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Author Topic: Dyson DC19 - Stripdown and Refurb (and new motor)  (Read 3165 times)

Online beko1987

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Dyson DC19 - Stripdown and Refurb (and new motor)
« on: June 18, 2016, 12:12:42 AM »
A while ago, I was contacted via my facebook page by someone who had a broken DC19, and had bought a new one, did I want it FOC, she would even drop it off for me. Win!

I came home one day to it sat outside the back gate

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It's just a DC19, not a T2 or whatever else these were bodged up as over their life

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I plugged it in, and was greeted by the sound of a very blown motor, so turned it off again! When I had a wash to do, I took the hose and filters out to put them through

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Under the Pre filter cover was minging

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But the filter itself was fine, and I think has been washed a few times in it's life.

Time for the post motor filter

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Ah

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I didn't bother washing that to be honest, it was  :dead-dyson:

So, hose and filters washed, I moved onto the main machine

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Which was bloody minging!

Hose handle end first

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The top cover pops off at the top, although does not easily remove yet. This allows access to the securing screw and palstic bush that centres the pivoting part

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #1 on: June 18, 2016, 12:19:06 AM »
The actual cover does remove, but is quite tricky. There is a locating peg that needs popping out from under the cover, it bends just enough to get a screwdriver in there

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The spring on the end of it is what makes the suction release valve springy

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The suction release valve slides out of it's holding channel now

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The pivoting centre sits against a seal inside the main unit, which pulls out of the top with the centre pivot removed

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The hose handle is done! Onto the extension wand now

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Which was filthy filthy filthy!

I started at the upper end, and popped the galmour cap off the locking tab

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With that off, the locking tab and spring lift off

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With some tapping, and pushing in of a locking tab the plastic end is removed from the wand

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Next, time to start on the adjusting mechanism. The piece that locks it all together is prised fairly easily out of the top, along with it's thin metal wire circlip

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #2 on: June 18, 2016, 12:28:02 AM »
With the locking cap removed, the outer skin pulls down and away

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A metal cover slides down and out of the way

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and 2 plastic pegs fall out. These are what locks the wand in position, and are pushed and lifted out of the way to adjust the wand

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This part here now is removed by pushing the tabs in and pulling it up and away

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Which releases the 2 halves of the wand

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The bits and bobs left on the thinner internal part of the wand can now slide off and away

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and the sealing ring removed as well

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The plastic part that holds the locking pegs pushes out of the wand

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and the plastic ring that holds 2 big springs slides easily off (it does come off with the above plastic part in place, but with more difficulty as I found out!
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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #3 on: June 18, 2016, 12:37:15 AM »
The second smaller spring sits against a 'stop', which slides off and down

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as well as the locking ring and circlip removed right at the start

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The 'tool' end of the wand is tapped off now, with the locking tab pushed in, and the little wheel removed

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The tubes are now componentised. Onto the flat out head

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which was a bit blocked itself

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First to come off are the rear wheels, which pop off either side

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The neck assembly pops off now too, being held in with the rear wheels

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Locking tab removed from the floor tool

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There is an inner sealing piece inside the swan neck bit

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Which falls out once the seal of shite is broken around it!


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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #4 on: June 18, 2016, 12:42:39 AM »
4 tiny phillips screws underneath, and releasing 4 clips at the front seperate the soleplate of the floortool from the frame

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The 2 tiny front wheels pop out too

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The flat suction channel part pops out of the top of the floortool, and the dirt can be scraped from it

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The tiny rear brush strip prises out of the stupid clips (I would recommend leaving it be tbh!)

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And that's the Flat Out Head apart! Onto the main machine now, which is always easier!

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Cyclone off

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Post motor filter cover and retaining cage out

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The Pre motor filter cover pops off it's 2 pivot tabs easily

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #5 on: June 18, 2016, 12:47:40 AM »
The parking bracket is released with a screw from inside

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The 3 tool clips unscrew from above and the clips pop out with a little help

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The cyclone suction seal pulls out of the filter cover

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Next, the wheels come off. Either pull them very hard or jimmy them off with a long screwdriver down the back

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This allows access to the 6 screws that release the top housing from the lower

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The cable guide pops out from inside, and pulls off the cable

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This little clear pipe, the purpose of which I'm not actually too sure but all the cylinder Dysons have it pulls off the top housing

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With 3 hands, the locking tabs can be pushed in and the cord rewind and power switch pedal removed, along with their big springs

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The release valve pushes out from above with a large, blunt screwdriver/pokey impliment

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #6 on: June 18, 2016, 12:54:50 AM »
The cord rewind assembly and motor assembly can be lifted out together now

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and disconnected. The white wires join together, the black wire goes to the switch. The cord rewind is pretty slow on this, and I did try to speed it up but failed, so left it alone!

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The hose inlet is removed now, it's held in with a screw inside, and pushing 2 locking tabs out

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The front wheel pops off the rotating part, but I couldn't get the rotating part out, and did not want to damage it

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Time for the motor now, pop the 4 tabs holding the top housing onto the main housing

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There is a rubber seal attached to the top lid, this can be removed as well.

The motor pulls out of the main housing. Disconnect the wires. Observe the ill ness of this one, it was so bad the camera did not want to focus...

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The top motor mount will be inside the main housing, pull it out and it splits into 2 parts, a clear palstic part and a rubber locating piece. On the outside of the motor bucket a seal is fitted that seals the motor to the chassis

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That's the main machine done, time for the cyclone now!

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With the bin removed, you can remove the lower seal part from inside

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #7 on: June 18, 2016, 01:01:23 AM »
revealing an empty but filthy bin

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The lower cone pops out of the shroud fairly easily, just concentrate on one tab, and push the shroud up with one hand and pull the cone down with another until it pops out and you get coated in dust...

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Up top, remove all the screws holding the top cover on

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The top handle needs to come off now

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and removing the 2 screws reveal the clip part is a seperate assembly to the main handle. There is a screw underneath it

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and one at the rear that makes the silver release clip springy

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The release clip pops out of the assembly easily

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and with a bit of fiddling the top handle comes away from the top cover completely

Underneath the top cover is another round of screws, which releases the cyclone top cover and reveals the (thankfully proper rubber, not the crap foam stuff they use nowadays) cyclone gasket

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Now to release the shroud from the cyclone, and this took a few minutes to find and work out, but it's screwed together, not friction fitted like nearly every other shroud I have come across. The screws hide under 3 of these tabs, pop them out with a thin driver

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #8 on: June 18, 2016, 01:03:02 AM »
and undo the screws

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The shroud lifts off the cones now

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and the bin seal lifts out of the cone assembly

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Done! Everything is as apart as it can possibly be, have fun putting it back together suckerz!!
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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #9 on: June 18, 2016, 01:07:20 AM »
Only joking! Everything was washed, dried, polished and laid out for an exploded diagram

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and everything needed for the cyclone plucked out ready for re-assembly.

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Bin seal refitted to the cones

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The shroud was placed back over the cone assembly and screwed down

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and the caps slid back on

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Place the cyclone seal in place at the top of the cones, making sure it's properly fitted

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Place the cyclone top on

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #10 on: June 18, 2016, 01:15:14 AM »
and screw it down

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Time to replace the top handle, slide it on from the front, making sure the 2 front locating pegs slide fully home

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Place the sideways clip release spring onto the rear part of the cyclone handle

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Snap the clip on

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Fit the upright spring

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and slide the lot home and screw it down

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This is when I found out that the handle is spring, which explains the seperate bit



Screw the top assembly onto the cyclone

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #11 on: June 18, 2016, 01:20:59 AM »
Fit the seal to the cone

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and fit the cone to the shroud

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Onto the bin

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The small seal that goes onto the standoff in the bin is fitted

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as is the big mahoosive top seal

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The whole lot is pushed into the bin

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and the bin is fitted to the cyclone

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Cyclone done!!
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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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #12 on: June 18, 2016, 01:32:53 AM »
I found a good motor, inside a DC05 that I didn't really want anymore (It needed a wand, which is and was a bit scrappy anyway), so I went and hoiked it out

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Top holder fitted to the motor

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Motor wired up, and the small loom passed through the motor housing

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The motor drops into the bucket, with the mount lined up with the case, and the top cover clipped on. It only clips on one way, all the tabs line up when it;s right

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Start to clip the wires through the wire clips

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Pop the motor bin seal on

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Next, the hose inlet needs fitting

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As you cant get to the screw with the motor in

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Then, fit the cord rewind cassette. There is a locating lug moulded into one side, that fits into the main case. When fitted properly, the 2 pivot bits either side will be fully home

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #13 on: June 18, 2016, 01:38:25 AM »
Wire the link wire up from the motor to cord rewind, although leave more slack that I have

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Push the switch back into the switch holder (it only goes one way)

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Fit the 2 black wires to the switch, and fit the switch to the housing. Then, fit the motor! The link wire covering block needs to sit quite far down to clear the housing however

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You should have this

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That job done, it's time to put the top cover back together. Clear pipe re-assembled

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and fitted

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Now for the release valve. The spring goes in first

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then this bit

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then finally this bit, that you push down and in to hold it all together

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Re: Dyson DC19 - Stripdown and Refurb (and new motor)
« Reply #14 on: June 18, 2016, 01:53:52 AM »
Pedals and springs now

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Now, push the plug and come cable through the top housing

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ensure the switch is fully pushed home

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and the top housing will sit nicely on the lower chassis and can be screwed down

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Fit the cord guide to the cord

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and push it home. It will only fit one way due to a locating lug

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Done!


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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