gear assembly remove the 4 bolts with the spring and flat washers, and place to one side.
B.3.8 – With the help from a colleague (if required) and using correct handling techniques, lift the bevel gear assembly from the machine chassis and place onto the wooden blocks.
B.3.9 – Inspect the bolts and washers, checking that the machined bolts were in the correct location, write any inspection notes in the notes section and click save.
B.3.10 – Re-proof mark bolts if necessary and refit into their respective holes on the chassis.
B.3.11 – Clean off any dirt/grease from the machine chassis.
B.3.12 – Return the finished tools back to the designated locations.
B.4.0 – Visually inspect throw bar and slide bar fixings, record any findings in the notes section and click save.
B.4.1 – Proof-mark the throw bar to indicate its orientation.
B.4.2 – Proof-mark the throw bar caps.
B.4.3 – Using a 5/16” Whitworth Socket release the fixings which hold the throw bar caps in position, on either side of the machine.
B.4.4 – Lift both caps from the machine along with the top slide packers.
B.4.5 – Lift out the throw bar, and clean.
B.4.6 – Place throw bar in the safe area.
B.4.7 – Remove and layout the remaining slide packers in their correct orientation and clean.
B.4.8 – Remove the split pin and Lift slide bar from the machine.
B.4.9 – Clean the slide bar and remove any surplus grease from the machine chassis.
B.4.10 – Visually inspect the parts again for signs of damage and wear, record any findings in the notes section and click save.
B.4.11 – Use the Vacuum Cleaner to remove any debris or foreign objects from the chassis.
B.4.12 – Return the tools back to the designated locations.
C.0.0 – Tool, Document, Equipment and Material List
C.0.1 – With the bevel gear housing supported on the Wooden Blocks, remove the Philidas nut.
C.0.2 – Carefully release the stub shaft by hitting the top of the threaded part of the stub shaft with the Nylon Mallet, until it has disengaged from the 2 roll pins.
C.0.3 – Lift the bevel gear housing from the blocks and position on the bench, ensure the housing is laid flat.
C.0.3 – Place the stub shaft on the bench, clean and degrease all components.
C.1.1 – Visually inspect all the following parts for signs of damage and wear, record any findings in the notes section and click save.
C.2.1 – Using diagrams 002 and 003, take dimensions as required and record them on notes below. Remember there is nine measurements in this section.
D.0 – Tools, Equipment and Material Lists
D.0.1 – Remove the bevel gear sub-assembly bolts and washers from the chassis and place to one side.
D.0.2 – Ensure the 2 roll pins is flush against the top of the bevel gear housing, if not, gently tap the roll pins in place using the Nylon Mallet and the Pin Punch.
D.0.3 – Support the bevel gear housing on the Wooden Blocks so that the underside of the housing is facing upwards.
D.0.4 – Apply a thin coat of grease to all moving interfaces using a brush.
D.0.5 – Ensuring correct orientation, place the bevel gear into the housing.
D.0.6 – Ensure the thrust washer is fitted onto the stub shaft.
D.0.7 – Slide the stub shaft through the bevel gear and housing until the shaft touches the roll pins.
D.0.8 – Rotate the shaft until you feel the holes in the shaft locate onto the roll pins.
D.0.9 – Using a Nylon Mallet, tap the shaft onto the roll pins until full location has been achieved. 
D.0.10 – Fit the Philidas nut onto the shaft and screw it down until it reaches a lock position (finger tight).
D.0.11 – Lift the bevel gear assembly onto the machine chassis using correct manual handling techniques and move until the fixing holes align.
D.0.12 – Ensure that the assembly lies flat on the chassis.
D.0.13 – Place the 2 machined bolts into their correct holes, ensure full alignment.
D.0.14 – Using a 7/16” Whitworth Socket and hand tighten the 2 machined bolts.
D.0.15 – Use the torque wrench and tighten to the torque of 30 Nm.
D.0.16 – Now that the bevel gear assembly is secure to the chassis, you can tighten the Philidas nut to a torque of 1000 Nm (100 Nm in the workshop and ½” to ¾” adapter required).
D.0.17 – Return the finished tools back to the designated locations. Ensure the torque wrench is backed off.
D.1.1 – Release the bevel gear assembly from the point’s machine chassis by removing the 2 machined bolts.
D.1.2 – Lift the assembly from the machine using correct manual handling techniques and place face down on the Wooden Blocks.
D.1.3 – Refit the assembly bolts and washers to the chassis in their correct positions.
D.1.4 – Using a Nylon Mallet tap the bevel gear to ensure correct seating.
D.1.5 – Bearing End float Measurement, record any findings in the notes section and click save.
D.1.6 – Return the finished tools back to the designated locations.
O_PEO_2 – Gear Box 115 Topics
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Session Content
0% Complete 0/115 Steps
E0 – Check that all the gearbox special tools are complete and serviceable, record any findings in the notes section and click save.
E.0.1 – Inspect the Manual Drive Lug and crank handle engagement
E.1.1 – Using a Nut Spinner or flat head remove the bearing Retaining Screws/cheese head screws and the washers situated on the gearbox frame
E.1.2 – Using a suitably sized Pin Punch and Nylon Mallet, remove the Roll Pin which secures the clutch assembly to the shaft.
E.1.3 – Support the clutch assembly and using a Nylon Mallet and Shaft Drift, remove the shaft from the gearbox frame in the direction of Arrow 1.
E.1.4 – Remove the clutch assembly from the gearbox frame.
E.1.5 – Using the Hollow Drift remove the bearing from the shaft.
E.1.6 – Clean all grease from the gears on the clutch assembly.
E.1.7 – Return the finished tools back to the designated locations.
E.1.8 – Visually inspect manual drive lug, bearing retaining screws, roll pin, clutch shaft, bearings and clutch gears for signs of wear or damage, record any findings in the notes section and click save.
E.2.1 – Using a Nut Spinner/ flat head screwdriver remove the bearing Retaining Screws and the washers situated on the gearbox frame.
E.2.2 – Using a 3mm Allen key, remove the Grub Screw which secures the intermediate drive gear to the shaft.
E.2.3 – Check the intermediate drive gear can slide freely on the shaft.
E.2.4 – Support the intermediate drive gear and using a Nylon Mallet and Shaft Drift, remove the shaft from the gearbox frame in the direction of Arrow 2.
E.2.5 – Remove the intermediate drive gear from the gearbox frame.
E.2.6 – Use the Hollow Drift if required to remove the bearing from the shaft.
E.2.7 – Clean all grease from the intermediate drive gear.
E.2.8 – Return the finished tools back to the designated locations.
E.2.9 – Visually inspect bearing retaining screws, grub screw, intermediate shaft, bearings and intermediate gears for signs of wear or damage, record any findings in the notes section and click save.
E.3.1 – Using a Nut Spinner/ flat head screw driver remove the Retaining Screws/cheese head screws with the washers situated on the gearbox frame.
E.3.2 – Using a 3mm Allen key, remove the Grub Screw which secures the pinion drive gear to the shaft.
E.3.3 – Check the pinion drive gear can slide freely on the shaft.
E.3.4
E.3.5 – Separate the components, noting orientation and position of the spacer.
E.3.6 – Clean all grease from the gear and pinion shaft.
E.3.7 – Return the finished tools back to the designated locations.
E.3.8 – Inspect bearing retaining screws, grub screw, pinion shaft & gear, pinion shaft support bearings, woodruff key, bearings and gearbox frame, for signs of wear or damage. record any findings in the notes section and click save..
E.4.1 – Using the Void Extractor, ¾” AF Socket and 19 mm Spanner, remove any remaining bearings from the gearbox sub-frame.
E.4.2 – Return the finished tools back to the designated locations.
E.5.1 – Use the 3-Legged Puller, the Bench Vice and the T-bar (limited availability), to remove the pinion shaft support bearing. Do Not clamp the gear teeth or the bearing.
E.5.2 – Return the finished tools back to the designated locations.
E.6.1 – Lay the clutch assembly onto a workbench, with the springs facing upwards.
E.6.2 – Proof-mark the clutch cover, pressure plate and centre gear.
E.6.3 – Use the 1/4” Whitworth Socket to release the 4 Nyloc nuts equally (releasing stored energy) until the springs are loose, then continue to remove the Nyloc nuts, washers, and tension springs.
E.6.4 – Lift out the pressure plate, first friction plate, fixed gear assembly, second friction plate and place in a clean area on the bench.
E.7.1 – Measure the thickness of the clutch friction plates and record your findings. Compare your findings to the thickness stated in Diagram 005 and decide if they require changing.
E.7.2 – Compare your findings to the thickness stated in Diagram 005 and decide if they require changing.
E.7.3 – Refit the two bearings on the clutch shaft. Using DTI and Vee Blocks check the Clutch Shaft for “Runout”, at both bearing points; record your findings.
E.7.4 – Remove the two bearings on the clutch shaft.
E.7.5 – Inspect the studs, tension springs, Nyloc nuts and washers.
E.7.6 – Use Diagram 006 as a guide, record any findings in notes below.
E.7.7 – Check the pressure plate for signs of wear, distortion or damage. (Note use Straight Edge and feeler gauges, to check for Flatness of the Pressure Plate).
E.7.8 – Check the fixed gear assembly for signs of wear or damage and the security of the rivets.
E.7.9 – Check the drive gear and dust shield for signs of wear or damage.
E.7.10 – Check the condition and security of the phosphor bronze bush, note if it is loose or damaged.
E.7.11 – Check the friction plates for signs of contamination, distortion, damage and discolouration, record any findings in the notes section and click save.
E.7.12 – Check the condition of the shaft, bearings and roll pin, record any findings in the notes section and click save.
E.7.13 – Return the finished tools back to the designated locations.
F.0.1 – Lay out all the parts required for assembly onto a clean surface.
F.0.2 – Check all items and ensure that there is no contamination from oil or grease on the friction plates or their mating surfaces.
F.0.3 – Place the drive gear on the two metal blocks on the bench with the studs facing upwards.
F.0.4 – Place the first friction plate onto the drive gear.
F.0.5 – Place the fixed gear assembly over the friction plate.
F.0.6 – Place the second friction plate over the fixed gear assembly and centralise.
F.0.7 – Check that the roll pin hole is central to any two studs, if not, rotate parts.
F.0.8 – Place the pressure plate over the studs and onto the second friction plate.
F.0.9 – Clutch Plates Alignment (dry fitting): Insert the clutch drive shaft through the assembly until it protrudes through to the other side. This will ensure that the assembly aligns when adjusting the clutch tension springs.
F.0.10 – Place the clutch springs and washers over the 4 studs.
F.0.11 – Place a Nyloc nut onto each of the studs and loosely rotate the nuts down to the lock position (hand tight).
F.0.12 – With the shaft still inserted, gradually tighten the lock nuts diagonally using a 1/4” Whitworth Socket, until all four nuts have been tightened to a distance of 34 mm (use a steel rule), between the pressure plate and the top of the Nyloc nut.
F.0.13 – Check the clutch drive shaft still slides freely through the clutch assembly, to ensure the correct alignment of the clutch plates.
F.0.14 – Remove the clutch drive shaft from the clutch assembly.
F.0.15 – Place the clutch assembly and shaft onto the bench.
F.0.16 – Remove all proof marking from the clutch components with a wire brush and return the finished tools back to the designated locations.
F.1.1 – Lay out all items on a clean work surface and pre inspect all components for cleanliness, damage and serviceability.
F.1.2 – Check all components are clean and free from contamination, oil or grease.
F.2.1 – Use the 3-Legged Puller, the Bench Vice and the T-bar (limited availability), to refit the pinion shaft support bearing.
F.3.1 – Select a bearing retaining screw and a washer, insert them into the gearbox frame at Position A and tighten using the Nut Spinner/ Flat head screw driver.
F.3.2 – Select a small bearing and position against its mating interface within the sub-frame then gently knock the bearing into the sub-frame using the Bearing Drift and Nylon Mallet until it touches the retaining screw.
F.3.3 – Select the spacer and place it onto the pinion gear shaft.
F.3.4 – Select the woodruff key and place it into the keyway in the pinion gear shaft ensuring it has fully located, and the key’s upper face is parallel to the shaft.
F.3.5 – To check alignment and orientation, slide the pinion drive gear onto the shaft over the key and check the grub screw hole aligns with the dimple on the shaft. Ensure smoothness between the components (use emery cloth or hand stone if necessary).
F.3.6 – Ensure correct orientation, hold the pinion drive gear into position in the gearbox frame and slide the pinion gear shaft through the drive gear in the direction of Arrow 3 until the key slides through the keyway in the drive gear.
F.3.7 – Align the shaft with the previously fitted bearing in the sub-frame, and the pinion shaft bearing with the interface in the sub-frame.
F.3.8 – Using a Nylon Mallet knock the pinion into place so that the pinion shaft bearing is fully located into the sub-frame.
F.3.9 – Select the 2 cheese head screws and washers and insert them into their mating holes shown at Position B and tighten using a large flathead screwdriver.
F.3.10 – Look down the tapped hole in the drive gear and align the hole with the dimple in the pinion shaft. Select a grub screw and insert it into the tapped hole in the drive gear, screw it down with the 3 mm Allen key until the screw locates into the dimple then tighten.
F.3.11 – Check the security of the drive gear, ensuring it cannot slide along the shaft.
F.3.12 – Rotate the completed assembly to ensure freedom of movement (Function Check).
F.3.14 – Return the tools back to the designated locations.
F.4.1 – Select a bearing retaining screws and insert into the sub-frame in Position A and tighten.
F.4.2 – Position A  – Select a bearing and position against its mating interface within the sub-frame then reconfigure the Void Extractor and assemble it over the bearing.
F.4.3 – Position A – Using a 19 mm Spanner and ¾” AF Socket push the bearing into the sub-frame, until it touches the retaining screw.
F.4.4 – Select the intermediate drive gear and slide the shaft into the gear to check its fit. If there is any tightness, check the components for any damage such as burrs or indentations use a Hand Stone or Emery Cloth to remove them until the parts fit correctly.
F.4.5 – Ensuring the tapped grub screw hole is uppermost, hold the intermediate drive gear into position over the gearbox sub-frame.
F.4.6 – Take the shaft and set the dimple uppermost then slide the shaft through the drive gear in the direction of Arrow 2 until the shaft locates into the previously fitted bearing.
F.4.7 – Using a Nylon Mallet, knock the shaft until the shoulder of the shaft touches the bearing.
F.4.8 – Select a second bearing and locate into the interface of the sub-frame and using a Bearing Drift and Nylon Mallet knock the bearing into the sub-frame.
F.4.9 – Look down the hole at Position B and continue to knock the bearing in until it passes the hole.
F.4.10 – Select a second retaining screw and insert it into the hole shown at Position B and tighten.
F.4.11 – Look down the tapped hole in the drive gear and align the hole with the dimple in the shaft at Position C.
F.4.12 – Select a grub screw and insert it into the tapped hole in the drive gear, screw it down with the 3 mm Allen key until the screw locates into the dimple then tighten.
F.4.13 – Rotate the completed assembly to ensure freedom of movement, check alignment of gears to establish correct assembly.
F.4.14 – Return the tools back to the designated locations.
F.5.1 – Select a bearing retaining screws and insert into the sub-frame in Position A and tighten.
F.5.2 – Select a bearing and position against its interface within the sub-frame then gently knock the bearing into position using the Bearing Drift and Nylon Mallet until it touches the retaining screw.
F.5.3 – Select the clutch assembly and slide the shaft into the gear to recheck freedom of movement.
F.5.4 – Ensuring correct orientation, hold the clutch assembly into position over the gearbox sub-frame with the roll pin hole at Position C facing uppermost.
F.5.5 – Set the roll pin hole uppermost on the shaft then slide it through the drive gear in the direction of Arrow 1 until the shaft locates into the previously fitted bearing.
F.5.6 – Using a Nylon Mallet knock the shaft into place so that the shoulder of the shaft touches onto the bearing.
F.5.7 – Select a second bearing and slide over the shaft to locate into the interface of the sub-frame and using the Hollow Drift and Nylon Mallet knock the bearing so that it passes the tapped hole at Position B.
F.5.8 – Select a second retaining screw and insert it into Position B and tighten (hand tight).
F.5.9 – Look down the hole in the drive gear and align it with the hole in the shaft.
F.5.10 – Insert the roll pin into the hole in the drive gear at Position C.
F.5.11 – Using a Pin Punch and Nylon Mallet drive it down until the roll pin has fully located into the hole and centred.
F.5.12 – Rotate the completed assembly to ensure freedom of movement, check alignment of gears to establish correct assembly.
F.5.13 – Return the tools back to the designated locations.
F.6.1 – Using the Universal Gauge at position 1, as a Height Gauge (Go Gauge), check the clutch springs preload adjustment.
F.6.2 – Adjust the tension on the Nyloc nuts if required, to obtain the required distance.
F.6.3 – Inspect the sub frame to ensure there are no cracks, record any findings in the notes section and click save.
F.6.4 – Inspect the security of all fixings, record any findings in the notes section and click save.
F.6.5 – Ensure the gears are meshed correctly.
F.6.6 – Ensure gearbox rotates in both directions.
F.6.7 – Apply a light coating of grease to all gear teeth.
F.6.8 – Return the finished tools back to the designated locations.
O_PEO_3 – HW1000 Complete Build 68 Topics
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Session Content
0% Complete 0/68 Steps
G.0.0 – Tool list
G.0.1 – Lay out all items on a clean work surface sequentially in readiness for assembly.
G.0.2 – Check all items are clean and uncontaminated.
G.1.1 – Apply a thin coating of grease to the slide bar bushes and the underside of the bar at the bush interfaces.
G.1.2 – Ensuring correct orientation and fit the slide bar.
G.1.3 – Prepare a split pin and correctly fit on the slide bar pivot pin, as per Network Rail Standards.
G.1.4 – Ensuring correct orientation fit the throw bar slide packers into the lower and side positions of the chassis ensuring they have completely located. Ensure the machined faces are on the inside.
G.1.5 – Lightly grease all the slide packer faces (machined).
G.1.6 – Place the throw bar into position ensuring correct orientation, ensure the machined side face down.
G.1.7 – Lightly grease top slide packer face (machined).
G.1.8 – Place the top slide packers and throw bar caps into position.
G.1.9 – Fit the fixings on each cap and hand tighten using a 5/16” Whitworth socket
G.1.10 – Use a torque wrench and tighten the fixing to 20 Nm.
G.1.11 – Check the throw bar moves fully backwards and forwards (Function Check).
G.1.12 – Remove all proof marking with a Wire Brush.
G.1.13 – Return the finished tools back to the designated locations. Ensure the torque wrench is backed off.
G.2.1 – Remove the bevel gear assembly bolts and washers from the machine chassis
G.2.2 – Centralise the throw and slide bar in the point’s machine chassis.
G.2.3 – Rotate the bevel gear until the throw bar cam follower bearing is in the correct orientation.
G.2.4 – Carefully lift the bevel gear assembly using correct manual handling techniques.
G.2.5 – Position the bevel gear assembly over the chassis and lower into position, ensuring the throw bar cam follower spigot locates through the throw bar and into the slide bar bush.
G.2.6 – If needed move the bevel gear assembly over the point’s machine chassis until the fixing holes align.
G.2.7 – Place the 2 machined bolts and washers into their correct holes and tighten by hand.
G.2.8 – Tighten the 2 machined bolts to 30 Nm using a 7/16” Whitworth Socket. Ensure they are tightened first.
G.2.9 – Place the 2 standard bolts and washers into the correct holes and hand tight them first. Then tighten the them to 30 Nm using a 7/16” Whitworth Socket.
G.2.10 – Perform a function check to ensure freedom of movement of the bevel gear, throw bar and slide bar.
G.2.11 – Remove all proofing marking with a Wire Brush.
G.2.12 – Return the finished tools back to the designated locations. Ensure the torque wrench is backed off.
G.2.13 – Return the finished tools back to the designated locations. Ensure the torque wrench is backed off.
G.3.2 – Remove the gearbox assembly bolts and washers from the machine chassis.
G.3.3 – Lift the gearbox using correct manual handling technique and position slightly away from the bevel gear assembly.
G.3.4 – Slide the gearbox toward the bevel gear assembly ensuring the pinion gear makes mesh with the bevel gear.
G.3.5 – If needed move the gearbox assembly over the point’s machine chassis until the fixing holes align.
G.3.7 – Place the 2 machined bolts and washers in the correct holes and hand tighten them first. Then tighten the machined bolts to 30 Nm using a 7/16” Whitworth Socket.
G.3.8 – Place the 2 standard bolts and washers in the correct holes and hand tighten them first. Then tighten them to 30 Nm using a 7/16” Whitworth Socket.
G.3.9 – Perform a function check to ensure freedom of movement.
G.3.10 – Remove all proof marking with a Wire Brush.
G.3.11 – Return the finished tools back to the designated locations. Ensure the torque wrench is backed off.
G.4.1 – Clean all interfaces prior to assembly.
G.4.2 – Remove the 3 nuts and washers from the gearbox frame.
G.4.3 – Place the Wooden Dowel in the chassis, so it acts as a roller for the motor. Then ensuring the correct orientation, lift the motor using correct manual handling techniques and rest it on the Wooden Dowel.
G.4.4 – Align proof marks on the motor and gearbox frame and roll the motor into position over the studs.
G.4.5 – Loosely fit the nuts and washers to the studs.
G.4.6 – Remove the Wooden Dowel and place it back on tool board.
G.4.7 – Ensuring the bottom of the motor has fully engaged with its gearbox interface, close the gap at the top of the motor and hand tighten the top nut and washers first, then the side nuts and washers.
G.4.8 – Use a ½” AF Spanner (limited availability) or 1/4” WW spanner to tighten the top nut and washers first, then tighten the 2 side nuts and washers.
G.4.10 – Perform a function check to ensure freedom of movement.
G.4.11 – Remove all proof marking with a Wire Brush.
G.4.12 – Return the finished tools back to the designated locations.
G.5.0 – Clean all interfaces prior to assembly.
G.5.1 – Remove the saddle clamps and fixings from their bases and position the conduit.
G.5.2 – Refit the saddle clamps and fixings, hand tighten but ensuring the conduit still has freedom of movement.
G.5.3 – Using the Universal Gauge at position 2, as a Clearance Gauge (Go Gauge), locate the gauge at the bottom of a gear tooth and move the conduit as required to ensure the proper running clearance.
G.5.4 – Secure the saddle clamps
G.5.5 – Perform a function check to ensure there is clearance between the conduit and gear.
G.5.6 – Reconnect the chassis wiring.
G.5.7 – Remove all proof marking with a Wire Brush.
G.5.8 – Return the finished tools back to the designated locations.
G.6.0 – Visually inspect the completed assembly and remove any contamination, debris or missed tools, record any findings in the notes section and click save.
G.6.1 – Perform a manual function test for freedom of movement and correct operation.
G.6.2 –  Measure the Throw Bar Travel – LH Side.
G.6.3 –  Measure the Throw Bar Travel – RH Side.
G.6.4 –  Throw Bar Clearance – LH Side.
G.6.5 –  Throw Bar Clearance – RH Side.
G.6.6 –  Throw Bar Backlash RH side and then LH side
G.6.7-  Measure Gearing Backlash.
G.6.10 – Present the machine for inspection by the tutor.
G.6.11 – Rectify any errors noticed during the inspection if applicable.
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