Difficulty

Difficult

Steps

16

Time Required

                          30 minutes            

Sections

4

  • Power Switch
  • 6 steps
  • Replacing Housing
  • 2 steps
  • Replacing Fan
  • 5 steps
  • Motor
  • 3 steps

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Introduction

What you need

Step 1

              Power Switch               
  • Unplug the popper.
  • Remove the plastic lid by lifting the lid up.

Unplug the popper.

Remove the plastic lid by lifting the lid up.

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Step 2

  • Lay the popper on its side.
  • Remove the five 12mm Philips #2 screws around the perimeter of the base with the Phillips #2 phillips head screwdriver.
  • Remove the two 15mm Philips #2 screws in the center of the base with the Phillips #2 phillips head screwdriver.
  • Save the screws you remove from the base in a safe place. They will be needed to reattach the housing to the base.

Lay the popper on its side.

Remove the five 12mm Philips #2 screws around the perimeter of the base with the Phillips #2 phillips head screwdriver.

Remove the two 15mm Philips #2 screws in the center of the base with the Phillips #2 phillips head screwdriver.

Save the screws you remove from the base in a safe place. They will be needed to reattach the housing to the base.

Step 3

  • Flip the base to view the interior surface of the base.
  • Unscrew the two screws (10 mm Philips #2 screws) from the base.
  • Remove the base and set it aside.

Flip the base to view the interior surface of the base.

Unscrew the two screws (10 mm Philips #2 screws) from the base.

Remove the base and set it aside.

Step 4

  • Locate the power switch connected to the side of the housing.
  • Carefully pinch the sides of the power switch.
  • Push the power button up and out of the housing.

Locate the power switch connected to the side of the housing.

Carefully pinch the sides of the power switch.

Push the power button up and out of the housing.

Step 5

  • Now that the power switch is removed from the housing, you must remove the wires connected to the power switch.
  • Use the plastic opening tool to gently pry the wires loose from the power switch.
  • The wires should easily pop out from the power switch.

Now that the power switch is removed from the housing, you must remove the wires connected to the power switch.

Use the plastic opening tool to gently pry the wires loose from the power switch.

The wires should easily pop out from the power switch.

Step 6

  • Remove the power switch from the device.
  • You can now replace the power switch if necessary.

Remove the power switch from the device.

You can now replace the power switch if necessary.

Step 7

              Replacing Housing               
  • Now that the power switch is disconnected from the popper, you will need to remove the white top.
  • Gently remove the heating component from the popper.
  • Unscrew the four screws (11mm Philips #2 screws) that connect the white top to the housing.

Now that the power switch is disconnected from the popper, you will need to remove the white top.

Gently remove the heating component from the popper.

Unscrew the four screws (11mm Philips #2 screws) that connect the white top to the housing.

Step 8

  • Remove the white top from the housing.
  • Save the screws from previous step. You will need them to connect the new housing to the white top.

Remove the white top from the housing.

Save the screws from previous step. You will need them to connect the new housing to the white top.

Step 9

              Replacing Fan               
  • Now that the white top is disconnected from the housing, remove the heating component from inside the device.

Now that the white top is disconnected from the housing, remove the heating component from inside the device.

Step 10

  • Unscrew the three screws (10 mm Philips #2 screws) that hold the heating component together.

Unscrew the three screws (10 mm Philips #2 screws) that hold the heating component together.

Step 11

  • Make sure to keep the screws. You will need them to put the heating component back together.
  • Pull the heating component apart.

Make sure to keep the screws. You will need them to put the heating component back together.

Pull the heating component apart.

Step 12

  • Locate the fan.
  • Pull the fan off the motor firmly but gently.
  • When you pull the fan off the motor, be careful. Do not pull to hard or you will break the motor.

Locate the fan.

Pull the fan off the motor firmly but gently.

When you pull the fan off the motor, be careful. Do not pull to hard or you will break the motor.

Step 13

  • You can now replace the fan.
  • If there is debris stuck in the fan, you can easily clean it out from the fan in this step.

You can now replace the fan.

If there is debris stuck in the fan, you can easily clean it out from the fan in this step.

Step 14

              Motor               
  • Unscrew the two screws (2.5mm #0 Philips screws) that connect the motor to the fan base using the #0 Philips screwdriver.
  • Remember to keep the screws. You will need them to reassemble the popper.
  • Remove the motor from the fan base.

Unscrew the two screws (2.5mm #0 Philips screws) that connect the motor to the fan base using the #0 Philips screwdriver.

Remember to keep the screws. You will need them to reassemble the popper.

Remove the motor from the fan base.

Step 15

  • Now you will need to un-solder the wires that are connected to the motor.
  • These websites might be helpful: Theoatc Wikipedia

Now you will need to un-solder the wires that are connected to the motor.

These websites might be helpful: Theoatc Wikipedia

Step 16

  • Once the motor is un-soldered, you can easily replace the motor. You will need to make sure you attach the wires correctly. This website might be helpful in deciding where the wires connect:How Stuff Works

Once the motor is un-soldered, you can easily replace the motor. You will need to make sure you attach the wires correctly. This website might be helpful in deciding where the wires connect:How Stuff Works

To reassemble your device, follow these instructions in reverse order.

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                    Dana Clarke                     

Member since: 09/26/2012

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                       Cal Poly, Team 16-57, Forte Fall 2012                        

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