Lead Contributors:

Jason Shah (June 6 2014)

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Graphic Design:

Jean-Baptiste Vervaeck

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Version:

Date:

CEB 6 Secondary Cylinder Assembly Module

Assembly Summary

Open Source Ecology Developer’s Manual

Safety Equipment & Tools

Safety is very important during the process of this assembly.

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Be sure to wear:

• Construction helmet hat
• Welding gloves
• Eye protection
• Full body clothing
• Steel Toed Shoes

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For tools refer to Tutorial on Tools and Their Uses

Preparation : Part list (13 parts)

All the parts:

Preparation

• Identify the fitting locations on Y 1. On the side of the chrome-plated shaft there is only one fitting. On the other side of the cylinder, there are 2 fittings. Choose the one that is not on the same face of the cylinder, as shown on the image below.
• Take Y11, 1/2" x 3/8" swivel elbow, and bolt it on the cylinder Y1, on the side of the chrome-plated shaft.
• Take Y10, 1/2" x 3/8" swivel, and bolt it on the other side of the cylinder Y1
• Take the shortest hose Y8 and bolt it on the swivel Y11
• Take the largest hose Y9 and bolt it on the swivel elbow Y10
• Take the Y14 and Y15 quick couplers and fit them on the Y8 and Y9 hoses

Y11

Y10

Y12

Y9

Y13

Y1

Y8

Use PTFF thread tape and wrap each connections 3x around in the direction the threads tighten. Dont cover the first and second threads.

Preparation

• Take Y4 and Y5 (3” X 3” piece of ½” metal)
• This is already CNC cut
• Alternatively, punch with ironworker punch
• Alternatively, use a power drill or annular cutter to make the 1” holes.
• Make sure you use a round file to deburr the holes. Slide a 1” metal rod through the holes prior to welding to make sure the pin will fit through the holes.

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Can also use or

Y5

Y4

The pin to attach the secondary cylinder to the drawer module should be completed along with the drawer. (See drawer instructional for more information)

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The shaft was prepared by turning it on a lathe. We cut a groove for the snap ring approximately .1” from the end of the shaft and .25” deep.

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We welded a washer on the opposite side to create the pin for attaching the secondary cylinder to the main drawer.

On the side of the secondary cylinder not connected to the drawer, you must machine a second shaft with grooves for snap rings on both sides. Cut a shaft 4” long with a large bandsaw (with coolant). Prepare the shaft by turning it on a lathe. We cut two grooves for the snap rings approximately .1” from each end of the shaft and .25” deep. Use a round file on the inside of each square piece (Y4 and Y5) to ensure the shaft can fit through both. Before you weld Y4 and Y5 to the secondary arms ensure that the piston is properly aligned.

Note: The hydraulic fittings in this image are not in the correct orientation, they should be swapped. The angled fitting should go on the side closer to the drawer and the straight fitting should go on the side attached to the primary arms.

• This does not happen until final assembly
• Take Y1, Y2, Y3, Y4 and Y5 and put them in place
• The chrome-plated shaft of the Y 1 cylinder should face towards the drawer module. The fittings for hoses should face towards the direction of the controller.
• Use the two 1” pins (Y2 and Y3) through the pieces Y4, Y5 and the cylinder Y1, to hold the Y 1 cylinder in its placement . Make sure the holes for the cotter pins are outside of the steel pieces

Y4

Y5

Y1

Y3

Y2

When installing the hydraulic fittings, you must be mindful of how the drawer moves. The fitting attached directly to the secondary piston and must be positioned so that they do not interfere with the drawer.

• This does not happen until final assembly
• Put two clamps on the steel pieces Y4 and Y5 to hold them in place
• Weld the pieces Y4 and Y5 on the face of the brickholder plate of the drawer module.

Y4

Y5

Y1

Y3

Y2