View source for Power Cube 6/Manufacturing Instructions

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==Overview==
This is the procedure for manufacturing version 6 of the OSE Power Cube.

[[Image:PowerCube6.png|thumb|PowerCube VI]]
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[[Power Cube/Intro Video Script | Intro to Power Cube Construction Script]]

==Preparation==

# [[PowerCube_Safety|Safety]]
# [[PowerCube_Workspace|Workspace]]
# [[PowerCube_Tools|Tools]]


==Steel Cut Sheet==

{| class="wikitable" style="text-align: center;"
! Type
! Cross Section
! Qty
! Cut Length
|-
|Flat Steel
|1/8" x 4"
|2
|1"
|-
|Angle Iron
|1/4" x 2" x 2"
|2
|4"
|-
|Angle Iron
|1/4" x 2" x 2"
|1
|2"
|-
|Angle Iron*
|1/4" x 2" x 2"
|10
|27" - 45 degree miter cuts (see diagram)
|-
|Tube - Rectangular
|1/4" x 6" x 12"
|2
|26"
|-
|Flat Iron
|1/8" x 4"
|1
|14"
|-
|Flat Iron
|3/8" x 4"
|2
|26"
|-
|Flat Iron
|1/4" X 6"
|4
|12"
|-
|Flat Iron
|1/4" X 6"
|1
|6"
|-
|Flat Iron
|1/4" x 8"
|1
|13.5"
|-
|Expanded Steel
|1/8" thick
|1
|14" x 26"
|}

* Note: These angle iron pieces are to be cut at specific 45 degree angles for a mitered frame, as shown below.
 
[[image:miteredframe.png|300px|Mitered Frame]]

=Fabrication=
=Design Files=
==Sketchup==
::[[File:PC6_Fuel_Tank_FAB.skp|Fuel Tank]]
::[[File:PC6_Hydraulic_Reservoir_FAB.skp|Hydraulic Reservoir]]
::[[File:PC6_Frame_FAB.skp|Frame]]
::[[File:PC6_Engine_Pump_Mount_FAB.skp|Engine Pump mount]]
::[[File:PC6_Control_Panel_FAB.skp|Control Panel]]

==Electrical Diagram==
::[[File:PC6_Wiring_FAB.png|Wiring Diagram|600px]]

==Resolving Correct Labeling on Key Switch==
Note: Convention on back of key switch. M and B have different label on the metal stud - I am assuming we go by the label imprinted in the plastic.

<html><img src="https://docs.google.com/drawings/pub?id=14sKP8bw0pvIXgpXrXbzYvp6MmNKw-dqUMjk7FDI4ky4&amp;w=300&amp;h=200"></html>

[https://docs.google.com/drawings/d/14sKP8bw0pvIXgpXrXbzYvp6MmNKw-dqUMjk7FDI4ky4/edit edit]

Jack's Small Engine says:

The letters on the back of an ignition switch stand for the following:
*M = Magneto
*S = Starter Solenoid
*L = Lights
*A = Accessory
*B = Battery
*G = Ground
*I = Ignition
*R = Regulator/Rectifier

Source: http://www.jackssmallengines.com/Products/TROY-BILT/ignition-switches-keys


As for the labeling on the switch itself, we can verity with an ohmmeter:

In OFF position, M should connect to ground. In ON position, M should not connect to anything

In OFF position, B should not connect to anything. In ON position, B should connect to L

=Video=
<html>
<iframe width="400" height="225" src="https://www.youtube.com/embed//ElkrD32G3TE" frameborder="0" allowfullscreen></iframe>

<iframe width="400" height="225" src="https://www.youtube.com/embed//5gtW3vl-em0" frameborder="0" allowfullscreen></iframe>

<iframe width="400" height="225" src="https://www.youtube.com/embed//tUJ4F5YMp2s" frameborder="0" allowfullscreen></iframe>

<iframe width="400" height="225" src="https://www.youtube.com/embed//iN74u63KpRQ" frameborder="0" allowfullscreen></iframe>

<iframe width="400" height="225" src="https://www.youtube.com/embed//GDALEaHXt1g" frameborder="0" allowfullscreen></iframe>

</html>

==Subassembly Fabrication==
The purpose of this section is to cut the raw steel into required lengths and shapes as required for final assembly.  These step includes drilling and cutting steel up to 1/4” in thickness.

# [[PowerCube6_Pump_Mount|Hydraulic Pump mount]]
# [[PowerCube6_Fuel_Tank|Fuel tank]]
# [[PowerCube6_Hydraulic_Reservoir|Hydraulic oil reservoir]]
# [[PowerCube6_Control_Panel|Control Panel]]
# [[PowerCube6_Battery_Mount|Battery Mount]]

==Assembly==

Power Cube assembly requires all the parts listed in the Bill Of Materials to be available and prepared as detailed in the “Fabrication” section (above).  Assembly requires a welder (electric or torch) capable of welding metal 3/8” thick.

A "Stronghand" clamp has proven useful for 90 degree alignment of the frame members

::[[Image:frameweld.jpg|thumb|Power Cube Frame welding]]

# [[PowerCube6_Frame|Frame]]
# [[PowerCube6_Fuel_Tank|Gas tank]]
# [[PowerCube6_Hydraulic_Tank|Hydraulic tank]]
# [[PowerCube6_Engine_Pump_Mounts|Engine and Hydraulic Pump Mounts]]
# [[PowerCube6_Battery_Mount|Battery mount]]
# [[PowerCube6_Oil_Cooler_Fan_Mount|Oil cooler and fan mounts]]
# [[PowerCube6_Solenoid_Mount|Solenoid Mounting Bolts]]
# [[PowerCube6_Throttle_Mount|Throttle mount]]
# [[PowerCube6_Keyswitch_Mount|Keyswitch mount]]
# [[PowerCube6_Quick_Attac_Plates|Quick Attach Plates]]
# [[PowerCube6_Painting|Painting]]
# [[PowerCube6_Install_Hydraulics|Install Hydraulic Components]]
# [[PowerCube6_Install_Engine_Pump|Install Engine and Pump]]
# [[PowerCube6_Install_Solenoid|Install Solenoid]]
# [[PowerCube6_Install_Muffler|Install Muffler]]
# [[PowerCube6_Wiring|Wiring]]
# [[PowerCube6_Throttle|Install Throttle Control]]

==Final touches==
# Install engine and secure with bolts, nuts and washers
# Connect wiring to key switch and solenoid
# Connect fuel line
# Connect coupling to engine shaft
# Install hydraulic pump on coupling and secure with nuts & washers
# Install fan and hydraulic oil cooler


==See Also==
See also [[Power_Cube_Fabrication_Procedure]] for older model.

Work in progress by Tom Griffing - [[File:powercube.odt]][[File:powercube.pdf]]

[[Image:PowerCube.skp|PowerCube Sketchup Drawing]]

==Previous Versions==

[[Power Cube/Manufacturing Instructions/Fabrication June 2011|Power Cube Fabrication June 2011]]

==Peer Review==
*I would do double chain coupler. I have had good experience with it - it will extend pump life because it will eliinate any strain on the pump shaft, while easing accuracy requirements for pump mount welding.

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