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Author Topic: Dyson DC04 Exploded Drawings. Schematic.  (Read 4454 times)

Online MVacs

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Dyson DC04 Exploded Drawings. Schematic.
« on: September 20, 2014, 06:28:14 PM »
DC04 without a clutch. Put here for reference so we can direct people to them to correctly identify spare parts.

If you click the images, they will blow up to full size.  ;)

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Online MVacs

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #1 on: September 20, 2014, 06:33:47 PM »
Variant items for machines with a clutch.

If you click the image, it will blow up to full size.

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Copyright on these images belongs to Dyson Ltd.

Offline Chainhurstman

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #2 on: July 15, 2016, 12:31:12 AM »
DC04 without a clutch. Put here for reference so we can direct people to them to correctly identify spare parts.
A wonderful resource, but do you know where the key to the part numbers can be found ?

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #3 on: July 15, 2016, 12:39:24 AM »
I don't think there is one.  Whats the number of the bits you need?
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 Chainhurstman

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #4 on: July 15, 2016, 12:46:25 AM »
I don't think there is one.  Whats the number of the bits you need?
Nothing in particular at the moment, thank you, but if there were a key to the part numbers it would not only make it easier to search for them (on the forum and elsewhere) but could also serve as a partial explanation of the function of the part.

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #5 on: July 15, 2016, 12:52:58 AM »
Aaah i see.  I don't think Dyson ever released the key,  none of the other schematics on the earlier models have them.

Ill see if I can put one together like I did for the DC01 schematics
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 Chainhurstman

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #6 on: July 15, 2016, 01:03:11 AM »
Aaah i see.  I don't think Dyson ever released the key,  none of the other schematics on the earlier models have them.

Ill see if I can put one together like I did for the DC01 schematics
That would be great.  And in the meantime, I have found such a key for the DC07 should that be of use to you ('though I expect you already have one !).

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #7 on: July 15, 2016, 03:03:38 PM »
Let's try this then! I'll work through each image in turn

IMAGE 1
49 - Wand Handle Cover
50 - Wand Cap
51 - Wand Cap Spring
53 - Wand Release Catch
52 - Wand Release Catch Spring
54 - Upper Cord Hook
85 - Upper Cord Hook Spring
56 - Upper Cord Hook Screw
55 - Upper Cord Hook Screw Cover
48 - Wand Assembly (the wand is different for Clutched and Non Clutched models)
40 - Cyclone Top Housing (The Handle, filter lid clip and internal spring are available separately as well)
42 - Not quite sure what that part is, it could be the whole Filter Lid Seal, but their usually stuck on)
45 - Cyclone Assembly (again, breaks down into Cyclone Shell, Inner Cone, Shroud and Relief valve, which again strips down further)
44 - Shroud Inner Seal (or possibly the upper bin seal)
46 - Lower Cone to Upper cone seal
The outer lower cone is also pictured but not numbered
43 - Outer Lower Cone seal
47 - The whole bin/lower cone assembly
88 - Instruction Book
58 - Hose (The hose is different with the Clutched and Non Clutched machines)
77 - Crevice Tool
78 - Dusting Brush
79 - Upholstery Tool

IMAGE 2
35 - Post Motor filter cover
36 - Post Motor filter cover seal
37 - Diffuser Screws
38 - Exhaust Air Diffuser
39 - Motor Housing
1 - Belt pulley motor rubber strengthening doo-dah (basically stops the belt on a non clutched machine catching on the smaller motor rubber)
33 - Belt Pulley side motor rubber
32 - Motor
31 - Fancase seal/mount
30 - Motor securing ring
66 - Cable Clip
107 - Cable Assembly
10 - Cable protector
67 - Switch Housing
41 - Live terminal protector
62 - Switch
60 - Switch housing securing screw
59 - Power Switch cover
28 - Motor Housing securing housing
13 - Screws for part number 28
105 & 106 - Constant Max specific here, the CM came with a 2 part cable originally
65 - Spine Cable
9 - Wand blockage u-bend/airflow duct
2 - Pivoting rings
109 - Wheel fixing kit/spacer washers
108 - Complete rear wheel assembly
5 - Wheel securing circlip
4 - Wheel spacer washer
3 - Wheel Axle
7 - Wheels
6 - Wheel glamour caps
27 - Upper chassis to cyclone seal
26 - Lower chassis to cyclone seal
71 - Brushroll air path blockage check duct/airflow duct
70 - Seal to seal 71 to the chassis
69 - Securing circlip for part 70
68 - The carrier part for part 71, part of the changeover valve
73 - Lock spring (locks the brushroll housing up when parked so it doesn't flop about when wheeling the machine around_
75 - Changeover valve connecting plate (and what part 68 runs up and down on)
76 - The seal that part 9 sits against when fitted
29 - Main chassis/spine
24 - Motor suction dust (connects the motor to the chassis)
25 - The seal that connects part 24 to the main chassis (they are ALWAYS very perished when removed, I use glue/sealant instead now)
102 - Internal hose/brushroll pivot spring
101 - Connects part 102 to part 75

IMAGE 3
110 - Locking arm
111 - Locking arm spring
23 - Securing circlips (secures the upper brushroll housing to the chassis
22 - Upper Brushroll housing (non clutched)
20 - Inner brushroll housing (non clutched, different to clutched models)
15 - Brushroll (bearings are replaceable though, but differ from machine to machine. Some are re-greasable too) (This is different between clutched and non clutched machines)

IMAGE 4 - Which covered CLUTCHED machines
108 - Locking arm
107 - Locking arm spring
22 - Upper brushroll housing (CLUTCHED only)
23 - Securing circlip
11 - Clutch control cap
21 - Clutch assembly (you can rebuild it as per here though https://manchestervacs.co.uk/DysonForum/index.php/topic,1196.0.html though)
21A - Clutch to Motor belt (replaceable without rebuilding the clutch)
12 - Clutch Cover
13 - Clutch Cover screws
20 - Lower brushroll housing (different on clutched and non clutched models)
14 - The baseplate seals again
15 - CLUTCHED machine brushroll (again, bearings are replaceable and sometimes re-greasable)
16 - CLUTCHED machine baseplate assembly
19 - Soleplate wheel axles (replaceable)
18 - Soleplate Wheels (available as a kit nowadays to re-wheel a whole baseplate)
17 - Baseplate locking tabs (easier to just buy a baseplate)

So there you have it! I hope this helps people, especially since the DC04 does not exist in Dysons world! We know and love the DC04 here though, and Manchestervacs stock every possible part you will need (second hand only for some bits though), and the knowledge in the section will enable even the most luddite user to repair their machines!

The DC04 is still a VERY competent machine, even though most are knocking on the door of 15-20 years old now! More than man enough for a daily vacuum, and with prices starting from free if you pull one out of a skip, to 5-10 on ebay with easily rectifiable faults like a blown motor, lack of suction (always a good one that), if you need a cheap but excellent vacuum, you wont go far wrong.

There is a full stripdown and refurbishment guide here, which will make the machine work as good as the day it was born (with new filters and belts fitted (clutched machines may not need belts, non clutched ones certainly will)
Non Clutched is here - https://manchestervacs.co.uk/DysonForum/index.php/topic,1880.0.html
Clutched is here (but lacks rebuild pictures, so follow the Haynes rule of re-assembly!) https://manchestervacs.co.uk/DysonForum/index.php/topic,1553.0.html
Spare parts are here - https://manchestervacs.co.uk/Dyson/DC04-spares.html but doesn't list 1/4 of what they have so email if you don't see it

Failing that, post up, say hello and tell us what the problem is!

Sam
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 Chainhurstman

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #8 on: July 15, 2016, 03:05:45 PM »
Great stuff, Sam -- many many thanks !

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #9 on: July 15, 2016, 03:09:37 PM »
No worrys!

I can imagine you scouring ebay and gumtree now for machines to refurbish and sell locally, it's what I do!

The pre motor sponge filter and cage, main hose and internal hose all go happily through the washing machine with a few towels to deaden the clunking and thunking, and generally come out spotless, or at least very clean if not a tad stained. I've had pot luck with post motor filter pads, as they sometimes break up, and generally don't go white again if their really badly stained, so I'd buy new of those, and the HEPA filters break up as the filter media is tissue paper, so buy new there!
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 Chainhurstman

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #10 on: July 15, 2016, 03:22:24 PM »
I can imagine you scouring ebay and gumtree now for machines to refurbish and sell locally, it's what I do!
If only I had the time !

Quote
The pre motor sponge filter and cage, main hose and internal hose all go happily through the washing machine with a few towels to deaden the clunking and thunking, and generally come out spotless, or at least very clean if not a tad stained.
I have not been that daring -- sponge filter washed out by hand with household washing-up liquid, and the other parts just given a more-or-less cosmetic wipe-over to get rid of the worst of the gunge.  Perhaps if spare hoses were still available I might be willing to risk putting them in the washing machine, but on the principle of "it it ain't broke, don't try to fix it", I generally prefer to leave things that appear to be working very much alone.

Quote
I've had pot luck with post motor filter pads, as they sometimes break up, and generally don't go white again if their really badly stained, so I'd buy new of those, and the HEPA filters break up as the filter media is tissue paper, so buy new there!
Would I be right in thinking that the DC04 does not come as standard with an HEPA filter, but one can be fitted as an after-market modification ?  If so, does it replace the pre- or post-motor filter (and for the benefit of idiots such as myself, who can never remember which is which) does it replace the one above the cyclone or the one below the dust colector and above the motor ?

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #11 on: July 15, 2016, 03:50:11 PM »
Depending on the trim level, some 04s came with a HEPA, and some didn't. However, either type of filter fits either machine.

The post motor filter sits under the cyclone, under the grille that the bin sits on. This is where you replace the pad with a HEPA cartridge. The Pre motor filter (the one under the cyclone top/carry handle) is the same sponge and cage affair throughout.

If you have a clutched machine, the hose is repairable, see here for details - https://manchestervacs.co.uk/DysonForum/index.php/topic,1910.0.html
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 Chainhurstman

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #12 on: July 15, 2016, 03:54:21 PM »
Thank you, Sam -- much appreciated.  In that case I will replace the post motor filter with a HEPA filter on the "new" machine, as the present filter is filthy.

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #13 on: July 15, 2016, 04:42:51 PM »
They get like that. Dyson advertised them as 'Lifetime', when what they should have said is 'replace it every 2-3 years'...

One of the most common faults of 'My DC04/07/14 died, or turns off after 5 minutes' is an ancient, blocked post motor filter! Provides oodles of cheap machines, testable by removing said filter and seeing if it runs for longer than 5 minutes!
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 Elgin

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Re: Dyson DC04 Exploded Drawings. Schematic.
« Reply #14 on: February 15, 2017, 12:10:54 AM »
No worrys!

I can imagine you scouring ebay and gumtree now for machines to refurbish and sell locally, it's what I do!

The pre motor sponge filter and cage, main hose and internal hose all go happily through the washing machine with a few towels to deaden the clunking and thunking, and generally come out spotless, or at least very clean if not a tad stained. I've had pot luck with post motor filter pads, as they sometimes break up, and generally don't go white again if their really badly stained, so I'd buy new of those, and the HEPA filters break up as the filter media is tissue paper, so buy new there!

Haha I go around eBay scavaging for the 10 pound ones that pop up needing a clutch turning on... Always near us though.

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