Product Assembly Plan
Purpose : The purpose of Gate 4 is to explain our reassembly procedure. Below is a detailed chart of each step.
Difficulty is on a scale of 1 to 3. A step with a difficulty level of 1 would be one that does not require much time, thought, or strain on the assembler. A step with a difficulty level of 2 would be one that may require a little more time, thought, or strain on the assembler. A step with a difficulty level of 3 would be one that may require the most time, thought or strain on the assembler. All of these difficulty levels are relative to putting togeter this leafblower. So, a step with a difficulty level of 3 may not be very difficult but it is defined as the most difficult part of the specific task of putting together this leafblower.
- 3 or more hands
-5/16" socket and ratchet
-torx divers set
|Product Reassembly Steps|
|Step||Description||Tool Required||Time Required||Difficulty (1-3)||Image|
|1||Slip the piston/rod assembly onto the crankshaft, being careful not to damage the roller bearings on the rod. The crankshaft and main bearing should already be assembled in the crankcase.||Hands||0:50||2|
|2||Place the cylinder head onto the crankcase, and secure with two Allen bolts. (see Footnote 1)||Allenwrench||0:40||2|
|3||Take fan blade and slip it over the
crankshaft, being cautious to align the blade correctly on the crankshaft. Follow the fan blade with two flat washers and a 5/16" nut, to be securely fastened to the crankshaft. It is imperative that the nut is sufficiently secured to prevent the blade from vibrating off at high speeds.
|Hands/ 5/16" Socket and Ratchet||1:30||2|
|4||Locate the magneto (see picture) and secure it to the crankcase with two Allen bolts provided. The magneto should ride just above the flywheel (round object attached to crankshaft with fins).||Allenwrench||1:15||2|
|5||Using four Allen bolts, fasten the black plastic magneto shroud/cover over the magneto.||Allenwrench||0:50||3|
|6||When looking down the blower with the air tube pointing away from you, locate the green right hand side plastic housing and lay it on a flat surface. Carefully lay the engines assembly in the housing.||Hands||0:45||2|
|7||Remove the cap on the gas tank and place in the preformed “cradle” that is located right behind the engine assembly. Slip the gas tank neck through the housing and reattach the gas cap.||Hands||0:50||3|
|8||Lay the black plastic air tube (see picture) into the green housing at the very front of the assembly. Also, take the black plastic handle and place it into the housing, noting that the handle will only fit in the correct position (due to pre-formed alignment holes).||Hands||1:00||1|
|9||On the side of the engine facing up into the air, place the carburetor on to the cylinder head and secure it with two torx screws. Attach rubber fuel lines from the fuel tank to the carburetor.||Hands/ Torxs Driver||0:40||2|
|10||Now take the left hand side, matching green outer housing, and place it over the engine and other previously mentioned components. Be careful not to move the gas tank from its position when aligning the two halves.||Hands||1:30||3|
|11||Use the eight (8)Allen bolts and fasten both green halves together.||Allenwrench||0:45||2|
|12||Using the black metal clamp with plastic wing-nut, tighten down the black plastic air tube to the green housings. The clamp should slip over tube and rest in the pre-formed slots in the green housings.||Hands||0:50||2|
|13||Locate the black plastic fan intake guard and clip it onto the bottom of the leaf blower. Using a screwdriver, pop the hinge into the green outer housings.||Hands/ Screwdriver||0:30||2|
|14||Take the muffler, and, using two Allen bolts, attach the muffler to the right hand side of the leaf blower.||Allenwrench||1:00||1|
|15||All that is left to finish the leaf blower is assembling the two purple plastic carburetor and muffler covers. Take the carburetor cover (it has white raised symbols signifying faster and slower, choke, etc.) and, using two Allen bolts place it over the carburetor. Be careful not to over tighten the bolts, as the green plastic housing beneath will easily crack. Do the same for the purple muffler cover.||Allenwrench||2:00||3|
- Congratulations, your new leaf blower is assembled and ready to use. Don’t forget to mix the gasoline and two cycle engine oil in a 40:1 ratio before running the engine. –
Footnote 1 A problem is often encountered where the engine block is attached backwards to the crankcase. Be sure to keep the orientation of the engine in respect with the muffler on the right and carburetor on the left. See step 5 for the orientation description.
After our entire disassembly/reassembly process, we have answered a few questions to tie up the project and make future reccomendations:
- Does your product run the same as it did before you disassembled it?
When we recieved the product it did not work. After our disassembly and reassembly, the product does not work.
- What were the differences between the disassembly/reassembly processes?
The dissassembly was more challenging becuse we had to pay attention to all of the small parts and their locations. All of the same tools were required for the reassembly as the dissassembly. However, an extra set of hands were needed for the reassembly to hold the pieces in place in the plastic casing when it was being reattached.
- What additional recommendations would the group make at the product level?
The group has one reccomendation for the product. We suggest creating a locking system to keep the gas tank in place and prevent movement when putting the enclosure back on.