Group 3 - Homelite Fluid Pump (Gasoline Powered) - Product Explanation

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Revision as of 14:30, 28 November 2012

Product Explanation (Product Archaeology)

This component of Product Archaeology includes an overview of the product's assembly followed by additional sections which document important mechanisms found in the product and propose design revisions for product improvement.

Product Reassembly

With the reassembly of the Homelite fluid pump product, we're interested in more than just how to assemble the product. Certain information regarding the product's assembly will be introduced in the following preface to assembly before the assembly process is then presented.

Preface (Assembly)

With the assembly of this product, certain measures are of interest. In the assembly how-to guide that follows, speculation regarding the product's original assembly method and a difficulty scale will be used to document this respective information. In this section, the above-mentioned information will be formally introduced and defined.

Original Assembly Methods

INTRODUCE AND DEFINE THE NOMENCLATURE:

[H] BY HAND
[R] BY ROBOT??
[O] OTHER - TO BE DESCRIBED IN REFERENCED NOTES

WE WILL PROBABLY USE A TABLE AS IN "CONNECTION TYPES" FROM GATE 2

Difficulty Scale

THIS IS THE COPIED TABLE FROM DISASSEMBLY

PROBABLY NEEDS EDITS!

A scale to accurately judge difficulty is an important part in any proper assembly. The table below (Difficulty Scale) is designed to give the user an accurate idea of each step's difficulty. The chart is divided into five different categories ranging from 1 (easily achieved) to 5 (specialist required). Any step can be placed into the appropriate difficulty based on one, or all of the following: tools required, experience and or physical effort.

Difficulty Scale
Difficulty		Requirements
Difficulty		Tools/Equipment	Technical Experience	Physical
L E A S T G R E A T E S T
	1	No tools General household tools (e.g. screw driver, hammer, etc.)	Requires little to no technical experience	Very minimal
	2	General mechanics tools (socket, ratchet ext.)	Minimal	Minimal
	3	Multiple tools required, used together or separate	Moderate (must exhibit the coordination to use tools simultaneously)	Moderate
	4	Requires specialty tools (e.g. mechanical pulley puller)	Technical Experience	Maximum
	5	Requires specialty machinery (e.g. hydraulic press)	Specialty Training	Machine Assistance

Assembly Process

This section applies the previous content of this report to practical demonstration of product assembly. It is imperative that the following sections, preparation and how-to guide be read in full, and in order, for the reader to be successful in proper assembly of the product.

Preparation

Proper assembly preparation consists of thorough reading, comprehension, and execution of the following sections. Important information regarding the required tools and equipment, nomenclature, and common tasks of assembly follows.

Tools & Equipment Required

THE FOLLOWING IS COPIED FROM DISASSEMBLY

NEEDS EDITS!

Be sure to gather the Items listed in the following table:

Required Tools & Equipment
Item	Details
Work Table	3ft x 8ft area Waist-Height Sturdy and Stable
Bench Vise	4in jaw
General Equipment	Spring Clamp Funnel Oil Pan Fuel Container
General Hand Tools	Hammer Rubber Mallet Punch Chisel Pry Bar
Screwdrivers	Flat Head, 3/16 in Flat Head, 3/8 in Number 2 Philips
Wrenches and Pliers	3/8 in Combination Wrench 8 in Adjustable "Crescent" Wrench Channel-Lock Pliers Needle Nose Pliers (with side cutter)
Sockets	3/8 in Drive: Metric (mm): 10, 11, 13, 14 Standard (in): 1/4, 1/2 1/2 in Drive: Metric (mm): 13 (deep-well) Standard (in): 3/4 (deep-well), 7/8
Sockets Drivers:	3/8 in Drive Ratcheting Wrench 1/2 in Drive Ratcheting Wrench 1/2 in Drive Impact Gun
Specialty Tools	Pulley Puller Valve Spring Compressor Flywheel Wrench

Nomenclature

Refer to the tables above for the denotation of product serviceability in terms of difficulty, and also the denotation of suspected methods of original assembly as this information will be referenced only briefly in the how-to guide. Care should be taken by the dissection personnel to be aware of personal strengths and limitations (e.g. in experience, physical strength, etc.) in completing the steps of assembly.

Common Tasks of Assembly

COPIED STRAIGHT FROM THE DISASSEMBLY

MAY NEED EDITS / ADDITIONAL INFORMATION!

Threaded Fasteners:

A great majority of the procedures detailed in the how-to guide involve assembling threaded connections. Whenever the part to be installed is referred to as a nut, bolt, or screw it may be assumed that the connection is threaded.

All threaded connections in this product are right-hand threaded. To remember how to assemble a right-handed threaded connection, it may be helpful to refer to the mnemonic, "Righty-tighty, lefty-loosy," where right and left determine which way to rotate the fastener when looking at the head of the fastener. Right corresponds with rotating toward the right, or clockwise (CW), whereas left corresponds with rotating toward the left, or counterclockwise (CCW).

Using Sockets & Socket Wrenches

Whenever instructed to use a socket to install a fastener, it may not be explicitly stated that a socket wrench is to be used. In these cases, it is to be assumed that for a 3/8 in drive socket, a 3/8 in drive socket wrench is required (and similarly for 1/2 in drive). It is important also to be sure that ratcheting socket wrenches are set to ratchet in the proper rotational sense to remove a fastener. Become familiar with the ratcheting socket wrench before attempting to use it in this assembly process.

The Use of Required Tool & Equipment

It is imperative that for all tools and equipment utilized in this assembly process, the user must be fully aware of proper usage. If the user requires information regarding proper use of any tools, he/she should consult the tools' owner's manuals for proper usage procedures.

How-To Guide

The Assembly Process
Number	Description	Procedure	Image
1	Install Crankshaft in Crankcase Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Punch Hammer Non-Marring Slender Rod (hammer handle)	Insert crankshaft (arrow) through hole in the crankcase (arrow) as shown Place the key (arrow) in the notch in the crankshaft as shown Slide the flywheel onto the crankshaft, taking care to align the notch in the flywheel (arrow) with the key. Thread the crankshaft nut (arrow) onto the end of the crankshaft by hand With a long, slender, non-marring rod (possibly a wooden hammer handle) inserted down through the cylinder in the crankcase (to prevent crankshaft rotation) place a punch on a tab on the crankcase nut and tap with a hammer to tighten the nut securely.	100_4172
2	Install Valves Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Valve-Spring Compressor Tool Needle-Nosed Pliers	For each of (2) assemblies Insert the valve-spring (arrows) into its installed location (arrow) Use the spring-compressor tool to compress the spring Insert the valve down through its hole (arrow) Note: the valve are differently sized. Make sure the valve is inserted to the proper hole. Using needle-nose pliers to grip the retaining clip (arrow) place is on the end of the valve stem and lock it into place. Release the valve-spring compressor tool	100_4175
3	Assemble Piston/Connecting Rod Assembly Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Needle-Nose Pliers	Using needle-nose pliers to grip the retaining clip, insert one retaining clip in the groove inside the piston's wristpin hole (arrow) Partially insert the wristpin (arrow) into the hole in the piston Insert the hole-end of the connecting rod (arrow) through the bottom of the piston, aligning the connecting rod hole with the hole in the piston Fully insert the wristpin into the piston, through both the piston and the connecting rod Install the second retaining clip to the other side of the piston as per the procedure in step 1	100_4177
4	Install Piston / Connecting Rod Assembly Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Needle-Nose pliers Piston Ring Compressor ??? Socket	Install the piston to the crankcase Using piston ring compressor tool, insert the connecting rod through the cylinder hole and install the piston into the cylinder Assemble the connecting rod to the crankshaft Align the connecting rod (b arrow) and crankshaft (b arrow) as shown. Plase the connecting rod cap (a arrow), bolt head locking tab (a arrow), oil slosher (a arrow) in that order in the configurations pictured Install the two bolts (b arrow) in the corresponding holes in the connecting rod and tighten Using needle-nose pliers, bend up the corners on the bolt head locking tab against the flats of the bolt heads	a: 100_4179 b: 100_4182
5	Install Lifters and Camshaft Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Hands Only	Install each of (2) lifters (arrows) into their holes Install the end of the camshaft (arrow) into the matching hole in the crankcase (arrow) Note: the lobes (egg-shaped features) of the camshaft may interfere with the lifters, so the camshaft will need to be rotated to be installed. Also, the gear teeth between the camshaft and crankshaft will need to be mated for full installation of the camshaft.	100_4184
6	Install Crankshaft Support Bearing Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Shop Press	Place the crankshaft support bearing (arrow) over the end of the crankshaft With the appropriate tooling/cup in place, use the shop press to press the bearing onto the shaft until it stops.	100_4186
7	Install Crankcase Cover Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	Position the crankcase cover (arrow) in place with the crankshaft inserted through the hole in the cover While applying pressure to the cover, rotate it back and forth in order to seat both the crankshaft support bearing and the end of the crankshaft in their holes in the cover Install (6) crankcase cover mounting bolts in their holes (arrows) and tighten	100_4187
8	Install Side Flywheel Shroud Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	Position the side flywheel shroud (arrow) in place by matching the mounting hole with that on the crankcase cover (show matching holes with arrows) and noting that the round edge of the shroud matches the round feature of the flywheel in its installed state. Install the side flywheel shroud mounting bolt using SIZE socket	100_4190
9	Install Mesh Flywheel Shroud Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE socket	pH1 Position the mesh flywheel shroud as pictured Install (2) mounting screws using SIZE socket	100_4192
10	Install Coil & Governor Mounting Plate Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	Position the coil in place by its mounting holes with those on the crankcase (DIFFERENT COLORS FOR THESE HOLES circles) Install (1) mounting screw in the right side hole (color) Position the governor mounting plate with the oddly shaped hole over the pin on the coil Lock the oddly shaped hole into place on the pin and then align the other hole in the governor plate with the left side mounting hole (color) Install the other mounting screw in this hole	100_4195
11	Install Pump Housing / Bell Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	pH1 Position the pump housing in place on the crankcase by lining up the 4 mounting holes (arrows) and making sure that the notch feature inside the pump housing is facing upward. Install the (4) mounting bolts with SIZE socket	100_4198
12	Install Impeller Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	The impeller threads onto the end of the crankshaft Start the thread by hand Once the impeller is partially threaded onto the crankshaft use SIZE socket to install it fully	100_4200
13	Install Engine Head Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE socket	Position the head by lining up the (8) matching mounting holes Install the mounting bolts using SIZE socket	100_4204
14	Install the Carry Handle Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	Position the carry handle by lining up the mounting holes (arrows) Install (2) mounting bolts using SIZE socket	100_4208
15	Install Exhaust Manifold Difficulty: # Original Assembly: [R],[H],[O] Tools Required: Channel-Lock Pliers	The exhaust manifold threads into the crankcase Thread the exhaust manifold into the crankcase by hand Tighten with channel-lock pliers	100_4209
16	Install Spark Plug and Spark Plug Wire Difficulty: # Original Assembly: [R],[H],[O] Tools Required: SIZE Socket	Install Spark Plug Use SIZE socket to securely install the spark plug to the engine head Install Spark Plug Wire Using hands (pliers optional) clip the end of the spark plug wire over the top of the spark plug	100_4210
17	Assemble Carburetor Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
18	Install Carburetor Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
19	Install Throttle Linkage & Return Spring Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
20	Install Governor Plate Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
21	Assemble Recoil Starter Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
22	Install Recoil Starter Housing Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
23	Install Crankcase Ventilation Tube Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
24	Install Fuel Fill Cap Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
25	Install Fuel Tank Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
26	Assemble Air Filter Box Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
27	Install Air Filter Box Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
28	Install Oil Fill Plug Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
29	Install Oil Drain Plugs Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
30	Install Pump Housing Gasket Plate Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
31	Install Primer Port Plug Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
32	Install Pump Drain Plug Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
33	Install Pump Housing Cover Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2
34	Install Base Feet Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2	File:G3 reass 34a.png
35	EXTRA Difficulty: # Original Assembly: [R],[H],[O] Tools Required: t1 12	pH1 s1 s2	File:G3 reass 35a.png

Challenges Faced with Assembly

Small Challenges

Substantial Challenges

Mechanisms

FIGURE OUT THE ORGANIZATION OF THIS SECTION!

Design Revisions