PowerCube Hydraulic reservoir: Difference between revisions

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====Hydraulic reservoir====
==Hydraulic reservoir==
 
This is the assembly for welding the hydraulic reservoir.  Keep the strainer away from welding sparks, as its fine metal mesh melts easily.


*[2] ¼” x 6” x 12”
*[2] ¼” x 6” x 12”
*6” x 12” x 27 ½” Tube
*6” x 12” x 27 ½” Tube
*2” x 2 ¼” x 1/8” Tube
*2” x 2” x 1/8” Tube
*[2] 3/4" Forged Weld-in Flange
*1 1/2" Forged Weld-in Flange
* Suction strainer
 
1. Cut two 1 7/16" holes and one 2" hole in the tube as in the diagram below.
 
2. Tack and weld the 3/4" flanges to the smaller holes with smooth, consistent welds to insure no leaks.


'''Clean tank components prior to welding'''
3. Tack and weld the 2" x 2" diameter pipe to the reservoir, insuring that it is centered over the reservoir hole.  Once welded, perform a "dry fit" by inserting the strainer into the extension tube to verify no binding when centered.
*Clean tank edges
 
*Clean inside of tank
4. Tack and weld the larger flange to the end of the extension pipe.  Again, perform the "dry fit" to insure no binding on the strainer.
*Clean-grind tank bungs
 
5. Use a wire brush to thoroughly clean the inside of the tube.
 
6. Tack and weld the two end plates to the tube, again with smooth consistent weld to insure no leaks.


::{{YoutubePopup|nfr2kZp8vGQ|big|powercube-window}}
::{{YoutubePopup|nfr2kZp8vGQ|big|powercube-window}}


'''Welding Plates to Tube'''
'''Welding extension and flange'''
* All welds assembling the reservoir must be quality welds that do not leak.  Be careful not to “over weld” the reservoir. 
* Tack and weld the 6” x 12” plates to both ends of the 6” x 12” tube.


'''Welding extension and flange'''
* Suction strainer
* Weld-in flange
* 2” x 2 ¼” x 1/8” tube
::[[Image:HydraulicReservoir.png|600px]]
::[[Image:HydraulicReservoir.png|600px]]
* Tack and weld the strainer extension tube to the tank, centered around the strainer hole.
* Insert the strainer into the flange and insert it into the strainer extension tube – verify that it slides without binding or bottoming and that the flange is flush with the end of the tube.  Remove the strainer from the flange, then tack and weld the flange to the tank.
CAUTION: Keep the strainer away from the welding and flames, as its thin wires burn easily.


::[[Image:HydraulicReservoir2.png]]
::[[Image:HydraulicReservoir2.png]]

Revision as of 04:12, 14 December 2011

Hydraulic reservoir

This is the assembly for welding the hydraulic reservoir. Keep the strainer away from welding sparks, as its fine metal mesh melts easily.

  • [2] ¼” x 6” x 12”
  • 6” x 12” x 27 ½” Tube
  • 2” x 2” x 1/8” Tube
  • [2] 3/4" Forged Weld-in Flange
  • 1 1/2" Forged Weld-in Flange
  • Suction strainer

1. Cut two 1 7/16" holes and one 2" hole in the tube as in the diagram below.

2. Tack and weld the 3/4" flanges to the smaller holes with smooth, consistent welds to insure no leaks.

3. Tack and weld the 2" x 2" diameter pipe to the reservoir, insuring that it is centered over the reservoir hole. Once welded, perform a "dry fit" by inserting the strainer into the extension tube to verify no binding when centered.

4. Tack and weld the larger flange to the end of the extension pipe. Again, perform the "dry fit" to insure no binding on the strainer.

5. Use a wire brush to thoroughly clean the inside of the tube.

6. Tack and weld the two end plates to the tube, again with smooth consistent weld to insure no leaks.

http://img.youtube.com/vi/nfr2kZp8vGQ/0.jpg

Welding extension and flange

HydraulicReservoir.png
HydraulicReservoir2.png
  • Video of reservoirs after welding:
http://img.youtube.com/vi/Q3Ygs9yk6Ls/0.jpg
  • After tack welding - measure location of engine mount 8 inches from inner edge of frame (not hydraulic tank) and 3 inches down from top of hydraulic tank:
http://img.youtube.com/vi/_h9LPdWWq9A/0.jpg