Gate 2 for Group 4

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A. Management Corrective Action Plan

I. Management Proposal

Thus far, our Management Proposal has proved to need some updates. First off, our group has realized that our group meeting dates have not been as feasible as we would have liked them to be. So, to improve this problem, our group meeting dates are now as follows: On Mondays, we will meet in the Bell Hall computer lab at 5 PM to discuss the project, and to complete the writing and documentation parts of this project. On Wednesdays, our group will meet at the dissection at 5 PM to do dissection lab work. Also, on Thursdays, we will meet at 3:30 PM to finish any dissection work that was not completed on the Wednesday meeting day. For this Thursday meeting, if we have finished our dissection work, we will then go to the Bell Lab at 3:30 PM to work on the documentation process. We have decided to revise our schedule due to the group members’ tests schedules, and also when the lab dissection hours were. Our original dissection plan included working in the lab on Mondays – which did not exist! This new schedule will ensure that more productivity will occur – this will be accomplished by providing more time for documentation and writing work.

Based on our groups’ abilities as a whole, we have also decided to move a job position to a different person, based on the needs of our group. The Group Manager position has moved from Sean Lyons to Jessica Allen (also the Communication Liaison) – this contact email is now She will ensure that everything gets done in a timely fashion, and ensure that everyone “pulls their weight” in this project. If a group member should not contribute to his part in the assignment, Jessica will talk to said member to try to resolve the problem. If no such improvement is seen, then she will talk to the teacher, Eric Devendorf, to inform him that a group member is not fairly contributing to the work assigned to them. The grading TA for the project will also be informed if such a problem should arise. Bhushan remains the CAD expert, and Tom is still the Wiki page publisher. Tom has spent time with the Wiki page learning how to operate the publishing – this has ensured that everything gets published to the page that we want and/or need.

For the positive aspects of our Management Proposal, our time table for tasks to be completed by has ran fairly smoothly. So far, we have already completely dissembled our Lawn Mower Motor – in this regard, we are ahead of schedule. This now allows us to have more time to complete more documentation, or to work ahead on the project – such as to move on to the reassembling of our product.

II. Work Proposal

So far, our Work Proposal has turned out to run much more smoothly than the Management Proposal. The Work Proposal has benefitted us more with regards in referencing the steps involved to disassembling the lawn mower motor, and also what tools we would need during the disassembling process. We also have concluded, throughout the process of taking our product apart, that our group has more knowledge of motors (and how they function) than we had originally evaluated. This also helped us take apart the motor faster than we had expected – we were able to successfully complete disassembly within one dissection lab period. We did not take into consideration, however, in our original timed dissection layout, that we may encounter some parts which might have been more difficult to take apart than others. This did in fact occur, with the main drive shaft in the motor. (This will be discussed in the Product Dissection Plan). This elongated our estimated dissection time from one to two hours to about two and a half hours. We also did not account for the time the documentation process was going to take in our original Work Proposal. This has now been corrected, as explained by the above revised planned group meetings – this now includes some group meetings that are strictly devoted to write-ups and written work pertaining to our group project.

Our tool list was fairly extensive, and helped us to know what we were going to need when we went into the lab to dissect our product. This also helped us to keep with our time schedule by allowing us to not waste time looking for tools that we were going to need. One tool that was not included in our original analysis was a clamp to hold bigger parts down. We were in need of this while we were trying to take out the main drive shaft in our motor. There was an end fitting on the end of the shaft that needed to come off in order for us to complete our dissection fully. Since this end fitting was on the shaft extremely tightly, we were in need of this clamp to hold on to the shaft, while the fitting was slowly pulled off. (Again, this process will be explained in full in the Product Dissection Plan section).

B. Product Dissection Plan

Easy = Direct access to components, using hands or tools to remove screws/bolts.

Medium = Less direct access to components, using tools only to remove screws/bolts.

Hard = Indirect/difficult access to components using tools, and sometimes application of force in order to indirectly remove screws, bolts, and components.

Step Description Tool Easy Medium Hard!
1 Unhook carburetor lines. Pliers X
2 Remove pull chord, removing two ¼” bolts. Nutdriver X
3 Remove air filter, removing two ¼” bolts. Nutdriver X
4 Remove air filter lid, removing one Phillips-head screw. Screwdriver X
5 Remove plastic gas tank (Figure 1). Nutdriver X
6 Remove oil dipstick. Hands X
7 Remove fan cover (Figure 2), removing two 3/8” bolts. Nutdriver X
8 Remove gold cap from top of flywheel (Figure 3), removing a ¾” bolt. Nutdriver X
9 Remove coil from top, removing two 5/16” bolts. Nutdriver X
10 Remove muffler (Figure 4), removing two 7/16” bolts. Nutdriver X
11 Unhook gas line to carburetor (Figure 5). Pliers X
12 Remove carburetor (Figure 5 and 6) from intake tube with gasket, removing two bolts. Nutdriver X
13 Unscrew valve gasket, removing two 5/16” bolts. Nutdriver X
14 Remove spark plug from head. Hands X
15 Remove engine head (Figure 3), unscrewing eight ½” bolts. Nutdriver X
16 Remove engine gasket. Hands X
17 Remove top, black engine cover, unscrewing six 3/8” bolts. Nutdriver X
18 Remove valve lifters from engine block. Hands X
19 Remove piston arm from piston (Figure 7), unscrewing two ¼” bolts. Nutdriver X
20 Pull out piston valve with spring from engine block, applying moderate force. Hands X
21 Remove flywheel (Figure 8), applying much force. Shaft Clamp X*
22 Pull out crank shaft (Figure 9). Hands X
23 Pull out cam shaft (Figure 10). Hands X
24 Remove two piston clips (Figure 7). Pliers X
25 Remove three piston rings (Figure 7). Small screwdriver and piston ring remover. X
26 Unscrew top cap from engine block, unscrewing two 5/16” bolts. Hands X
27 Remove oil filter (top and bottom components) (Figure 11 and 12). Hands X
28 Pull out piston from engine block (Figure 7). Hands X

*Was most difficult step! Took the most time to complete; around 30 minutes.


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Figure 1 – Plastic gas tank. Figure 2 – Fan cover.
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Figure 3 – Gold cap and engine head. Figure 4 – Muffler(exhaust)
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Figure 5 – Carburetor with gas line. Figure 6 – Carburetor.
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Figure 7 – Piston and piston arm.F Figure 8 – Flywheel.
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Figure 9 – Crank shaft. Figure 10 – Cam shaft.
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Figure 11 – Oil Filter on top of engine block. Figure 12 – Oil filter.
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Figure 13 – Bottom of Engine block with cam shaft. Figure 14 – Broken gear.

Piston In Motion

Below is a link for a video of the piston and valves in motion in the engine block.

Main Page

To go back to the main page, click on the link below.

Group 4 - Lawn Mower Engine