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Author Topic: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!  (Read 48575 times)

Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #15 on: August 26, 2018, 10:06:49 pm »
And as usual, we have the laid out exploded diagram shots!

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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

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

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All looking a bit cleaner under here

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Then the top and middle part can be bought together

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Then the middle seal goes on

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

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

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #16 on: August 26, 2018, 10:16:13 pm »
It sits here

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

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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

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The shroud can be slid on

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Top bin seal fitted

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The bottom seal is popped on

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Top gubbins now

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The filter cap seal goes on

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #17 on: August 26, 2018, 10:28:57 pm »
Learn foreign with Dyson!

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The bin release button pushes down and snaps into place

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Then the top handle clips onto the cyclone top

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Tadah

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Pop the bin release rod onto the bin

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Seals onto the bottom flap

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

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Onto the brushroll motor

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The middle brushroll bearing was greased

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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

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #18 on: August 26, 2018, 10:40:13 pm »
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Middle tensioner fitted

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

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Middle wheel axle gets a little drop of grease

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And the wheel fitted

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Cover on

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The motor is fitted to its support part

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Brushroll cogs go on

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

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #19 on: September 03, 2018, 10:02:05 pm »
The now moving freely wheels were fitted

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

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The wire loops round underneath as shown

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

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The little cover that covers the wires sits on the bottom

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Then the top motor cover goes on and screws everything together

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Brushroll bearings/end caps now

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

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #20 on: September 03, 2018, 10:11:12 pm »
Then the ball bearing itself pushes out, and you can remove the plastic cover that goes over the race....Crikey

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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

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Time to fit the ERP bit onto the brushroll

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

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But you'll get there eventually

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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

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

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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!

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2 down

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #21 on: September 03, 2018, 10:36:07 pm »
The exploded diagram is a bit smaller now

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Motor stuff first

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Which was much cleaner

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The washed fan went on

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Then the washed fancase

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Wheel carriage lock refitted

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And it's cover

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The white little cam went on

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Motor top rubber on

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #22 on: September 03, 2018, 10:45:28 pm »
With a cock and refit of the carbon brush, the motor can go back into its housing

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The rubber inner clips onto the fancase cover

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Then the cover screws onto the motor housing

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

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

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

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And then fit the hose retaining bracket

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Time to join the 2 halves now

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #23 on: September 03, 2018, 10:58:20 pm »
Start by running the spine wires from the top

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

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

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Brushroll switch and wiring goes on next

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Releif valve goes into where it belongs

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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

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We'll pop this seal back on here

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

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Then the PCB cover can go on

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #24 on: September 03, 2018, 11:18:50 pm »
Time to clip the internal hose into the bottom chassis now

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

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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

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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

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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!

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Feed the wires down towards the suction hole

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Fit the plug to the outer housing observing the orientation

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

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Pop the spring onto the yolk locking peg

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Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #25 on: September 03, 2018, 11:24:30 pm »
Then clip the locking peg into place, maybe one last naughty word as the wiring dislodges itself again...

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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:

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

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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

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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

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Pop the 2 ball shell wheels in

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

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

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Fit the cover

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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

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #26 on: September 03, 2018, 11:31:27 pm »
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

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Then fit the non filter side

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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

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Then assemble the shell

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

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

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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

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #27 on: September 03, 2018, 11:40:36 pm »
Time to move right on up and pop the switches back in

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And the switch buttons

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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%

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Next, lob the top handle stuff back together

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



I got this a little gift

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

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Which fill a hole nicely

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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

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #28 on: September 04, 2018, 12:50:56 pm »
Looks brill, I'd buy that!
You sure you forgot who sent you the tools? Haha

Offline beko1987

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Re: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!
« Reply #29 on: September 04, 2018, 02:44:45 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!

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