D. Install Interior Control Assembly
(1)
Install control cable casing (if removed).
(a)
Orient casing sections in accordance with markings etched on surface of casing and place sections of casing in position.
(b)
Join connectors at each end of casing section being installed; tighten connectors after all components have been assembled.
(c)
Set micro-adjust assembly to 2.30-inch nominal length (View 2).
(d)
Install tubing clamps securing sections of casing to structure. (Do not tighten tubing clamps at this time.)
(2)
Install control box (if removed).
(a)
Position control box on support bracket, insert control shaft through bearing into splines in control box and rotate shaft to check that shaft turns freely in the bearing. If shaft movement is stiff or if rough spots are felt, disengage shaft, remove control box and insert AN960PD10 or AN960PD10L washers between control box and bracket at bolt locations as required to align control box with shaft bearing. If control box has 1/8-inch diameter drain hole on aft face near bottom edge, check that drain hole is not obstructed.
NOTE: If the same control box is being installed the same quantity of washers (if any) should be installed on the shaft and at the four attach locations as were used when control box was previously installed.
(b)
Install bolts and shaft and recheck for freedom of shaft rotation.
(c)
Place modeling clay on full-length outboard side of lever striker pin and close and latch door.
(d)
Open entry door and check that forward edge of control box actuating lever is 0.10-inch minimum from striker pin mounting surface and lever engages pin a minimum of 0.50-inch (Ref. Sec. C-C).
(e)
Add one or two (AN960D616) washers between shaft collar and forward face of control box to obtain proper engagement if required.
(f)
Carefully disengage shaft from control box.
NOTE: Take care not to slide washers from shaft while disengaging shaft from control box.
(g)
Connect micro-adjust to control box.
(3)
Install telescoping unit (if removed).
NOTE: One end of casing section is marked either FWD or UP with an arrow to indicate orientation.
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(a) Position telescoping unit and washers on mounting bracket and secure with jam nuts.
NOTE: Telescoping unit is spring-loaded in the retracted position and is installed with AN960PD1016 washer on upper side of bracket and AN960PD1016L washer on lower side of bracket.
(4) Install control cable.
(a)
Prior to installation of cable, hand lubricate cable assembly with BMS 3-24 grease.
(b)
Insert end of cable into opening on upper side of control box and push cable through casing until cable emerges from telescoping unit adjacent to forward end of lock pin rocker arm (Detail B).
(c)
Install cable lock on end of cable at telescoping unit so that cable extends 0.60 (+ 0.05/- 0.05) inch past cable lock, and push cable into telescoping unit to seat cable lock (Sec. A-A).
(d)
Screw fork-end fitting into telescoping unit and torque to 200 pound-inches. Check that cable is visible at inspection hole in fork-end fitting.
(e)
Connect fork-end fitting of telescoping unit to forward end of rocker arm with bolt, washer and nut.
(f)
Position control shaft actuating lever as shown in Detail D and engage with control box to closest spline. Use micro-adjust unit if necessary to position lever within required tolerance (Detail D).
NOTE: If adjustment range of micro-adjust unit is exceeded, reset unit to nominal
2.30 dimension and reposition shaft in control box to adjacent spline and repeat step.
(g)
Install washer and nut on control shaft. Do not tighten.
(h)
Close and latch entry door and check that end of control cable is below upper face of control box within 0.2 (+ 0.7/- 0.05) inch.
NOTE: If end of cable is not within tolerance, the cable lock in telescoping unit must be released and reset required amount, or if cable is long, cable end can be trimmed required amount. Repeat steps (c) thru (g).
(i)
Install spent travel tube on upper side of control box (Detail C).
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