The World's #1 Vacuum Cleaner Advice, Repair, Discussion & Information Forum

Author Topic: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!  (Read 9539 times)

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #15 on: August 27, 2018, 12:06:49 AM »
And as usual, we have the laid out exploded diagram shots!

ila_rendered

ila_rendered

And with the aid of the very laptop I'm using now to write this, my Thinkpad X60 Tablet, we can nail this back together!

Cyclone first

ila_rendered

The cyclone top cover goes on with the tab lined up with the bin release rod housing

ila_rendered

All looking a bit cleaner under here

ila_rendered

Then the top and middle part can be bought together

ila_rendered

Then the middle seal goes on

ila_rendered

The inside of the middle cyclone didnt come up spotless, but no one is ever going to see this again, so meh

ila_rendered

The middle part of the release rod goes on next, the spring needs to sit like so

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #16 on: August 27, 2018, 12:16:13 AM »
It sits here

ila_rendered

When the shroud/middle part is bought up, the spring needs to sit like so

ila_rendered

The spring for the bin latch is also fun, but it sits on one side nicely, then the spring can be held shut with a screwdriver as the 2 halves are clipped together, then released

ila_rendered

The shroud can be slid on

ila_rendered

ila_rendered

Top bin seal fitted

ila_rendered

The bottom seal is popped on

ila_rendered

Top gubbins now

ila_rendered

The filter cap seal goes on

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #17 on: August 27, 2018, 12:28:57 AM »
Learn foreign with Dyson!

ila_rendered

The bin release button pushes down and snaps into place

ila_rendered

Then the top handle clips onto the cyclone top

ila_rendered

Tadah

ila_rendered

Pop the bin release rod onto the bin

ila_rendered

Seals onto the bottom flap

ila_rendered

Even clean, the bin is pretty trashed but it looks better now

ila_rendered

Onto the brushroll motor

ila_rendered

The middle brushroll bearing was greased

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #18 on: August 27, 2018, 12:40:13 AM »
ila_rendered

Middle tensioner fitted

ila_rendered

Then it can be fitted to the motor, and the belt fitted to both halves

ila_rendered

Middle wheel axle gets a little drop of grease

ila_rendered

And the wheel fitted

ila_rendered

Cover on

ila_rendered

The motor is fitted to its support part

ila_rendered

Brushroll cogs go on

ila_rendered

And it can all go into the much cleaner main housing!

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #19 on: September 04, 2018, 12:02:05 AM »
The now moving freely wheels were fitted

ila_rendered

ila_rendered

Then it was time for the motor wiring to attach to the plastic housing to clip it onto the brushroll chassis

ila_rendered

The wire loops round underneath as shown

ila_rendered

The motor can be sat on its tray and dropped on, then the wires run and plugged in

ila_rendered

The little cover that covers the wires sits on the bottom

ila_rendered

Then the top motor cover goes on and screws everything together

ila_rendered

Brushroll bearings/end caps now

ila_rendered

You can service these by removing the circlip that holds the bearing in place.

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #20 on: September 04, 2018, 12:11:12 AM »
Then the ball bearing itself pushes out, and you can remove the plastic cover that goes over the race....Crikey

ila_rendered

You want to pick out as much hair as you can and spoon fresh grease in. Roll the bearing around in your fingers for a bit then replace the covers and spin it some more, then wipe off any excess, and refit the bearing to the holder

ila_rendered

Time to fit the ERP bit onto the brushroll

ila_rendered

It needs to sit in here, and be clipped around 3 plastic pegs, and sit behind 2 plastic tabs, it's a bit fiddly

ila_rendered

But you'll get there eventually

ila_rendered

Now attach the blue front squeegee to the black bar. Again, very fiddly and youll end up taking the black bar out in places to clip the blue strip to it

ila_rendered

But eventually this too will fit, and smooth operation will be operated!

ila_rendered

Once done, you can fit the front and baseplate back onto the housing, fit the brushrolls, do up the baseplate and the brushroll housing is done!

ila_rendered

2 down

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #21 on: September 04, 2018, 12:36:07 AM »
The exploded diagram is a bit smaller now

ila_rendered

Motor stuff first

ila_rendered

Which was much cleaner

ila_rendered

The washed fan went on

ila_rendered

Then the washed fancase

ila_rendered

Wheel carriage lock refitted

ila_rendered

And it's cover

ila_rendered

The white little cam went on

ila_rendered

Motor top rubber on

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #22 on: September 04, 2018, 12:45:28 AM »
With a cock and refit of the carbon brush, the motor can go back into its housing

ila_rendered

The rubber inner clips onto the fancase cover

ila_rendered

Then the cover screws onto the motor housing

ila_rendered

Time to start piecing the changeover valve together, stick a small smear of grease on all the pivoting parts as you go

ila_rendered

ila_rendered

Annoyingly, I snapped off the tiny bit of plastic the main changeover spring attaches to, a small screw did the job at replacing it!

ila_rendered

Once all back together, check the operation by moving the main black plastic part up and down to flip the hose

ila_rendered

And then fit the hose retaining bracket

ila_rendered

Time to join the 2 halves now

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #23 on: September 04, 2018, 12:58:20 AM »
Start by running the spine wires from the top

ila_rendered

Then as you get to the bottom, half screw the motor housing on, run the wires across the join

ila_rendered

Then once run correctly (match up the bends and kinks in the cable), do up the screws and fit the blockage port cap

ila_rendered

Brushroll switch and wiring goes on next

ila_rendered

Releif valve goes into where it belongs

ila_rendered

Then the main suction ducting can be fitted to the motor housing, being sure that everything is clipped together well before screwing it up, or yourll get a big air leak

ila_rendered

We'll pop this seal back on here

ila_rendered

Then fit the PCB (well, glue it in in our case) and fit all the wires as shown

ila_rendered

Then the PCB cover can go on

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #24 on: September 04, 2018, 01:18:50 AM »
Time to clip the internal hose into the bottom chassis now

ila_rendered

Then pop the wheels and the bottom assembly onto the motour housing unit

ila_rendered

The dreaded yolk loom now, I hate this part! Start by finding the original bends in the wires, and feeding them onto the black rear plastic part like so

ila_rendered

Then go to pick up the grey outer part, and watch the wires fall off. Mutter a rude word and fit them back again, then clip the grey cover over the top

ila_rendered

Swear some more as the grey cover falls off several more times as you push the black holding part into the chassis, then clip the corner bit into the space in the top cover. Once it's in, it's still liable to move, so be careful!

ila_rendered

Feed the wires down towards the suction hole

ila_rendered

Fit the plug to the outer housing observing the orientation

ila_rendered

Then with 1 hand holding the wires into their channel, push the housing into it's place below

ila_rendered

Pop the spring onto the yolk locking peg

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #25 on: September 04, 2018, 01:24:30 AM »
Then clip the locking peg into place, maybe one last naughty word as the wiring dislodges itself again...

ila_rendered

Time to fit the clear cog. Now you may ask why we didnt do this earlier, and that's because it is a right sod to line the teeth up to fit the housing. The easier way to do it is:

ila_rendered

Peel back the housing slightly from the motor housing, slip the cog under and line the teeth up that way, then fit the screw

ila_rendered

With the assembly in 'reclined' mode as shown (wheels flipped up), the arm of the clear cog will sit as shown above

Now we can fit the top sliding cover

ila_rendered

As you can see, the socket will fall out again, one last time pop it into place, then once the cover is on it'll never move again, fit the screws at the bottom quickly, then fit the rest at leisure

ila_rendered

Pop the 2 ball shell wheels in

ila_rendered

Fit the 2 washers and retaining 'clip' on the filter side of the housing

ila_rendered

Then fit the 3 screws (you could do this before the above step tbh) that hold this side of the assembly together

ila_rendered

Fit the cover

ila_rendered

Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #26 on: September 04, 2018, 01:31:27 AM »
On the other side, fit the white top part of that pivot and screw it down. I forgot to take any pictures of that part,  so use your imagination!

If you dismantled the bearings on the ball shells (which you don't really need to do), now it's time to reassemble them

ila_rendered

ila_rendered

ila_rendered

Then fit the non filter side

ila_rendered

Then, on the filter side, fit the post motor filter. I put this one through the washing machine and it came out very well indeed

ila_rendered

Then assemble the shell

ila_rendered

ila_rendered

TBH the reason I don't recommend doing this is this blue part took AGES and made me  >:( to refit...

ila_rendered

But eventually, it clicked in, and the fake ball (as their really 2 big wheels) was assembled again

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #27 on: September 04, 2018, 01:40:36 AM »
Time to move right on up and pop the switches back in

ila_rendered

And the switch buttons

ila_rendered

Once youve fitted the switch buttons to the machine, check they push and click properly, they can jam if everything is not lined up 100%

ila_rendered

Next, lob the top handle stuff back together

ila_rendered

Now it's starting to look like a vacuum cleaner again!



I got this a little gift

ila_rendered

I can't remember who sent it now, I would have thanked them at the time but it contained some tools!

ila_rendered

Which fill a hole nicely

ila_rendered

We can wind the cable up then, and she is done!



But how did it come out? Well...


Very well indeed!
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline Parwaz7862

  • Member
  • Posts: 3358
  • Country: gb
  • Gender: Male
  • Dyson geek 😃
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #28 on: September 04, 2018, 02:50:56 PM »
Looks brill, I'd buy that!
You sure you forgot who sent you the tools? Haha
DC14s are tanks, just need a slightly longer motor life. Do plastic parts often break on DC14s? Nope. DC41- Sexy looking futuristic and powerful machine. Just needs a better designed cleaner head wheel and cyclone clip along with a dense metal rod in the chassis.

Offline beko1987

  • Member
  • Posts: 4562
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #29 on: September 04, 2018, 04:44:45 PM »
I think it was you actually! You've just jogged my memory, plus your the only person I know who sticks the whole sheet on the box rather than just cutting the label part out!
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Dyson Spare Parts


 

 

Dyson Spare Parts

 

 

Freestanding Dyson Cordless Vacuum Stand

 

 

Buy a Dyson DC04 Wand Handle

 

 

 

 

Sebo Vacuum Cleaners

 

 

Instagram

Dyson Spares, Parts, Advice   Follow us on Twitter

Manchester Vacson Google+

Manchester Vacs on Instagram

Registration