MANUFACTURING INSTRUCTION OPERATIONS RECORD

PART NUMBER DESCRIPTION DWG REV MI REV

565-5208-3-ROHS Switch, 6 position A

NEXT HIGHER ASSEMBLY NO CUSTOMER / PROGRAM SALES ORDER #

WORK ORDER # QTY SERIAL # PREPARED BY DATE

D. Logue 12/12/23
APPROVALS
ENGINEERING DATE MANUFACTURING DATE QUALITY ASSURANCE DATE

(THE TABLE BELOW SHOULD BE COMPLETED FOR THE MI COPY BEING SPLIT FROM, A COPY OF SPLIT# QTY
THE JOB ORDER AND COPY OF THE MI WITH SPLIT ID# SHALL MOVE WITH THE SPLIT QTY.)
SPLIT LOT# SPLIT QTY REASON
BY

NOTES
(1) Reference BOM for Drawing
(2) Reference EPP for Process Procedures

EMPL NO
OP. NO DEPT. OPERATION DESCRIPTION QTY
STAMP/DATE
SWITCH ASSEMBLY (PER REFERENCE ITEMS BELOW)
MFG EMPL NO.
100 ACCEPT REJECT
DEPT. STAMP/DATE
Note: All signed off operations must be dated.

105 MFG Kit Verification (verify LCN’s are recorded on pick-list)

INSTALL RF CONNECTORS INTO CAVITY (11051-287,

EPP9-9024, CPS3-16)

Tools/Equipment Required (Ref): Drop gauge, T2162, calibrated torque

driver, curing oven

(Six position switch shown in pictures)

1. Install radial connectors

and center connector.

110 ASSY 2. Measure probe height

to ensure meets
drawing depth .056
±.001. Install shims as
needed to achieve
noted dimension.

3. Apply Black Epoxy

CPS3-16 to first thread
of Connectors and
torque per EPP9-9024.

4. Cure Black Epoxy CPS3-16 at 95°C for 90 minutes minimum.

Page 1 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

Page 2 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

115 ASSY
PRESS ALIGNMENT PINS INTO CAVITY COVER

Tools/Equipment Required (Ref): T2158, T2096, arbor press

1.

Page 3 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

1. Install cavity cover onto fixture T2158 as shown above.

2. Install fixture T2096 onto cavity cover as shown above.

3. Using an arbor press, press alignment pins until they are flush
with T2096.

PRESS ALIGNMENT PINS INTO CAVITY COVER

Tools/Equipment Required (Ref): T2158, arbor press

1.

120 ASSY

Remove T2096 from cavity cover

2. Using the arbor press, press the alignment pins until they hard
stop on T2158.

3. Ensure no material has been raised on the bottom side of the

cavity cover. Clean and remove any debris and/or burrs.

Page 4 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

INSTALL SPRINGS AND PUSH RODS

Tools/Equipment Required (Ref): T2096, phillips head screw driver, #2-56

X 3/16” (3X)

125 ASSY

1.
Install springs and push
rods into each position
of the cavity cover.

2. Place T2096 on to
cavity cover.

3. Rotate 180º and secure

with 3 #2-56 X 3/16”
screws.

RF BLADE INSTALLATION

1. Install blades onto push

rods.

130 ASSY

Note orientation of
blade, shown to
the right. Tie-tab
should be away
from cavity cover.

Page 5 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

THERMAL FORM (PP7-7001)

1. Install thermode T2079-1 per PP7-7001.

Permissible to use other thermodes as required as long as visual
inspection criteria of PP7-7001 are met.
135 ASSY 2. Input and verify the following settings:

Settings are reference only.

Pre-heat Temperature: 150⁰C
Pre-heat Time: 2.0 seconds
Rise Time: 1.5 seconds
Reflow Temperature: 325 ⁰C
Reflow Time: 3.0 seconds
Cooling Temperature: 150 ⁰C
Force Indicator Dial: 465

3. Thermal form all blades into position.

4. Inspect quality of the thermal form per PP7-7001.

SONIC DEGREASE CAVITY COVER ASSEMBLY AND CAVITY

ASSEMBLY PER EPP5-5001
1. Sonic degrease cavity cover assembly and cavity assembly.
- Cavity cover assembly should be installed on T2096.
140 ASSY - Cavity should be oriented so the connector shells are facing
up.
2. Move assemblies directly from the degreaser to a flow bench or a
dry box until they are ready to be processed.

INSTALL GUIDE PINS

THIS OPERATION MUST BE COMPLETED UNDER A FLOW
BENCH.

1. Visually inspect cavity

cover assembly for debris
or damaged components.
Clean/replace as
145 ASSY
required.
2. Remove 3 #2-56 screws
holding the cavity cover to
fixture T2096.
3. Install guide pins into
cavity cover as shown to
the right.

Page 6 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

CLOSE RF HEAD ASSEBLY

THIS OPERATION MUST

BE COMPLETED UNDER A
FLOW BENCH.

150 ASSY

1. Visually inspect cavity

assembly for debris or damaged components. Clean/replace as
required.
2. Using the alignment pins in the cavity cover and the alignment
holes in the cavity as a guide, lower the cavity onto the cavity
cover as shown above.
3. Rotate assembly 180º so that it is resting on the connectors.

SECURE RF HEAD ASSEMBLY WITH SCREWS (EPP9-9005)

THIS OPERATION MUST BE COMPLETED UNDER A FLOW
BENCH.

155 ASSY

1. Remove T2096 from RF head assembly.

2. Secure RF head assembly with 3 #2-56 X 3/16” pan head
screws and 3 #2 lock washers.
3. Epoxy stake screws per EPP9-9005.

APPLY RF CONNECTOR LABEL

1. Place RF connector label on

160 ASSY the RF head assembly.

Page 7 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

ASSEMBLE ACTUATOR ASSEMBLY

Tools/Equipment Required: T2146

165 ASSY

PARTS SHOULD FALL INTO PLACE, DO NOT FORCE ONTO

FIXTURE.
CONSULT ENGINEERING IF THERE IS AN ISSUE WITH LOADING
PARTS ON THE FIXTURE.
IF FIXTURE PINS BECOME BENT OR DAMAGED DO NOT USE
FIXTURE.

1. Apply a small amount of grey epoxy into the top threads of each
spacer.
2. Mount spacers to top coil plate using 3 #2-56 X 3/16” pan head
screws. Wipe away excess epoxy.
3. Place top coil plate/spacer assembly onto fixture T2146 as
shown to the right.
4. Install coils over center locating pins on fixture T2146.
5. Apply a small amount of grey epoxy into the bottom threads of
each spacer.
6. Place bottom coil plate onto assembly.
7. Secure coil plate with 3 #2-56 X 3/16” screws.
8. Remove assembly from fixture carefully.
9. Cure Grey Epoxy CPS3-3 in assembly at 95°C for 30 minutes
minimum.

Page 8 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

INSTALL ACTUATOR ASSEMBLY ONTO RF HEAD

1.

170 ASSY

Using the alignment pins in the cavity cover as guides, place actuator
assembly onto RF head assembly.
2. Secure with 3 #2-56 X ¼” screws.
3. Place plungers into coil bobbins. Plungers should rest on the
bushing actuator guides.
EMPL NO. QTY.
OP.NO DEPT.
STAMP/DATE Accept Reject
Switch Assembly Verification
100 MFG
Note: By signing off on this step, you are verifying that the
operations above are signed off and completed.

Page 9 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

EMPL NO
OP.NO DEPT. OPERATION DESCRIPTION QTY
STAMP/DATE
SWITCH ADJUSTMENT (PER REFERENCE ITEMS BELOW)
MFG *Proceed after completion of OP. 100 EMPL NO.
200 STAMP/DATE
ACCEPT REJECT
DEPT.
Note: All signed off operations must be dated.
Tools/Equipment Required: Drop
gauge, T2162

1. Place switch onto T2162.

2. Zero drop gauge on the top
surface of the plunger for the
first position.

210 ADJ Zero the drop

gauge on this
surface

Plunger should
be resting on
the bushing
actuator guide

Page 10 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

3. Remove plunger and insert

actuator pin into the bushing
actuator guide.
4. Place plunger back into coil
bobbin.
5. Place the drop gauge back onto
the top surface of the plunger.

- Drop gauge should read

between .006” and .009”.
- Repeat for remaining positions

Place drop gauge

back here after
installing actuator
pin and plunger.

Gap should
be .006”-.009”.

220 ADJ

- If specification is not
achieved:

1. Use shims on the 3 screws holding the actuator assembly

to the RF head assembly. See photo below.
2. Shims should be placed in between the actuator assembly
and the RF head assembly.
3. Repeat steps 1-5 until specification is achieved.

DO NOT SAND ACTUATOR PIN, CONSULT ENGINEERING IF

SPECIFICATION IS NOT ACHIEVED.

Use shims
here

Use shims Use shims

here here

Page 11 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

SWITCH ADJUSTMENT (CONT.)

6. Install solenoid cover
plate once adjustment is
completed.

7. Cycle switch 2k times at

nominal voltage.
230 ADJ
8. Verify conforming DC
characteristics:

- Pick up voltage
- Drop out voltage
- Contact Resistance
- Switching Time

Solder Coil Wires to Lead Wires per 11024-230 note 1

1. Cut the Coil wires .75” long.

Cut the Lead wires 8.75” long, using the colors from the chart on the
diagram.
Strip and tin the Coil wires and one end of the Lead wires .25” from
end. Do not strip or tin the other end of the Lead wires.
2. Lay wires side by side so that the stripped wire lengths overlap.
3. Wind wires around each other 4-6 loops each.
4. Use flux and high temp SN96 solder to solder the connected
wires together. Remove all flux with alcohol.
5. Do not apply shrink tubing at this time.

240 SOLD

Page 12 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

1. Inspect solder per J-STD-001S.

250 INSP 2. Verify correct wiring per drawing.
3. Verify all traces of flux have been removed.

EMPLY NO. QTY.

OP.NO DEPT. OPERATION DESCRIPTION
STAMP/DATE Accept Reject
Switch Adjustment Verification
200 MFG
Note: By signing off on this step, you are verifying that the
operations above are signed off and completed.

EMPL NO.
OP.NO DEPT OPERATION DESCRIPTION QTY
STAMP/DATE
FINAL ASSEMBLY (PER REFERENCE ITEMS BELOW)
MFG *Proceed after completion of OP. 200 EMPL NO.
300 STAMP/DATE
ACCEPT REJECT
DEPT.
Note: All signed off operations must be dated.
1. Clean switch before closing.
2. Install Grommet into Enclosure.
3. Feed lead wires through Grommet.
4. Seal Enclosure to Cavity with continuous bead of Grey Epoxy per
EPP9-9005. Install, torque, and stack Enclosure screws per
EPP9-9024.
5. Cure per Grey Epoxy CPS3-3 at 95°C for 90 minutes minimum.

310 ASSY

CLEAN & LABEL

320 ASSY 1. Clean RF connectors and any other contamination on the switch
assembly.
2. Apply labels according to the sales drawing.

EMPLY NO. QTY

OP.NO DEPT OPERATION DESCRIPTION
STAMP/DATE Accept Reject
Final Assembly Verification
Verify the following:
1. LCN’s recorded on pick list
2. Sales order included in the work folder
300 MFG
3. MI stamped/signed for all requirements

Note: By signing off on this step, you are verifying that the
operations above are signed off and completed.
Page 13 of 14
Manufacturing Instruction Template NON QMS Form
 MANUFACTURING INSTRUCTION OPERATIONS RECORD
WORK ORDER # QUANTITY SERIAL NUMBER PART NUMBER MI REV

565-5208-3 A
OP. EMPL NO. QTY.
DEPT OPERATION DESCRIPTION
NO. STAMP/DATE ACCEPT REJECT

EMPL NO.
OP.NO DEPT OPERATION DESCRIPTION QTY
STAMP/DATE
PRODUCT ACCEPTANCE TESTING
(PER REFERENCE ITEMS BELOW)
TEST EMPL NO.
400 *Proceed after completion of OP. 300 STAMP/DATE
ACCEPT REJECT
DEPT.
Note: All signed off operations must be dated.

Final Test per standard ATP-99038

410 TEST

Test Rejection ID (as required) _________________________

EMPL NO. QTY

OP.NO DEPT OPERATION DESCRIPTION
STAMP/DATE Accept Reject
Product Acceptance Testing Verification
400 TEST
Note: By signing off on this step, you are verifying that the
operations above are signed off and completed.

EMPL NO.
OP.NO DEPT OPERATION DESCRIPTION QTY
STAMP/DATE
FINAL INSPECTION (PER REFERENCE ITEMS BELOW)
INSP EMPL NO.
500 *Proceed after completion of Op. 400 STAMP/DATE
ACCEPT REJECT
DEPT.
Note: All signed off operations must be dated.

510 QC Final inspection per MOP2-09-03

EMPL NO. QTY

OP.NO DEPT OPERATION DESCRIPTION
STAMP/DATE ACCEPT REJECT
Final Inspection Verification
500 INSP
Note: By signing off on this step, you are verifying that the
operations above are signed off and completed.

Page 14 of 14
Manufacturing Instruction Template NON QMS Form