Group 1 Honda Generator-Product Reassembly

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Product Reassembly

\'\'\'Difficulty scale definition:\'\'\'
\'\'\'1\'\'\' - Very easy, highly intuitive, trivial. Part is reassembled easily and quickly.
\'\'\'2\'\'\' - Somewhat easy, intuitive, some thinking. Minor difficulties encountered. (i.e. many bolts, time consuming but still easy.)
\'\'\'3\'\'\' - Average difficulty, awkward part location. (i.e. parts were hard to get to or required special tools like a ratchet extension)
\'\'\'4\'\'\' - Difficult, requires large force, not intuitive. (i.e. required planning in order to reassemble)
\'\'\'5\'\'\' - Very difficult, requires maximum planning, parts were previously broken.

The following table describes the process for reassembling the generator. Significant notations include a sequential numbering of steps involved, the tool(s) used in each step, challenges presented to us and how they were overcome, differences from the dis-assembly process as well as the relative difficulty of each step.

\'\'\'Honeywell Generator Reassembly Process\'\'\'

Step # What was done with what tool? Challenges? how were they overcome? Changes from Disassembly? Difficulty (1-5) Picture Link
1 Put piston back into the cylinder by screwing the piston squeezer with a hex nut screwdriver around the piston to compress rings. Extreme tightness of piston while sliding into the cylinder. Use hammer to bang piston through the cylinder. None 5 Insert Piston
2 Insert Push-rods into cylinder wall. None 1 Add Pushrods
3 Put connection-A through engine wall. None 1 Insert Connection A
4 Crankshaft hammer into place. Use 10 mm socket wrench to screw piston head to crankshaft. Space is limited when using socket wrench to screw piston head. None 4 Insert Crank Shaft
5 Slide camshaft and gears into place while making sure to line up camshaft and gears. None 2 Insert Gears and Camshaft
6 Screw charger coil into engine side with using 10 mm socket wrench. None 1 Attach Charger Coil
7 Attach flywheel to crankshaft end with using a hammer to apply force to lock into place. Extreme force needed to have flywheel sit properly on crankshaft. None 3 Attach Flywheel
8 Attach fan to flywheel with using recoil starter catch cylinder to lock fan in place. Do to disassembly destruction had to saw off end of crankshaft threads in order for the recoil starter catch cylinder to fit. Use filer on end of threads to smooth out edges. None 1 Attach Fan
9 Screw in recoil starter catch cylinder with 3-10 mm bolts using a socket wrench. None 1 Attach Recoil Starter Catch Cylinder
10 Connect engine-generator interplate. Screw in 7-12 mm bolts. Pound bearings flat for engine generator interplate to slide together. None 2 Atatch Engine Generator Inter-plate
11 Attach gasket and push rods to cylinder and slide on cylinder head screwing in two 14 mm bolts with the cylinder head. None 1 Attach Gasket and Cylinder Head Cover
12 Attach breather cap to cylinder head screwing in a 10 mm bolt. None 1 Attach Breather Cap to Cylinder Head
13 Slide engine-carburetor interplate and carburetor onto cylinder head bolts. None 1 Attach Interplate
14 Use 12 ton hydraulic press to press flywheel onto crankshaft at one end and the stater on the other. During the pressing process the press cracked the flywheel in 3 places. This process has alter the rest of the assembly process. Yes 5 Press Flywheels and Stater onto Crankshaft
15 Slide Commutater over Stater and attach Commutater to Engine housing. Ball bearing and slip ring assembly of the stater would not fit into commutater slot. Had to be removed in order to fit. Yes 4 Attach Commutater
16 Screw commutater into stater sheild with using 10 mm socket wrench for 4 commutater bolts. Commutater cover was broken off during the disassembly process so it will be absent from the commutater. Yes 1 Attach Stater shield
17 Screw in flywheel recoil catch starter into flywheel with a 10 mm socket wrench for 3 bolts. In order for the flywheel recoil catch starter to screw into flywheel the fan had to be subtracted from reassembly process do to the flywheel cracking. Yes 1 Attach Recoil Starter Catch
18 Attach bolt magneto to cylinder casing with a 10 mm socket wrench for to bolts. None 1 Attach Magneto
19 Screw in 3 of 5 8 mm bolts of the fan shroud into engine housing with a 8 mm socket wrench. 1 Of the 5 bolt holdings on the engine housing broke in the pressing process and 1 of the 5 bolts was sheered in the reassembly process. Yes 1 Attach Fan Shroud
20 Screw the recoil starter to fan shroud with a 10 mm socket wrench for 3 bolts. None 1 Attach Recoil Starter
21 Screw the cylinder cover to the cylinder housing using a 10 mm socket wrench for 2 bolts. None 1 Attach Cylinder Cover
22 Attach throttle linkage into throttle valve of the carbuerator by linking the spring and rod onto the throttle at one end and connecting to connection CA and cylinder cover. None 1 Attach Throttle Linkage
23 Attach killswitch solenoid to engine housing using a 10 mm socket wrench for one bolt. None 1 Attach Kill Switch Solenoid
24 Attach air cleaner housing to cylinder head bolts using 10 mm socket wrench for 2 bolts. None 1 Attach air cleaner housing
25 Attach air filter to air cleaning housing with a 8 mm socket wrench for 6 nuts. None 1 Attach Air Filter
26 Attach whole engine-generator assembly to steel frame. Screw in with a 14 mm wrench for 4 bolts Needs 3 people to lift into place. None 3 Attach engine Generator Assembly to Frame
27 Attach carbon canister to frame with using 2- 8 mm bolts and a 8 mm wrench with making sure to attach rubber tubing to air cleaner. None 1 Attach Carbon Canister
28 Attach battery to frame using 2-10 mm nuts and 2 j-bolts with 10 mm wrench. None 1 Attach Battery
29 Attach muffler to cylinder with using a 12 and 13 mm wrecnh for 2-13 mm bolts and 2-12 mm nuts. None 1 Attach Muffler
30 Attach front panel to steel frame with 10 mm socket wrench using 4-10mm bolts. None 1 Attach From Panel
31 Connect the wiring from the control panel to the appropriate sensors. None 1 Connect all Wiring
32 Insert 4-8mm nuts and washes to end of wire attachments None 1 Attach wires to generator
33 Attach Generator wire covering with 2-8mm bolts None 1 attach generator cover
34 Attached fuel tank to top of generator 4-8mm bolts None 1 Attach Fuel Tank

Our reassembly process differed from the original factory assembly in multiple ways. For example we were unable to press the flywheel and commutator back onto the crank shaft without breaking the flywheel in three places. We assume the commutator was originally expanded using a high temperature source to heat the metal component so it would fit snugly over the crankshaft upon cooling. We were also forced to remove the bearing at the top of the commutator on which the brushes contacted the slip rings, in order to be able to place the stator back on the generator over the commutator. Another issue we encountered was the use of excessive torque on some of the bolts when we were reassembling as this led to shearing or general damage to the bolts. The manufacturer would have had some sort of pre-programmed set up to tighten the bolts to a specified torque. Another difference we encountered was the damage to the threads of the crankshaft onto which the armature nut was tightened had to be sawed off of the unhurt threads in order for the bolt to have a chance at fitting on. The manufacturer would not have dealt with the damage to the threads because there wouldn\'t have been any in the original assembly.