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Lead Contributors:

Tom Griffing, Marcin Jakubowski

Greg Sedbrook, Moriah Baltz, Devin Ward, Brenna Fitzpatrick, Emily Dixon, Victor Macul, Guillaume Coudray, Edo Licina, Michael Hess, Aidan Williamson, Sephen Whiting, Gabriel Kind, Claire Sprenger

Source File:

OSE [Machine name] Development Board

Graphic Design:

Jean-Baptiste Vervaeck

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Power Cube - Structural Frame

Version 8

Open Source Ecology Build Instructions

Link for wiki

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To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

Table of Content

• Phase 1: General Orientation
• Phase 2: Pre-Assembly
• Phase 3: Modules Assembly
• Phase 4: Modules Integration

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

SAMPLE TEMPLATE

Files

Bill Of Materials: PCSF_BOM

Phase 1: General Orientation

SAMPLE TEMPLATE

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

Safety Equipment

Safety is important during assembly.

Be sure to wear:

Be sure to know the location of your emergency equipment:

Hard hat

Ear protection

Protective gloves

Steel toed boots

Safety glasses

Welding shield

Emergency shower

First aid kit

Fire extinguisher

Eyewash station

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

SAMPLE TEMPLATE

Phase 2: Pre-Assembly

• Cutting
• 20 short square tubing
• 8 leg holders
• 4 feet
• 8 hopper support clamps
• 8 long square tubing
• 4 legs
• 4 hopper supports

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• Shearing
• 31 slats and the center-piece for the grate members
• Shaker hammer
• Hopper hinges

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• Punching
• Marking hopper hinge holes
• Punching hopper hinge holes

• Mag drilling
• 20 clamp tube holes
• 2 holes press foot

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• Rounds Cutting
• 1 pin for main cylinder
• 2 threaded rods for press foot
• 3 pin bushings for the main cylinder
• 1 collar for the main cylinder
• 2 end collars for the main cylinder
• 2 pins for secondary cylinder
• Keyed hammer shaft
• Coupler for the hopper shaker

Phase 3: Modules Assembly

If this slide isn't enough , create a copy of this slide and add the remaining modules

Check out the OSE Database for any previously module code. The module code must follow the pattern OSE.Mx (in place of ‘x’ set the module code)

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

[Module Name]

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Bill of Materials

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Phase 4: Modules Integration

Step 1 [Step Title]

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Phase 4: Modules Integration

[Directions for Assembly]

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[Directions for Assembly]

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Build Instructions

Frame - structural 4x4 steel - Claire

[2] Hydraulic Reservoir - Aidan + Michael

[2] Fuel Tank - Gabe + Guillaume

[2] Engine Module - Engine, Muffler, Engine Mount Plate - Brenna, Stephen

Coupler - Devin

Wiring Harness - see Power Cube 7 page - Tom

Control Panel - Edo

[2] Pump Module - pump mount + plates - Moriah + Greg

Cooler Module - Emily

Solenoid - Claire

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Resources

Fabrication.pdf

Power Cube v7 WKSP

Power Cube v7 wiki

OSE BOM

Frame

1. Check to see you have all needed parts

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Step 1 Parts needed

End Goal

Frame

2. Cut steel for frame members to form twelve 1’ members.

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3. Cut the ends of each member to form 45 degree angles on each side.

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Steps 2 & 3 Cut frame members to size, cut ends

Above: inside view

Below: outside view

Cut the ends of each frame member along the red lines to form 45 degree angles

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12”

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Frame

4. Grind the edges of the steel on either side of each end to create 45 degree slopes as depicted.

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(By doing this, we create space for the welds to fill, allowing us to connect the frame members without excess metal distorting the cube shape.)

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Steps 4, 5 Grind edges of frame member ends

There are 12 frame members like the one depicted here in total

Grind each frame member on both ends along the red lines

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Frame

(The order captured here is simply what has tried and worked for Power Cube developers thus far. If you find a more effective procedure to follow, please share!) :)

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6. Weld the ends of each member together to form corners in the order depicted.

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Step 6 Weld corners to form cube

First form a 90 degree “V” shape using two members.

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Repeat.

Attach your two V’s to form a square.

Then attach two perpendicular members to both corners on one side.

Repeat the process to the left with new members once more.

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Next, attach both components

(Repeat, then...)

Frame

4. Grind the edges of the steel on either side of each end to create 45 degree slopes as depicted.

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(By doing this, we create space for the welds to fill, allowing us to connect the frame members without excess metal distorting the cube shape.)

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Steps 4, 5 Grind edges of frame member ends

There are 12 frame members like the one depicted here in total

Grind each frame member on both ends along the red lines

Frame

4. Grind the edges of the steel on either side of each end to create 45 degree slopes as depicted.

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(By doing this, we create space for the welds to fill, allowing us to connect the frame members without excess metal distorting the cube shape.)

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Steps 4, 5 Grind edges of frame member ends

There are 12 frame members like the one depicted here in total

Grind each frame member on both ends along the red lines

Phase 4: Frame

2. Grind the ends of the steel frame members where they will connect to one another, ensuring they will align once assembled.

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Step ?.2 Grind ends of frame members

Screenshots of each part portrayed in a CAD file

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Two frame members, weld where

(SketchUp portrayal of step 2)

(photo of step 2)

Tubing Frame

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[Module Name]

Bill of Materials

Its a checklist box to help during the inventory

If this slide isn't enough , create a copy of this slide and add the remaining items

Check out the OSE Database for any previously parts numbers. The part number must follow the pattern Mx.pn (in place of 'x' and ‘pn’set the module code and the part number code)]

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

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Step 1 [Step Title]

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Step 1 [Step Title]

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[Module Name]

[Use this image size. This should be the image of a specific assembly sub step, captured by a CAD file screenshot. Highlight the specific part assembled in this sub step. Upload this image on Trovebox and label it with the title P3MxSyVz (in place of 'x', ‘y’ and ‘z’ set the module, step and view codes)]

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Phase 3: Engine, Exhaust, Plate

Phase 3: Engine Plate Fabrication Drawing

Directions for Assembly:

Cut plate: 8“ x 15 1/2“, grind edges

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Step 1.1 [Sub Step Title]

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Directions for Assembly: Link to Drawing with precise measurements. (And in a format you can actually read)

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Begin with the center hole and move out from there.

Tips on torching a perfect hole! Weld a nail in the center of the central hole. Use a piece of string and tie one end to the nail and the other end to the tip of the oxy/acetylene torch tip so that the torch is just shorter that 1” from the nail in the center. Rotate the torch around the nail 180 degrees, and then go around in the other direction. Another suggestion: use a centerpunch to punch holes around the perimeter of the circle. This will make it easier to see the outline of the circle when you are trying to torch it.

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Everything will be measured out from the center, so make sure your placement is precise. Torch and grind the center hole.

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Drill or punch small (5/16“) holes, measuring out from center hole, grind slots

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picture of cutting plate? Torching hole?

Phase 3: Engine Plate Fabrication Drawing

Directions for Assembly:

paint plate, let dry

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Bolt plate to engine

Bolt muffler to engine with gaskets

Bolt muffler extension to muffler

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Engine Coupling

1. Cut the 1.5”OD spline shaft coupling and the 1.75” OD keyed shaft coupling in half with the bandsaw. You will only use one half of each for the coupling assembly.

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• Clean and prep all weld surfaces. Insert alignment plug between one half of the spline shaft coupling and one half of the keyed shaft coupling.
• Note: Mating coupling faces should be factory faces. Cut faces should face away from alignment plug.

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• Clamp coupler assembly together using alignment jig.
• Precision Note: Coupling halves must be aligned precisely to prevent the shaft from binding.

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• Weld the coupler halves together around the alignment plug.

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• Using a cutoff saw, remove ½” from the end of the engine shaft and smooth/chamfer with a grinder. Let the engine shaft shaft cool before proceeding {Tom, should we omit this step since the shaft wound up being a bit short?}.

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• Secure the coupling to the engine shaft using a key and a set screw.

Phase 3: Hydraulic and fuel reservoir fabrication

• Cut holes in the top and side faces of the reservior as well as the control panel bracket as follows:
• Drill two 1/2" holes on the front face placed 1” from the top and bottom faces and 6 3/4” from the right face.
• Drill a 7/16” hole to the left of the bottom sight mount hole spaced 1” from the bottom.
• Drill a 7/16” hole on the front face 3 1/2" from the top face and 2 1/4” from the left face.
• Torch a 1 7/16 “ hole on the top plate 1 1/2" from the left plate and
• Torch a 1 7/16” hole 6 1/4" from the left plate and 6 1/2" from the bottom plate.
• Torch a 2 7/8" hole three inches from the right side and 1” from the bottom
• Using a grinding wheel on an angle grinder, grind a 45 degree bevel on the interfacing edges of the plates and the tube. Also grind the areas around the torched holes.
• Grind the mill scale off the flange as well.
• Clean all edges for welding if necessary after grinding.
• Weld the bungs (weld-in flange) to their proper bung holes
• Tap hole for tank return using a 1/4" tap. When tapping, ensure that the tap remains perpendicular to the face of the plate. Turn the tap a 1/4 turn (meaning 90 degrees of rotation) and back it off to break chips in the teeth of the tap.
• Mount sight gauge with supplied bolts
• Weld end plates – Precision Note: Use gap of between 1/8" and 3/16” between tube and plate. You can achieve this by sliding a drill bit of the proper size along the length of the gap while holding the plate with a mag square.
• Weld mounting brackets together, then to tank
• Weld control panel bracket to reservoir
• Pressure test:
• Mix some soap with some water. Use about 1 to 1.
• Rub this mixture along alll welded seams
• Cap all holes except for the low pressure return hole
• Force compressed air into the uncapped hole and look for bubbles along the welds.
• In case of bubbles, mark that spot with soapstone or a marker and grind the weld out
• Re-weld
• Re-test

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Step 1.1 [Hydraulic Reservoir]

Hydraulic and fuel reservoir fabrication

Bill of Materials�[number of pieces] pieces

Hydraulic and fuel reservoir fabrication

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Step 1 [Step Title]

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Directions for Assembly: [Text]

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

[Use this picture size. This should be the specific step for the module build.]

Cut holes in the top and side faces of the reservior as well as the control panel bracket as follows:

• Drill two 1/2" holes on the front face placed 1” from the top and bottom faces and 6 3/4” from the right face.
• Drill a 7/16” hole to the left of the bottom sight mount hole spaced 1” from the bottom.
• Drill a 7/16” hole on the front face 3 1/2" from the top face and 2 1/4” from the left face.
• Torch a 1 7/16 “ hole on the top plate 1 1/2" from the left plate and
• Torch a 1 7/16” hole 6 1/4" from the left plate and 6 1/2" from the bottom plate.
• Torch a 2 7/8" hole three inches from the right side and 1” from the bottom

Hydraulic and fuel reservoir fabrication

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Step 1.1 [Sub Step Title]

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Directions for Assembly: [Text]

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

[Use this picture size. This should be the specific step for the module build.]

[Number of people involved in step]

Directions for Assembly: [Text]

Wiring Harness

Schematic

signal port on hot side of solenoid

Cut Wires

Keyswitch harness (all 16 gauge)

• Blue - N/C
• Yellow - N/C
• White - 14”
• Red - N/C
• Black - N/C

Red 16 gauge - 11”

Black 16 gauge - 28”

Red 6 gauge - 7.5” and 16”

Black 6 gauge - 19”

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Cut Copper for Lugs

Cut 6 ea: 1 ½” lengths of ⅜” copper pipe

Use flaring tool to expand one end of each piece to accept wire with insulation

Strip 1 ¼” of wire for copper lugs

Insert bare wire and ¼” of insulation in copper, use hammer to flatten, then drill ⅜” hole in each lug

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Finish

Attach an eyelet lug to the white wire

Strip wires and crimp male terminals on blue, red and yellow wires per wiring diagram

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Pump Module

1

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Pump Module

Bill of Materials

Check out the OSE Database for any previously parts numbers. The part number must follow the pattern Mx.pn (in place of 'x' and ‘pn’set the module code and the part number code)]

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

Pump Module

Bill of Materials

Check out the OSE Database for any previously parts numbers. The part number must follow the pattern Mx.pn (in place of 'x' and ‘pn’set the module code and the part number code)]

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

Pump Module

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Step 1 [Step Title]

[Caption]

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Cut plates and angle iron.

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20” x 5”

6” x 6”

4 ⅛” tall

(make 4 of these)

Pump Module

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Step 2 [Step Title]

[Caption]

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Torch large holes, drill small

(5/16“) holes

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Measurements pdf

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DIA 5/16”

(Four Corners)

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DIA ¾”

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DIA 2”

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DIA1/2”

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DIA 3 ½”

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Pump Module

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Step 3 [Step Title]

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Grind edges, test fit pump & bolts

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Pump Module

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Step 4 [Step Title]

[Caption]

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-Space angle iron evenly on 6“

plate, tackweld inside corner

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-Weld inside and out

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Pump Module

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Step 5 [Step Title]

[Caption]

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-Align plates with spacers, clamp with “C“ clamps

-Precision note: Plates must be parallel else shaft may bind

-Tackweld inside corners (do not weld spacers)

-Weld inside and out, remove clamps & spacers

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Pump Module

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Step 6 [Step Title]

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Bolt pump to plate assembly

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Pump Module

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Step 7 [Step Title]

[Caption]

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-Install hosebarb on pump

-Install elbow on pump loosely

-Note: keep holes on pump plugged

to prevent debris

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Control Panel

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Control Panel

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Step 1.1 Overall Fit

Control Panel

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Step 1.1 Overall Fit

Throttle

Bracket

Placeholder

Control Panel

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Step 1.1 Final Result

Oil Cooler

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Oil Cooler

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Step 1 [Step Title]

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Oil Cooler

Step 1 [Step Title]

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Oil Cooler

[Directions for Assembly]

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[Directions for Assembly]

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Step 1.1 [Sub Step Title]

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Oil Cooler

Bill of Materials

Oil Cooler

Bill of Materials

Oil Cooler

Step 1.1 Mounting the EVA Foam on the Fan Brackets

Keep the borders

[Use this image size. This should be the image the overall assembly step, captured by a CAD file screenshot]

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Oil Cooler

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Step 1.1 Mounting the EVA Foam on the Fan Brackets

[Caption]

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Directions for Assembly: Place spring on fan bracket (standing up like a pyramid) and the retaining clips on top of the fan bracket

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[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

Directions for Assembly:

Attach 4 fan brackets to fan in the 45 degree placeholders

Place fan atop oil cooler (just to see placement of fan brackets, then remove), place 4 foam squares on far side of oil cooler in alignment with the fan brackets, and remaining 4 squares on back of fan brackets so that the foam will sit between the brackets and the cooler

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Oil Cooler

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Step 1.2 Mounting the fan on the Cooler

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Directions for Assembly: Wrap NPTM elbow threads in teflon tape, going with the groove direction

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Screw NPTM ends of elbows into cooler (using a backup wrench), tighten so JIC elbow ends point as in illustration

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

Directions for Assembly: Place fan on cooler, pull plastic rods through foam squares, cooler, and retaining clips. The base of the plastic rods should be on the far side of the cooler. Clip off extra plastic.

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Oil Cooler

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Step 2 Preparing the Pipes Elbow to be mounting

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Directions for Assembly: [Text]

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

[Use this picture size. This should be the specific step for the module build.]

Directions for Assembly: [Text]

Oil Cooler and Fan

• unpack fan
• wrap elbow threads with teflon tape (tape should be wrapped counter-clockwise)
• screw elbows into oil cooler
• attach fan to oil cooler using plastic brackets with springs
• there should be a foam washer on either side of the cooler for protection
• attach the oil cooler and fan unit to the west side of the powercube using a rubber block and bolt for each corner -- these are friction fit between the round bars of the cooler and fed through the grate on the side of the powercube

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SAMPLE TEMPLATE

Step 1. [Overview]

Oil Cooler and Fan

Phase 4: [Modules Integration]

Directions for Assembly: [Text]

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Step 1.1 [Carefully unbox oil cooler]

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SAMPLE TEMPLATE

Directions for Assembly: [Text]

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

[Use this picture size. This should be the specific step for the module build. Highlight the specific part.]

[Number of people involved in step]

Directions for Assembly: [Text]

Phase 4: [Modules Integration]

Directions for Assembly: [Text]

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Step 1.1 [Screw NPTM ends of elbow into cooler, tighten so JIC elbow ends point as an illustration]

[Caption]

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SAMPLE TEMPLATE

Directions for Assembly: [Text]

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

[Use this picture size. This should be the specific step for the module build. Highlight the specific part.]

[Number of people involved in step]

Directions for Assembly: [Screw NPTM ends of elbow into cooler, tighten so JIC elbow ends point as an illustration]

Oil Cooler and Fan

Phase 4: [Modules Integration]

Directions for Assembly: [Text]

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Step 1.1 [Secure fan to cooler]

[Caption]

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SAMPLE TEMPLATE

Directions for Assembly: [Text]

[Use this picture size. This should be the specific step for the module using the CAD file. Highlight the specific part.]

[Use this picture size. This should be the specific step for the module build. Highlight the specific part.]

[Number of people involved in step]

Directions for Assembly: [Screw NPTM ends of elbow into cooler, tighten so JIC elbow ends point as an illustration]

Oil Cooler and Fan

[Hydraulics Reservoir]

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[Hydraulics Reservoir: OSE.M18]

Bill of Materials

Its a checklist box to help during the inventory

If this slide isn't enough , create a copy of this slide and add the remaining items

SAMPLE TEMPLATE

Check out the OSE Database for any previously parts numbers. The part number must follow the pattern Mx.pn (in place of 'x' and ‘pn’set the module code and the part number code)]

To better understand when this template should be used, check the note box. Remember to clean the note box after copy the template

hydraulic reservoir notes

• measuring → soapstone beware of offset when drawing lines
• measure from the outside of the tank bevels
• measurements in .pdfs are with the side plates attached and not attached → beware of discrepancy
• for circles use socket to mark
• acetylene → until there is no smoke then add oxygen until large cone disappears leaving 6 baby cones
• drill small hole in middle
• pushing works better than pulling
• heat it up a lot → you cant over heat it
• snail method BABY!! get the junk out of the middle and then worry about cleaning up the sides
• come at your cut at a soft angle to avoid over cutting

Hydraulic Reservoir Resources

http://opensourceecology.org/w/images/8/8c/Reservoir.pdf

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http://opensourceecology.org/w/images/6/60/Reservoir_assy.pdf

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Bill of Materials (pdf) (for power cube VII)

(for power cube VI)

Hydraulics Reservoir

• part inventory
• grind 30 angle on edges of reservoir and two side plates
• torch holes in reservoir →
• cut tube piece in half (with the bandsaw)
• welds (3) flanges over two torched holes, and weld the tube over one.
• drill holes for temperature gauge
• drill and tap hole for hydraulic fitting
• pressure test → soap spray
• grind/reweld if there are leaks
• weld back brackets together
• weld brackets onto the back side of the tank (use ¼ inch metal length to align and space the brackets)
• weld bolts on top for solenoid bracket → attach but washers and vibration isolators
• plumbing feature → teflon tape everything → direction matters?
• machine the brackets (using a mill)
• weld brackets to the tank
• drill two holes in flange for control panel connection
• weld flange to reservoir
• Plumbing (final assembly?)
• Cut tubes to length (connecting to the hydraulic pump, to the control panel)

Hydraulics Reservoir

Hydraulics Reservoir

Hydraulics Reservoir

Hydraulics Reservoir