STEP 1
Remove the telescopic wand
To start, remove the telescopic wand from the hose—you can extend it and it snaps into place. / Q: Why do you think the engineers made the wand collapsible?
Q: How did they stop it collapsing when in use?
STEP 2
Remove the bin
Press the silver bin release button in the direction of the arrow shown and lift the bin off the chassis.
By removing the bin and cyclone assembly you’ve revealed the red bin empty button—press it to open the base of the bin. You can see the bin empty mechanism working if you look at the rear of the bin. / On removing the bin and cyclone assembly:
Q: Why does the bin open from the bottom?
Q: Why is the bin empty button red?
Q: Look at the rubber seal in the base of the bin. How does it seal the cyclone?
STEP 3
Remove the pre-motor filter
Locate the pre-motor filter, which is situated in the center of the cyclone assembly. Pull out the purple pre-motor filter. / Q: Have a look at the pre-motor filter. Why do you think it’s made of foam?
Q: Which way do you think the air flows through the filter?
Q: Look inside the cyclone assembly where the pre-motor filter sits. Along the top, you’ll see the top of the two tiers of small cyclones. Why did the engineers add this to the design when an outer cyclone already filters dirt and debris in the bin?
Q: Have a look at the back of the machine. There are a set of instructions. What do they tell you? How often should you wash the filter?
STEP 4
Remove steering assembly
Turn the chassis over. Use a T15 screwdriver to remove the four screws that connect the baseplate to the chassis. Keep the loose screws in a cup or container.
Pull the steering plate away from the main ball by lifting up on the inlet duct assembly and hose while pushing down on the steering plate to free the sliding pin of the steering plate from its slot on the chassis.
STEP 5
Remove the ball shells
Turn the main ball on its side. Use a T15 screwdriver to remove the screws, located at the center of the ball shell, that connect the ball shell to the main ball. Add the loose screws to the cup or container, then pull away the sides.
STEP 6
Separate the upper and lower halves of the main ball to remove the lower half
Look at the machine from above. On both sides of the machine is a recessed screw located near the ball shell axis. Use a T15 screwdriver to remove both screws, then add these screws to the cup or container.
Next, flip the machine upside down. In the same type of recesses along the circumference of the machine are eight screws. Use the T15 screwdriver again to remove these eight screws, and add them to your cup or container.
Once you’ve finished removing the screws, the bottom half of the main ball can be removed. This will reveal the white pleated post-motor filter. / Q: Why do you think the material is pleated?
Q: Have a look at the construction of the post-motor filter. It’s different from the pre-motor filter. Why do you think that is?
Q: Why do you think we have such a high level of filtration in this machine?
STEP 7
Remove the lower assembly from the main ball
Use a Phillips-head screwdriver to remove the screw that attaches the tool catch to the main ball; this is located behind the neck/handle. Place the screw and the tool catch in your cup or container.
Next, push the bin release button to make the handle pop up. Then, lift the handle back until the hooks catch. Put the head of a flathead screwdriver in between one of the hooks and the main ball, then push the screwdriver in while leveraging the handle down to pry the hook in and out from the main ball. Once one hook is released, repeat the process on the other side.
Once the handle is released, you’ll be able to use the T15 screwdriver to remove the two screws attaching the top of the main ball to the lower assembly. Once removed, place these screws in your cup or container.
Next, note the small, exposed white tab on either side of the main ball. Using the flathead screwdriver, pry the upper assembly loose from the main ball by putting the screwdriver under white tab, then leveraging the handle up to pop the tab inward. Repeat on the other side until the lower assembly is loosened and can be lifted up and off to reveal the cable rewind unit and the housing unit of the motor.
The James Dyson Foundation Engineering Box – Lesson 3
DC39 Disassembly Instructions and Questions