Dyson & Sebo Vacuum Cleaner Repair & Advice Forums

Dyson Models => Dyson DC04 => Topic started by: beko1987 on September 08, 2015, 12:14:52 PM

Title: My first DC04 Zorbster!
Post by: beko1987 on September 08, 2015, 12:14:52 PM
I've got today and tomorow off work for unrelated reasons, and had arranged for a DC14 I sold to come back for some remedial work (clutch has jammed). The lady said she had an old dyson in the back of the car that didnt work, and would I like it?

(https://lh3.googleusercontent.com/-qa5gqyx-zfY/Ve6l9xEVSlI/AAAAAAAArFY/hhLwXvnXHUA/s512-Ic42/upload_-1.jpg)

No hopper of course, but a DC04 Zorbster! I've never had a zorbster!

She's not without her issues though, the lady mentioned something about burning, and plaster dust, and it does have some damage

(https://lh3.googleusercontent.com/-M8d54lYCP9I/Ve6l_HLIjyI/AAAAAAAArFg/yrEj4g5HK2M/s800-Ic42/upload_-1.jpg)

This is a shame, as I doubt I'll be able to get a wand with the original purple sticker on, just one with a grey one

(https://lh3.googleusercontent.com/-Yu9DGuAc41k/Ve6mAn9h7vI/AAAAAAAArFo/ZWJwibOZilE/s512-Ic42/upload_-1.jpg)

Needs a new wand ubend catch too

Not plugged it in yet, will get the DC14 fixed first, but the initial list of bits needed in the future are:

Wand (any wand will do, I'll swap the bits over)
Hopper
Upholstry and dusting brush in that lilac
U bend clip

Nice start to a tuesday that was!
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 08, 2015, 11:11:56 PM
Heh

I did my jobs for the day (and Amy went out) so had a look at this. The lady did mention there was fire when she gave it to me...

I checked the cable, it was cracked at the top so I cut it off and did the usual, although the inner cable was fine...

I checked the fuse by swapping it into the Miele as usual, and ah, it was dead.

Fitted a new fuse, put it in the garden as I knew it would billow out a load of dust.

Amy was back by now, and watching TV. We had her neice round as she was poorly and amys sister couldnt blag a day off, she was watching tv also.

Hoover turned on, I go to the TV unit, and plug it in to the 4 way we have there. (it's a switched 4 way), I turn it on...

it runs for 3 seconds very badly then the TV goes off, and I have to pull the TV unit out to change the fuse in the extension...

I then looked at the post motor filter...

(https://lh3.googleusercontent.com/-UmL-xomlCAw/Ve9AhkqWIGI/AAAAAAAArF8/Hn8oS7FdWMU/s800-Ic42/upload_-1.jpg)

I put it away at this point...

ALWAYS CHECK THE EASY STUFF FIRST!!! :'( :'( :'(

Post motor filters can tell the whole life story of a hoover sometimes!

Still, it's a ZORBSTER! And looks like a banging project. Just need to get some money together first to buy it some bits.
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 08, 2015, 11:13:56 PM
Oooh, whislt idly picking at it earlier, the wand sticker peels nicely off, and sticks nicely back on again! So I just need A. N. Other clutched wand that's not too faded (which will be tricky!)
Title: Re: My first DC04 Zorbster!
Post by: Tech12 on September 08, 2015, 11:20:58 PM
That's a lovely looking filter, must have at least another thousand miles left in it :underchair:
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 08, 2015, 11:25:39 PM
If you scraped the burnt layer off it migth have improved.

I accidentally threw it in the bin on the way back to the shed after taking that photo though. Drat...
Title: Re: My first DC04 Zorbster!
Post by: Tech12 on September 09, 2015, 12:54:04 AM
What a waste ;D
Title: Re: My first DC04 Zorbster!
Post by: Madrat on September 09, 2015, 04:47:39 PM
Ah yes I've been the villain of the household before by plugging in an unknown dyson and tripping the the electric  :underchair:

Its a bugger when there were PCs running and Mrs Madrat was watching something and is waiting for the sky box to re boot giving you the evil eye  :D  then of course there are all the clocks to re set,  I'll get me coat  :snivel:
Title: Re: My first DC04 Zorbster!
Post by: Parwaz7862 on September 09, 2015, 08:58:15 PM
LOL unknown Dyson? xD How do you not know :P
I like the DC04 zorbster, looks like an Animal even though it isn't :) I love the 110 volt feature when the cyclone is removed
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 09, 2015, 11:14:09 PM
Does it? What does that do? Infact, how does it work at all? I presume the suction has to be stopped so it doesnt suck the zorb powder straight up, but doesnt the brushroll keep turning? And it's spun off the motor, so surely the motor has to keep turning?

I really should put my last new motor in it and find out hadnt I!
Title: Re: My first DC04 Zorbster!
Post by: Tech12 on September 09, 2015, 11:18:04 PM
Go on, you know you want to ;)

Only thing is, you can almost guarantee that your next repair will need the motor you just used. It's that bloody murphys law.  :'(
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 09, 2015, 11:22:21 PM
That'll be the one! I'll steal it back out of the zorbster though...
Title: Re: My first DC04 Zorbster!
Post by: Madrat on September 10, 2015, 12:02:16 AM
Removing the cyclone assembly releases a micro switch which reduces the voltage to the motor, slowing the brush bar so it can groom the zorb into the pile, with the cyclone removed there is no suction so the zorb stays on the carpet.  On the DC05 motorhead the power switch had a 3rd position, it would operate the brush bar only, this was for use with zorb.
Title: Re: My first DC04 Zorbster!
Post by: __russ__ on September 10, 2015, 12:05:44 AM
If you look on the frame at the base of the bin, there is a switch that when the bin is removed, slows the motor right down to work the Zorb granules into the carpet.

You can just switch the TOC from the Zorbster motor and put it on the other one you've got.
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 10, 2015, 10:15:23 AM
Are they YDK motors then?
Title: Re: My first DC04 Zorbster!
Post by: Madrat on September 10, 2015, 08:09:39 PM
Yes. Only the TOC is different but that is just swapped from the old motor.
Title: Re: My first DC04 Zorbster!
Post by: MVacs on September 10, 2015, 10:31:07 PM
Or you can do away with the micro switch thing and use the normal TOC.
Title: Re: My first DC04 Zorbster!
Post by: __russ__ on September 10, 2015, 10:49:24 PM
Yes. Only the TOC is different but that is just swapped from the old motor.

 :thumbsup:
Title: Re: My first DC04 Zorbster!
Post by: Madrat on September 10, 2015, 11:25:02 PM
Or you can do away with the micro switch thing and use the normal TOC.

Yes but then you cant use the zorb feature.
Title: Re: My first DC04 Zorbster!
Post by: __russ__ on September 11, 2015, 08:44:50 AM
Or you can do away with the micro switch thing and use the normal TOC.

Yes but then you cant use the zorb feature.

True but then I've never come across anyone that has used it anyway  :))
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 11, 2015, 10:27:04 AM
I want to use it! (Mainly because I NEVER have before!)
Title: Re: My first DC04 Zorbster!
Post by: Parwaz7862 on September 11, 2015, 09:46:06 PM
Its wicked, it halves the voltage of the motor! ;D
Title: Re: My first DC04 Zorbster!
Post by: __russ__ on September 12, 2015, 05:35:57 PM
Or you can do away with the micro switch thing and use the normal TOC.

Yes but then you cant use the zorb feature.

True but then I've never come across anyone that has used it anyway  :))

I want to use it! (Mainly because I NEVER have before!)

To be fair, if anyone was ever going to use it, it was going to be you   :biglaugh:
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 12, 2015, 05:38:22 PM
Hehe thanks! At least if it does turn out to be a pile of toss I can say I tried,  and bave an opinion if anyone ever asks me about it again!
Title: Re: My first DC04 Zorbster!
Post by: Parwaz7862 on September 12, 2015, 09:24:45 PM
You should be alright :) My DC05 motorhead looked a bit complex cos it was already taken apart with the previous owner, but managed to get it working optimally by guessing how the wires go, that's old Dyson's for ya! they are too easy;D
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on September 22, 2017, 01:26:58 AM
How old is this thread? Well guess what I finished tonight... Refurb images coming soon! (Although not a full step by step, just an overview with detailed shots of the zorbstery bits!)
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:02:23 AM
So, here we are! I've had this since 2015, and a month ago I cleaned it all up! This thread isn't a full step by step refurb, there's plenty of those on these forums!

So this will concentrate mainly on the differences between a DC04 Zorbster, compared to a normal DC04 All Floors!

I finally did a 'before' video

Not a valid youtube URL
It came in from the cold

[attachimg=1]

I stripped the wand down

[attachimg=2]

Opening the switch up, someone has been here before!

[attachimg=3]

Hardly surprising though! Popped the cable out and removed the rubbers

[attachimg=4]

I don't think I've seen this style of airflow guard on the suction side on a DC04 before. Could be wrong though

[attachimg=5]

Changeover valve inspection pipe out now, and oh look, it's blocked!

[attachimg=6]

Split apart

[attachimg=7]

Post filter cover off

[attachimg=8]

Clutch knob off

[attachimg=9]
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:08:48 AM
The U bend clip is broken sadly

[attachimg=1]

Underneath now

[attachimg=2]

Baseplate off

[attachimg=3]

Brushroll out, it's VERY soft, which is a shame because it's purple!

[attachimg=4]

The first physical difference! The brushroll chamber within the brushroll housing is more round than usual, with the moulding used being different

[attachimg=5]

Next, I went to pull the clutch out, as I usually would at this stage, but could not move it

[attachimg=6]

So I popped the whole head off

[attachimg=7]

And found the second difference! There is an extra part off the side of the clutch!

[attachimg=8]

This part has a slightly offset cam on the end, which is what shakes the cleanerhead when the Zorb hopper is fitted, shaking the powder out of the machine! With the hopper not fitted, it doesn't touch anything, so doesn't shake.

[attachimg=9]

It's seen belts at some point, these are I think Europart ones with that DBB number
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:15:57 AM
With the clutch out, we can see the third big difference, the Zorb hopper securing gubbins!

[attachimg=1]

This chunky pedal is what clamps the hopper to the machine. It just pops out, and has a big spring underneath it

[attachimg=2]

This part is what the clutch shakes!

[attachimg=3]

Back to normality now! Changeover valve out

[attachimg=4]

Wheels off

[attachimg=5]

I've lost count of the differences now, so another one is that each rear wheel has a thick rubber scraper, presumably to de-clag the wheels during a good zorbing session!

[attachimg=6]

So, the next step on a DC04 at this stage is to remove the motor, but it would not budge with all the screws out. This leads us to another difference, the 2 speed switch, which annoyingly on mine has been glued to the chassis

[attachimg=7]

Some considerable screwdrivering later had it released with only some damage

[attachimg=8]

[attachimg=9]
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:22:45 AM
For the first time in ages, the rubber seal that seals this to the chassis was not perished!

[attachimg=1]

And now we come to the big difference, the gubbins that controls the dual speed!

This is the switch that sits behind the glued in part. When pushed in (bin on) it's full speed, when released (bin off) it drops the motor to half speed

[attachimg=2]

It all sits in this bracket that screws onto the motor housing

[attachimg=3]

[attachimg=4]

There we go, 250v/120v. I wonder if you could plug this in in america with the bin off and it would run at full speed?

[attachimg=5]

The switch all comes apart nicely anyway

[attachimg=6]

Now we come to the main event, the utterly trashed motor!

[attachimg=7]

[attachimg=8]

I don't think a drop of oil and a fan wash will help this much, it's totally  :dead-dyson:

We need this little red wiring loom though

[attachimg=9]
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:26:19 AM
All that heat (and I imagine actual proper flames) had given  the inside of the motor housing some lovely patina

[attachimg=1]

Main machine done, the cyclone assembly is a bog standard job, just in purple, so bin cone and seals out/off

[attachimg=2]

Top part split up

[attachimg=3]

Upper cone removed

[attachimg=4]

[attachimg=5]

Release valve split for washing

[attachimg=6]

And it's apart!

[attachimg=7]

Everything was washed, polished and laid out, so here is EVERY part of a Dyson DC04 Zorbster!

[attachimg=8]

And we start with the motor! Wires put in

[attachimg=9]
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:29:49 AM
Making sure the rubber seals sit properly

[attachimg=1]

I seem to have not got a picture of the fugging mint second hand motor I got for it... So here it is fitted to the motor housing  8)

[attachimg=2]

Cleaned up nicely though, diffuser bracket screwed in

[attachimg=3]

Speed switch fitted

[attachimg=4]

And all that was refitted to the chassis

[attachimg=5]

Wheels fitted

[attachimg=6]

Changeover valve stuffs refitted

[attachimg=7]

Hopper vibration pad fitted

[attachimg=8]

Then the clamp's big spring

[attachimg=9]
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:44:42 AM
Clamp fitted

[attachimg=1]

Then the clutch, and ah  :censored: I forgot the clutch had to go in before the head...

[attachimg=2]

That's better,

[attachimg=3]

but it kept falling out so I popped a screw in just to keep it in place

[attachimg=4]

And back on with the head and on with the cover!

[attachimg=5]

When I tried to take the brushroll apart, I found both bearings were pretty ruined, and it was just so damn soft, so I put a much better used one on! Sadly, not in purple...

[attachimg=6]

Back on with the baseplate

[attachimg=7]

Back on with the cable

[attachimg=8]

Back together with the wand

[attachimg=9]

Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 12:57:03 AM
Done!

[attachimg=1]

New post filter

[attachimg=2]

Faded to buggary, but spotless and working well

[attachimg=3]

I might have mentioned it, but I got given a brand new zorb hopper and 2 tubs of zorb in the past too, by a lady who'se DC25 I fettled. Gave one tub to George for his NIB Zorbster, and kept one!

[attachimg=4]

So, one after video


And despite NEVER having used zorb before, I quickly formed my initial opinions of it... Especially when you dont wait for it to dry before vacuuming it up...

[attachimg=5]

[attachimg=6]

And then I used it for October! Because I had plans, so it may as well have been out and ready!


My cunning plan was a nice detailed Zorb video, what with us having a filthy beige carpet, it was a good test bed. But I happened upon some vintage DA/DC01 era Zorb!

[attachimg=7]

[attachimg=8]

[attachimg=9]
Title: Re: My first DC04 Zorbster!
Post by: beko1987 on November 20, 2017, 01:01:54 AM
[attachimg=1]

[attachimg=2]

[attachimg=3]

[attachimg=4]

Shame the box was trashed, and it didnt have the bottle of spray, but for 5 I'm happy with it! So I started to plan my demonstration video, and thought Ooooh, I'd best get the crap brush they had to demonstrate that as well, so for another 3, I got this box, a DC03/04 Cleaning Kit

[attachimg=5]

[attachimg=6]

Which just had the brush in, I already had the tub of powder!

Finally, just incase my early 90's or late 90's stuff had gone off I got a pack of brand new, 2017 powder, and put this video together!

Not a valid youtube URL
Which had predictable results!

But, either way, it gave me a good excuse to use a DC04 Zorbster for Zorbing! I'm going to flog the machine on facebook soon, as it's pretty cruddy, will keep the hopper though, and do have more Zorb videos planned, including a VS with Duo-P and Kobosan, but I'll use another vac to brush that in etc!