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

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=== Design Revisions ===
 
=== Design Revisions ===
 
FIGURE OUT THE ORGANIZATION OF THIS SECTION!
 
FIGURE OUT THE ORGANIZATION OF THIS SECTION!
 +
==== 1. Convert Power Source From Gasoline Engine to Diesel Engine ====
 +
===== GSEE Factor(s) =====
 +
;Global:Diesel fuel requires less refining than gasoline does therefore it can be made more simply worldwide. Changing from a gasoline power source to a diesel power source would allow this fluid pump to be sold worldwide with less concern to the refining capabilities of the area it is being sold at, thus expanding the market.
 +
;Environmental:Diesel fuel burns much cleaner than gasoline does reducing carbon monoxide being polluted into the atmosphere.
 +
 +
===== Advantages =====
 +
*Diesel fuel has many benefits over gasoline, the first of which being diesel is more efficient to burn than gasoline. Most gasoline engines convert about 30 percent of their fuel energy into actual power. A traditional diesel converts about 45 percent (1). This means that less fuel could be used in order to create a given amount of work.
 +
*This leads into the next advantage of diesel, since diesel engines are more efficient; they also have less heat waste. This means that the engine can run at a lower temperature than a gasoline engine of the same size can. As a result of this the engine has less stresses applied on it which increase the cycle life.
 +
*Another benefit to diesel fuel is that it is safer than gasoline. Since diesel fuel is harder to ignite and slower burning than gasoline is will not explode unlike gasoline.
 +
 +
===== Disadvantages =====
 +
*Diesel engines tend to be heavier than a gasoline powered engine which is not ideal for a portable fluid pump
 +
*Diesel engines are slightly more expensive than a gasoline engine of equal power output
 +
 +
==== 2. Convert Power Source From Gasoline Engine to Diesel Engine  ====
 +
===== GSEE Factor(s) =====
 +
;Category:explanation
 +
===== Advantages =====
 +
===== Disadvantages =====
 +
 +
 +
==== 3. Convert Power Source From Gasoline Engine to Diesel Engine  ====
 +
===== GSEE Factor(s) =====
 +
;Category:explanation
 +
===== Advantages =====
 +
===== Disadvantages =====

Revision as of 12:28, 29 November 2012

Group 3 Home Page

Contents

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
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)
  1. Insert crankshaft (arrow) through hole in the crankcase (arrow) as shown
  2. Place the key (arrow) in the notch in the crankshaft as shown
  3. Slide the flywheel onto the crankshaft, taking care to align the notch in the flywheel (arrow) with the key.
  4. Thread the crankshaft nut (arrow) onto the end of the crankshaft by hand
  5. 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.
G3 reass 1a.png

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
  1. Insert the valve-spring (arrows) into its installed location (arrow)
  2. Use the spring-compressor tool to compress the spring
  3. Insert the valve down through its hole (arrow) Note: the valve are differently sized. Make sure the valve is inserted to the proper hole.
  4. Using needle-nose pliers to grip the retaining clip (arrow) place is on the end of the valve stem and lock it into place.
  5. Release the valve-spring compressor tool
G3 reass 2a.png

100_4175

3 Assemble Piston/Connecting Rod Assembly

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Needle-Nose Pliers
  1. Using needle-nose pliers to grip the retaining clip, insert one retaining clip in the groove inside the piston's wristpin hole (arrow)
  2. Partially insert the wristpin (arrow) into the hole in the piston
  3. 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
  4. Fully insert the wristpin into the piston, through both the piston and the connecting rod
  5. Install the second retaining clip to the other side of the piston as per the procedure in step 1
G3 reass 3a.png

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
  1. 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

  1. Align the connecting rod (b arrow) and crankshaft (b arrow) as shown.
  2. Plase the connecting rod cap (a arrow), bolt head locking tab (a arrow), oil slosher (a arrow) in that order in the configurations pictured
  3. Install the two bolts (b arrow) in the corresponding holes in the connecting rod and tighten
  4. Using needle-nose pliers, bend up the corners on the bolt head locking tab against the flats of the bolt heads
G3 reass 4a.png

a: 100_4179

b: 100_4182

5 Install Lifters and Camshaft

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Hands Only
  1. Install each of (2) lifters (arrows) into their holes
  2. 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.

G3 reass 5a.png

100_4184

6 Install Crankshaft Support Bearing

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Shop Press
  1. Place the crankshaft support bearing (arrow) over the end of the crankshaft
  2. With the appropriate tooling/cup in place, use the shop press to press the bearing onto the shaft until it stops.
G3 reass 6a.png

100_4186

7 Install Crankcase Cover

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. Position the crankcase cover (arrow) in place with the crankshaft inserted through the hole in the cover
  2. 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
  3. Install (6) crankcase cover mounting bolts in their holes (arrows) and tighten
G3 reass 7a.png

100_4187

8 Install Side Flywheel Shroud

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. 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.
  2. Install the side flywheel shroud mounting bolt using SIZE socket
G3 reass 8a.png

100_4190

9 Install Mesh Flywheel Shroud

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE socket
pH1
  1. Position the mesh flywheel shroud as pictured
  2. Install (2) mounting screws using SIZE socket
G3 reass 9a.png

100_4192

10 Install Coil & Governor Mounting Plate

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. Position the coil in place by its mounting holes with those on the crankcase (DIFFERENT COLORS FOR THESE HOLES circles)
  2. Install (1) mounting screw in the right side hole (color)
  3. Position the governor mounting plate with the oddly shaped hole over the pin on the coil
  4. 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)
  5. Install the other mounting screw in this hole
G3 reass 10a.png

100_4195

11 Install Pump Housing / Bell

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
pH1
  1. 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.
  2. Install the (4) mounting bolts with SIZE socket
G3 reass 11a.png

100_4198

12 Install Impeller

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. The impeller threads onto the end of the crankshaft
  2. Start the thread by hand
  3. Once the impeller is partially threaded onto the crankshaft use SIZE socket to install it fully
G3 reass 12a.png

100_4200

13 Install Engine Head

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE socket
  1. Position the head by lining up the (8) matching mounting holes
  2. Install the mounting bolts using SIZE socket
G3 reass 13a.png

100_4204

14 Install the Carry Handle

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. Position the carry handle by lining up the mounting holes (arrows)
  2. Install (2) mounting bolts using SIZE socket
G3 reass 14a.png

100_4208

15 Install Exhaust Manifold

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Channel-Lock Pliers
  1. The exhaust manifold threads into the crankcase
  2. Thread the exhaust manifold into the crankcase by hand
  3. Tighten with channel-lock pliers
G3 reass 15a.png

100_4209

16 Install Spark Plug and Spark Plug Wire

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
Install Spark Plug
  1. Use SIZE socket to securely install the spark plug to the engine head

Install Spark Plug Wire

  1. Using hands (pliers optional) clip the end of the spark plug wire over the top of the spark plug
G3 reass 16a.png

100_4210

17 Assemble Carburetor

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Flat-Head Screwdriver
  • 12
Assemble Cover Plate and Contained Components
  1. See the first image -- the parts are shown exploded, install the spring first, then the metal ring, finally place the cover plate on top
  2. Use SIZE flat-head screwdriver to install (4) mounting screws

FINISH THIS LATER

G3 reass 17a.png

a: 100_4211

b: 100_4215

18 Install Carburetor

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. Position the carburetor by lining up the mounting holes (arrows)
  2. Install mounting bolts with SIZE socket
G3 reass 18a.png

100_4220

19 Install Throttle Linkage & Return Spring

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Needle-Nose Pliers
  1. Insert the end of the linkage without the loop (arrow) into its hole in the throttle arm (arrow)
  2. Grip the spring with needle-nose pliers and attach it to its hole in the throttle arm (arrows)
G3 reass 19a.png

100_4223

20 Install Governor Plate

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Needle-Nose Pliers


  1. Attach the governor plate to the throttle linkage by hooking the hole (arrow) around the loop end of the throttle linkage (arrow)
  2. Position the governor plate over the tabs in the governor mounting plate (arrows)
  3. Using needle-nose pliers, bend the tabs to lock the governor plate in place
G3 reass 20a.png
21 Assemble Recoil Starter

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Needle-Nose Pliers
Prepare Spring and Hub
  1. Insert one end of the spring into its matching slot in the hub
  2. Carefully coil the spring around the hub tightly
  3. Attach pull cord to the hub and wind it through the groove

Install Spring/Hub Assy to Housing

  1. Carefully unwind about 12in of the spring to insert the end into its slot in the housing
  2. Being sure to not allow the spring to uncoil, insert the assembly down into its spot in the housing
  3. Using needle-nose pliers, bend down the tabs
  4. Judging the spring tension necessary to recoil the length of pull cord being used, rotate the hub assembly to proper position
  5. Thread the loose end of the pull cord through the hole in the housing

Install the pull start handle

  1. Thread the pull cord through the rubber handle
  2. Tie the cord around the metal rod
  3. Insert the metal rod into the rubber handle and pull the cord through
G3 reass 21a.png

100_4229

22 Install Recoil Starter Housing

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  1. Position the recoil start housing in place over the flywheel and engine crankcase
  2. Using SIZE socket, install (2) mounting bolts in their holes (arrows)
G3 reass 22a.png

100_4233

23 Install Crankcase Ventilation Tube

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Hands Only
  1. Insert the ventilation tube into the fitting in the valve cover (arrow)
  2. Slide the rubber fitting on the end of the ventilation tube then assemble this fitting to the nipple on the carburetor
G3 reass 23a.png

100_4234

24 Install Fuel Fill Cap

Difficulty: 1

Original Assembly: [R],[H],[O]

Tools Required:

  • Hand Only
  1. Screw the fill cap onto the fuel tank by hand
G3 reass 24a.png

100_4236

25 Install Fuel Tank

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Phillips Screwdriver
  • SIZE Socket
  1. Position the fuel tank such that the 3 holes on top of the tank align with the 3 corresponding holes in the carburetor (arrows)
  2. Install 3 mounting screws with phillips screwdriver
  3. Install 1 mounting bolt with SIZE socket (arrow)
G3 reass 25a.png

100_4238

26 Assemble Air Filter Box

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Hands Only
  1. Assemble the air filter element and spacer to the air filter box as pictured
G3 reass 26a.png

100_4240

27 Install Air Filter Box

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Flat Screwdriver
  1. Place the assembled air filter box on the carburetor air intake gasket
  2. Install the mounting screw using flat screwdriver
G3 reass 27a.png

100_4242

28 Install Oil Fill Plug

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Hands Only
  1. Screw in the fill plug by hand in the location as pictured
G3 reass 28a.png

100_4244

29 Install Oil Drain Plugs

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Adjustable Wrench
For each of (2) drain plugs
  1. Use adjustable wrench to install the plug in the location shown (the other location is similar on the other side of the crankcase).
G3 reass 29a.png

100_4245

30 Install Pump Housing Gasket Plate

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Hands Only
  1. Position the gasket plate on the pump housing cover in the orientation pictured
G3 reass 30a.png

100_4246

31 Install Primer Port Plug

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Adjustable Wrench
  1. Using adjustable wrench install the primer port plug in the hole on top of the pump housing cover
G3 reass 31a.png

100_4247

32 Install Pump Drain Plug

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • Screw driver
  1. Thread the drain plug partially by hand
  2. Using the shank of the screwdriver as a lever between the raised protrusions on top of the plug to screw it in the rest of the way
G3 reass 32a.png

100_4248

33 Install Pump Housing Cover

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket


  1. Position the pump housing cover on the pump housing / bell in the orientation shown, taking care to align the holes (arrows)
  2. Install (4) mounting bolts using SIZE socket
G3 reass 33a.png

100_4249

34 Install Base Feet

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • SIZE Socket
  • SIZE wrench
  1. Place the product on top the base feet as pictured

For each base foot:

  1. On the engine side - install mounting nut and bolt using the SIZE wrench and SIZE socket
  2. On the pump side - install mounting bolt using SIZE socket
G3 diss 1a.png
35 EXTRA

Difficulty: #

Original Assembly: [R],[H],[O]

Tools Required:

  • t1
  • 12
pH1
  1. s1
  2. s2
File:G3 reass 35a.png

Challenges Faced with Assembly

Small Challenges
Substantial Challenges

Mechanisms

FIGURE OUT THE ORGANIZATION OF THIS SECTION!

Design Revisions

FIGURE OUT THE ORGANIZATION OF THIS SECTION!

1. Convert Power Source From Gasoline Engine to Diesel Engine

GSEE Factor(s)
Global
Diesel fuel requires less refining than gasoline does therefore it can be made more simply worldwide. Changing from a gasoline power source to a diesel power source would allow this fluid pump to be sold worldwide with less concern to the refining capabilities of the area it is being sold at, thus expanding the market.
Environmental
Diesel fuel burns much cleaner than gasoline does reducing carbon monoxide being polluted into the atmosphere.
Advantages
  • Diesel fuel has many benefits over gasoline, the first of which being diesel is more efficient to burn than gasoline. Most gasoline engines convert about 30 percent of their fuel energy into actual power. A traditional diesel converts about 45 percent (1). This means that less fuel could be used in order to create a given amount of work.
  • This leads into the next advantage of diesel, since diesel engines are more efficient; they also have less heat waste. This means that the engine can run at a lower temperature than a gasoline engine of the same size can. As a result of this the engine has less stresses applied on it which increase the cycle life.
  • Another benefit to diesel fuel is that it is safer than gasoline. Since diesel fuel is harder to ignite and slower burning than gasoline is will not explode unlike gasoline.
Disadvantages
  • Diesel engines tend to be heavier than a gasoline powered engine which is not ideal for a portable fluid pump
  • Diesel engines are slightly more expensive than a gasoline engine of equal power output

2. Convert Power Source From Gasoline Engine to Diesel Engine

GSEE Factor(s)
Category
explanation
Advantages
Disadvantages

3. Convert Power Source From Gasoline Engine to Diesel Engine

GSEE Factor(s)
Category
explanation
Advantages
Disadvantages
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