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

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|  
 
|  
 
# Position the carry handle by lining up the mounting holes (arrows)
 
# Position the carry handle by lining up the mounting holes (arrows)
−
# Install (2) mounting bolts using SIZE socket
+
# Install (2) mounting bolts using 3/8in socket
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
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| [[File:G3 reass 14a.png|thumb|center|upright=1.0]]
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| '''Install Exhaust Manifold'''
 
| '''Install Exhaust Manifold'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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−
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| '''Install Spark Plug and Spark Plug Wire'''
 
| '''Install Spark Plug and Spark Plug Wire'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
  
−
* SIZE Socket
+
* 3/4in Socket
  
 
<!-- COL 3 (PROCEDURE) -->
 
<!-- COL 3 (PROCEDURE) -->
 
| Install Spark Plug
 
| Install Spark Plug
−
# Use SIZE socket to securely install the spark plug to the engine head  
+
# Use 3/4in socket to securely install the spark plug to the engine head  
 
Install Spark Plug Wire
 
Install Spark Plug Wire
 
# Using hands (pliers optional) clip the end of the spark plug wire over the top of the spark plug
 
# Using hands (pliers optional) clip the end of the spark plug wire over the top of the spark plug
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
| [[File:G3 reass 16a.png|thumb|center|upright=1.0]]
 
| [[File:G3 reass 16a.png|thumb|center|upright=1.0]]
−
100_4210
 
 
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| '''Assemble Carburetor'''
 
| '''Assemble Carburetor'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 3
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
  
−
* SIZE Flat-Head Screwdriver
+
* 3/16in Flat-Head Screwdriver
 +
 
 +
* 1/2in Socket
  
−
* 12
 
  
 
<!-- COL 3 (PROCEDURE) -->
 
<!-- COL 3 (PROCEDURE) -->
 
| Assemble Cover Plate and Contained Components
 
| Assemble Cover Plate and Contained Components
 
# See the first image -- the parts are shown exploded, install the spring first, then the metal ring, finally place the cover plate on top
 
# See the first image -- the parts are shown exploded, install the spring first, then the metal ring, finally place the cover plate on top
−
# Use SIZE flat-head screwdriver to install (4) mounting screws
+
# Use 3/16in flat-head screwdriver to install (4) mounting screws
  
−
FINISH THIS LATER
+
Install Idle Adjustment Components
 +
# Install the components in the order pictured (exploded view)
 +
# Use the 1/2in socket
  
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
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| [[File:G3 reass 17a.png|thumb|center|upright=1.0]]
 
  [[File:G3 reass 17b.png|thumb|center|upright=1.0]]
 
  [[File:G3 reass 17b.png|thumb|center|upright=1.0]]
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a: 100_4211
 
  
−
b: 100_4215
 
 
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| '''Install Carburetor'''
 
| '''Install Carburetor'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
  
−
* SIZE Socket
+
* 3/8in Socket
  
 
<!-- COL 3 (PROCEDURE) -->
 
<!-- COL 3 (PROCEDURE) -->
 
|  
 
|  
 
# Position the carburetor by lining up the mounting holes (arrows)
 
# Position the carburetor by lining up the mounting holes (arrows)
−
# Install mounting bolts with SIZE socket
+
# Install mounting bolts with 3/8in socket
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
| [[File:G3 reass 18a.png|thumb|center|upright=1.0]]
 
| [[File:G3 reass 18a.png|thumb|center|upright=1.0]]
−
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+
 
 
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| '''Install Throttle Linkage & Return Spring'''
 
| '''Install Throttle Linkage & Return Spring'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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| [[File:G3 reass 19a.png|thumb|center|upright=1.0]]
−
100_4223
+
 
 
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| '''Install Governor Plate'''
 
| '''Install Governor Plate'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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| '''Assemble Recoil Starter'''
 
| '''Assemble Recoil Starter'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 3
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R],[H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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| [[File:G3 reass 21a.png|thumb|center|upright=1.0]]
−
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+
 
 
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| '''Install Recoil Starter Housing'''
 
| '''Install Recoil Starter Housing'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
  
−
* SIZE Socket
+
* 11mm Socket
  
 
<!-- COL 3 (PROCEDURE) -->
 
<!-- COL 3 (PROCEDURE) -->
 
|  
 
|  
 
# Position the recoil start housing in place over the flywheel and engine crankcase
 
# Position the recoil start housing in place over the flywheel and engine crankcase
−
# Using SIZE socket, install (2) mounting bolts in their holes (arrows)
+
# Using 11mm socket, install (2) mounting bolts in their holes (arrows)
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
| [[File:G3 reass 22a.png|thumb|center|upright=1.0]]
 
| [[File:G3 reass 22a.png|thumb|center|upright=1.0]]
−
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+
 
 
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| '''Install Crankcase Ventilation Tube'''
 
| '''Install Crankcase Ventilation Tube'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 1
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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'''Difficulty:''' 1
 
'''Difficulty:''' 1
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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'''Difficulty:''' #
 
'''Difficulty:''' #
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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* Phillips Screwdriver
 
* Phillips Screwdriver
  
−
* SIZE Socket
+
* 10mm Socket
  
 
<!-- COL 3 (PROCEDURE) -->
 
<!-- COL 3 (PROCEDURE) -->
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# Position the fuel tank such that the 3 holes on top of the tank align with the 3 corresponding holes in the carburetor (arrows)
 
# Position the fuel tank such that the 3 holes on top of the tank align with the 3 corresponding holes in the carburetor (arrows)
 
# Install 3 mounting screws with phillips screwdriver
 
# Install 3 mounting screws with phillips screwdriver
−
# Install 1 mounting bolt with SIZE socket (arrow)
+
# Install 1 mounting bolt with 10mm socket (arrow)
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
| [[File:G3 reass 25a.png|thumb|center|upright=1.0]]
 
| [[File:G3 reass 25a.png|thumb|center|upright=1.0]]
−
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+
 
 
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| '''Assemble Air Filter Box'''
 
| '''Assemble Air Filter Box'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 1
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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| '''Install Air Filter Box'''
 
| '''Install Air Filter Box'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
 
'''Original Assembly:''' [R],[H],[O]
 
'''Original Assembly:''' [R],[H],[O]
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<!-- COL 4 (IMAGES) -->
 
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| [[File:G3 reass 27a.png|thumb|center|upright=1.0]]
−
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+
 
 
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| '''Install Oil Fill Plug'''
 
| '''Install Oil Fill Plug'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 1
  
 
'''Original Assembly:''' [R],[H],[O]
 
'''Original Assembly:''' [R],[H],[O]
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<!-- COL 4 (IMAGES) -->
 
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−
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+
 
 
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| '''Install Oil Drain Plugs'''
 
| '''Install Oil Drain Plugs'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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| [[File:G3 reass 29a.png|thumb|center|upright=1.0]]
−
100_4245
+
 
 
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| '''Install Pump Housing Gasket Plate'''
 
| '''Install Pump Housing Gasket Plate'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 1
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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−
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+
 
 
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| '''Install Primer Port Plug'''
 
| '''Install Primer Port Plug'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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−
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+
 
 
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| '''Install Pump Drain Plug'''
 
| '''Install Pump Drain Plug'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 1
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
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+
 
 
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| '''Install Pump Housing Cover'''
 
| '''Install Pump Housing Cover'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 2
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [R]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
  
−
* SIZE Socket
+
* 11mm Socket
  
  
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|  
 
|  
 
# Position the pump housing cover on the pump housing / bell in the orientation shown, taking care to align the holes (arrows)
 
# Position the pump housing cover on the pump housing / bell in the orientation shown, taking care to align the holes (arrows)
−
# Install (4) mounting bolts using SIZE socket
+
# Install (4) mounting bolts using 11mm socket
 
<!-- COL 4 (IMAGES) -->
 
<!-- COL 4 (IMAGES) -->
 
| [[File:G3 reass 33a.png|thumb|center|upright=1.0]]
 
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| '''Install Base Feet'''
 
| '''Install Base Feet'''
  
−
'''Difficulty:''' #
+
'''Difficulty:''' 3
  
−
'''Original Assembly:''' [R],[H],[O]
+
'''Original Assembly:''' [H]
  
 
'''Tools Required:'''
 
'''Tools Required:'''
  
−
* SIZE Socket
+
* 13mm Socket
  
−
* SIZE wrench
+
* 14mm wrench
  
 
<!-- COL 3 (PROCEDURE) -->
 
<!-- COL 3 (PROCEDURE) -->
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−
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'''Tools Required:'''
 
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* t1
 
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−
* 12
 
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# s1
 
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# s2
 
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Revision as of 15:06, 30 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

Throughout the assembly process, Group 3 has tried to resolve the question, "How was this assembly operation performed in the product's original assembly process?" In order to answer this question in this report, the two possible answers are represented by the following denotations in square ( [] ) brackets.

  • [H] Originally assembled by Hand
  • [R] Originally assembled by Robot

These [H] & [R] notes for each step of assembly will be used in the How-To Guide.

Difficulty Scale

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. valvespring compressor, piston ring compressor)

Technical Experience

Maximum


5

Requires specialty machinery
(e.g. shop 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

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
  • Piston Ring Compressor
  • Shop Press
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
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: 2

Original Assembly: [H]

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
2 Install Valves

Difficulty: 4

Original Assembly: [H]

Tools Required:

  • Valve-Spring Compressor Tool
  • Needle-Nose 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
3 Assemble Piston/Connecting Rod Assembly

Difficulty: 3

Original Assembly: [H]

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
4 Install Piston / Connecting Rod Assembly

Difficulty: 4

Original Assembly: [R]

Tools Required:

  • Needle-Nose pliers
  • Piston Ring Compressor
  • 7/16in 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
G3 reass 4b.png
5 Install Lifters and Camshaft

Difficulty: 1

Original Assembly: [H]

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
6 Install Crankshaft Support Bearing

Difficulty: 4

Original Assembly: [R]

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
7 Install Crankcase Cover

Difficulty: 2

Original Assembly: [R]

Tools Required:

  • 11mm 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
8 Install Side Flywheel Shroud

Difficulty: 2

Original Assembly: [H]

Tools Required:

  • 11mm 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 11mm socket
G3 reass 8a.png


9 Install Mesh Flywheel Shroud

Difficulty: 2

Original Assembly: [H]

Tools Required:

  • 1/4in socket
pH1
  1. Position the mesh flywheel shroud as pictured
  2. Install (2) mounting screws using 1/4in socket
G3 reass 9a.png


10 Install Coil & Governor Mounting Plate

Difficulty: 2

Original Assembly: [H]

Tools Required:

  • 1/4in 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
11 Install Pump Housing / Bell

Difficulty: 3

Original Assembly: [R]

Tools Required:

  • 13mm Socket
  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 13mm socket
G3 reass 11a.png
12 Install Impeller

Difficulty: 3

Original Assembly: [R]

Tools Required:

  • 7/8in 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 7/8in socket to install it fully
G3 reass 12a.png


13 Install Engine Head

Difficulty: 2

Original Assembly: [R]

Tools Required:

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

Difficulty: 2

Original Assembly: [H]

Tools Required:

  • 3/8in Socket
  1. Position the carry handle by lining up the mounting holes (arrows)
  2. Install (2) mounting bolts using 3/8in socket
G3 reass 14a.png
15 Install Exhaust Manifold

Difficulty: 2

Original Assembly: [R]

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
16 Install Spark Plug and Spark Plug Wire

Difficulty: 2

Original Assembly: [R]

Tools Required:

  • 3/4in Socket
Install Spark Plug
  1. Use 3/4in 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
17 Assemble Carburetor

Difficulty: 3

Original Assembly: [H]

Tools Required:

  • 3/16in Flat-Head Screwdriver
  • 1/2in Socket


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 3/16in flat-head screwdriver to install (4) mounting screws

Install Idle Adjustment Components

  1. Install the components in the order pictured (exploded view)
  2. Use the 1/2in socket
G3 reass 17a.png
G3 reass 17b.png


18 Install Carburetor

Difficulty: 2

Original Assembly: [R]

Tools Required:

  • 3/8in Socket
  1. Position the carburetor by lining up the mounting holes (arrows)
  2. Install mounting bolts with 3/8in socket
G3 reass 18a.png


19 Install Throttle Linkage & Return Spring

Difficulty: 2

Original Assembly: [H]

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


20 Install Governor Plate

Difficulty: 2

Original Assembly: [H]

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: 3

Original Assembly: [R],[H]

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


22 Install Recoil Starter Housing

Difficulty: 2

Original Assembly: [H]

Tools Required:

  • 11mm Socket
  1. Position the recoil start housing in place over the flywheel and engine crankcase
  2. Using 11mm socket, install (2) mounting bolts in their holes (arrows)
G3 reass 22a.png


23 Install Crankcase Ventilation Tube

Difficulty: 1

Original Assembly: [H]

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


24 Install Fuel Fill Cap

Difficulty: 1

Original Assembly: [R]

Tools Required:

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


25 Install Fuel Tank

Difficulty: #

Original Assembly: [H]

Tools Required:

  • Phillips Screwdriver
  • 10mm 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 10mm socket (arrow)
G3 reass 25a.png


26 Assemble Air Filter Box

Difficulty: 1

Original Assembly: [H]

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: 2

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


28 Install Oil Fill Plug

Difficulty: 1

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


29 Install Oil Drain Plugs

Difficulty: 2

Original Assembly: [R]

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


30 Install Pump Housing Gasket Plate

Difficulty: 1

Original Assembly: [R]

Tools Required:

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


31 Install Primer Port Plug

Difficulty: 2

Original Assembly: [R]

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


32 Install Pump Drain Plug

Difficulty: 1

Original Assembly: [R]

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


33 Install Pump Housing Cover

Difficulty: 2

Original Assembly: [R]

Tools Required:

  • 11mm 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 11mm socket
G3 reass 33a.png


34 Install Base Feet

Difficulty: 3

Original Assembly: [H]

Tools Required:

  • 13mm Socket
  • 14mm 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

Challenges Faced with Assembly

Small Challenges
Substantial Challenges

Mechanisms

INTRO

Equations
The following are a set of general governing equations that may be applied to the analysis of the rotating mechanisms. Further equations for kinematic analysis may be derived from the basis of the integral/derivative relationships between position, velocity, and acceleration, and may be further combined with the following.
Governing Equations


1. Crankshaft

Purpose
The crankshaft creates the “up-down” translational movements in the piston by a transfer of energy through a linkage component (connecting arm).
How it Works
The connecting arm connects the crankshaft to the piston and creates alternating “up-down” translational motion by converting the rotational energy from the arm (from the crankshaft) to translational motion of the piston. On the other side of the connecting arm, the crankshaft is connected to the flywheel, which stores kinetic energy and renders the pulsating forces that create the alternating movement of the piston. Once the piston is in motion, its translational motion continues to work in conjunction with the rotational motion from the crankshaft/connecting arm.


2. Camshaft & Valvetrain

Purpose
To properly let air/fuel mixture in and out the engine. The camshaft is an essential part of the engine because the valve movements must be timed perfectly so that fuel can be let in and out by the movement of the piston.
How it Works
The camshaft is placed above the valves within the cylinder head, and is designed to ensure that the valves open and close at the appropriate time to intake and exhale fuel. The initial downward motion of the piston is called the intake stroke – at this point, the intake valve would open. When the intake valve is open, the air/fuel mixture rushes into the cylinder. When it hits the bottom stroke, the valve closes. When the bottom stroke rises, the exhaust valve would open (to release exhaust), and the exhaust valve will close at the end of the combustion stroke. From there, the cycle is repeated.

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 All Fasteners to Metric

GSEE Factor(s)
Global
Very few countries use the imperial system and having all fasteners being metric the fluid pump would be easier to produce and maintain worldwide
Advantages
  • When servicing is required, it would require less effort to determine the correct size of each fastener considering the only decision that would have to be made was the correct size, instead of unit and size
  • Less expensive to produce and maintain since only one unit system of tools would be required to assemble/ disassemble
Disadvantages
  • Requires redesign of all imperial fasteners

3. Convert Power Source From Gasoline Engine to Diesel Engine

GSEE Factor(s)
Societal
Societal demands have evolved into a desire for ease of use and adding wheel would help facilitate this demand by providing ease of transporting the pump. This would reduce the physical demand created from lifting the pump to transport it.
Advantages
  • Improve the ability to transport the fluid pump from one location to another
Disadvantages
  • Increased cost created from extra materials including wheels and a frame
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