Power Cube/Manufacturing Instructions: Difference between revisions

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Intro to Power Cube Construction Script [[http://opensourceecology.org/wiki/Power_Cube/Intro_Video_Script]]
[[Power Cube/Intro Video Script | Intro to Power Cube Construction Script]]


==Preparation==
==Preparation==
Line 45: Line 45:
# [[PowerCube_Engine Mounts and Hydraulic Motor Mount|Engine and Hydraulic Motor Mount]]
# [[PowerCube_Engine Mounts and Hydraulic Motor Mount|Engine and Hydraulic Motor Mount]]
# [[PowerCube_Battery mount|Battery mount]]
# [[PowerCube_Battery mount|Battery mount]]
# [[PowerCube_Quick Attach Plates|Quick Attach Plates]]
# [[PowerCube_Oil cooler and fan mounts|Oil cooler and fan mounts]]
# [[PowerCube_Oil cooler and fan mounts|Oil cooler and fan mounts]]
# [[PowerCube_Keyswtich and Choke Brackets|Keyswtich and Choke Brackets]]
# [[PowerCube_Solenoid Mounting Bolts|Solenoid Mounting Bolts]]
# [[PowerCube_Solenoid Mounting Bolts|Solenoid Mounting Bolts]]
# [[PowerCube_ThrottleSwitchMounts|Keyswitch and Throttle mounts]]
# [[PowerCube_Quick Attach Plates|Quick Attach Plates]]
# [[PowerCube_Finish and Painting|Finish and Painting]]
# [[PowerCube_Finish and Painting|Finish and Painting]]
# [[PowerCube_Install Hydraulic Components|Install Hydraulic Components]]
# [[PowerCube_InstallEnginePump|Install Engine and Hydraulic Pump]]
# [[PowerCube_Install Solenoid|Install Solenoid]]
# [[PowerCube_Install Mufflers|Install Mufflers]]
# [[PowerCube_Wiring|Wiring]]
# [[PowerCube_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


===Keyswtich and Choke Brackets===
* Clamp the keyswitch bracket to the frame as shown and weld in place.
* Clamp the choke bracket to the frame as shown and weld in place.


===Solenoid Mounting Bolts===
==See Also==
* Weld the solenoid mounting bolts to the hydraulic reservoir as shown below.
::[[image:SolenoidMount.jpg]]
 
===Finish and Painting===
* Remove the engine if present
* Cover holes of tanks and any other place that should not be painted.
* Check all external surfaces for sharp edges and smooth with angle grinder.
* Remove any surface rust with wire brush and / or sandpaper.
* Apply a thorough coating of paint to all steel surfaces.
 
===Install Hydraulic Components===
* Install hydraulic suction filter in tank and hose barb in suction filter
* Connect one end of suction hose to strainer hose barb, the other end to the hose barb on pump and secure with hose clamps
* Connect adapter, nipple and male quick coupler for fluid power output port
* Screw 3/4" male elbow into one end of oil cooler and female quick coupler to other end of elbow
* Screw 3/4" male elbow into other end of oil cooler and JIC to 3/4" NTPF swivel adapter to 1' hose
* Connect opposite end of hose to JIC to 3/4" NTPM adapter, then to filter head input
* Connect . . .
 
 
::[[Image:Hydraulics.png]]
 
===Install Solenoid===
* Secure the solenoid on the bolts with two nuts.
 
===Install Mufflers===
* Unscrew the muffler from the elbow joint. 
* Bolt the elbow / flange to the engine. 
* Screw the muffler once again into the elbow joint.
 
===Wiring===
* The keyswitch has spade connectors for wiring and bolts to the frame for stability.  These should be connected with matching crimp-on connectors.
::[[Image:keyswitch.jpg]]
* Connect the remaining wires, as in the diagram below:
::[[Image:wiringdiagram.png]]
* Note that the thicker lines represent the heavier wires that will carry high electrical current.
 
===Keyswitch and Choke Installation===
* Install the keyswitches in the brackets and wire as in the wiring illustration below.
::[[image:KeyswitchWiring.jpg]]
* If your engine has a manual choke control, secure the choke control in its bracket.
 
===Choke installation===
* NOTE: Only necessary if your engine has a manual choke adjustment!
* Secure the engine choke knob as shown in the illustration below
::[[image:ChokeBracket.jpg]]
 
===Throttle Adjustment===
 
* The engine throttle is adjusted with a push-pull cable as shown in the image below.
 
::[[image:ThrottleAdjustment.jpg|400px]]
 
===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.
See also [[Power_Cube_Fabrication_Procedure]] for older model.


Work in progress by Tom Griffing - [[File:powercube.odt]]
Work in progress by Tom Griffing - [[File:powercube.odt]][[File:powercube.pdf]]
 
=Update Request from Tom=
We're still not done with the Power Cube documentation - it still needs some updates:


*Once the next power cube is complete, take photo of the current model and replace old photos / images on these pages: [[Power_Cube]], [[Power_Cube/Manufacturing_Instructions]]
[[Image:PowerCube.skp|PowerCube Sketchup Drawing]]
*Painting: Procedures, BOM entries, tools


==Previous Versions==
==Previous Versions==

Latest revision as of 13:02, 6 January 2012


Power Cube
   Home  |  Research & Development  |  Bill of Materials  |  Manufacturing Instructions  |  User's Manual  |  User Reviews    Power Cube.png
v · d · ePower Cube Manufacturing Instructions
Prepare
Subassembly Fabrication
Assembly


Overview

Powercube4.jpg


Intro to Power Cube Construction Script

Preparation

  1. Safety
  2. Workspace
  3. Tools

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 3/8” in thickness.

  1. Engine & Hydraulic Pump mounts
  2. Quick attach mounts
  3. Fuel tank
  4. Oil Cooler Mount
  5. Key Switches and Choke
  6. Electrical cables
  7. Battery Mount
  8. Mufflers
  9. Hydraulic reservoir

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 Power Cube Jig can be very useful during the welding stage:

Power Cube Frames welding - 45 minutes per frame with one person assisting on jig clamping.
  1. Frame
  2. Gas tank
  3. Hydraulic tank
  4. Engine and Hydraulic Motor Mount
  5. Battery mount
  6. Oil cooler and fan mounts
  7. Solenoid Mounting Bolts
  8. Keyswitch and Throttle mounts
  9. Quick Attach Plates
  10. Finish and Painting
  11. Install Hydraulic Components
  12. Install Engine and Hydraulic Pump
  13. Install Solenoid
  14. Install Mufflers
  15. Wiring
  16. Install Throttle Control

Final touches

  1. Install engine and secure with bolts, nuts and washers
  2. Connect wiring to key switch and solenoid
  3. Connect fuel line
  4. Connect coupling to engine shaft
  5. Install hydraulic pump on coupling and secure with nuts & washers
  6. 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.odtFile:Powercube.pdf

File:PowerCube.skp

Previous Versions

Power Cube Fabrication June 2011


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