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Author Topic: Dyson DC40 MK2 (Erp) - Step by Step Stripdown, Refurb and Re-assembly!  (Read 2416 times)

Offline beko1987

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A friend obtained me this from an abandoned house (he's a surveyor) and bought it round. A deal was struck that once it was refurbished and sold, we would get a massive fatty fatty fat fat curry in and some beers. So, let's see what we have:

<a href="https://www.youtube.com/watch?v=CsUGKhXPatY" target="_blank">https://www.youtube.com/watch?v=CsUGKhXPatY</a>

I'm a man with a strong stomach, but even this made me feel  :sick0012:

So let's fix that!



First things first, the hose and filters went in the washing machine, the hose needing 3 goes (including one 90 degree wash with the towels) to get it clean! TBH a new hose would have cost less than the water and electric, but meh, man maths!

Wand off, and the tool latch button pops off. This usually gets gummed up with fluff and general crap

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The button has a little spring underneath it

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If you loose this, a cut down biro spring works fine! Next, remove the top part of the chassis/the top handle by pushing this button in and pulling it up

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The top flap and handle cover is removed by popping this little tab out under here

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And lifting the top cover off. The flap can then be popped out from the cover itself

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Time to move down! Remove the bin

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Aha, it's credentials!

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I always thought ERP was the first EU rules change for motor wattage, hence why this is 700w and not 1300w, and the re-designed brushroll housing to make up for the lack of watts, however Tayyab informed me that this is not always the case (I have a DC54 Erp with a 1300w motor...) Hopefully he can come along and clarify it for us!

Up behind the switch, we have 2 screws and 2 tabs.

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Remove and release all of those and the switch housing comes off.

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 #1 on: August 25, 2018, 09:44:43 PM »
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The power button with its spring lifts out, as does the brushroll on/off switch

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This sprung part for the bin does not easily come off, nor does it need to

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This is the wiring and switches

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all of it needs to be unplugged and removed, leaving just the spinal wire, as the mains cable comes off at this stage

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Next, remove the brushroll housing from the main cleaner

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Remove the filter side ball shell, and say hello to my little slug friend...

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Don't do this usually, but for the purposes of this thread, I removed the blue cap from the spinny part

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On the inside of the shell, a clear plastic cap holds the thread to the inside

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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 #2 on: August 25, 2018, 09:53:10 PM »
The other parts push out from the inside

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This bearing sits inside the whole shebang, although did not come out easily and I didnt want to break the shell, so left it in. Probably wont be many years before greasing this will be as common as greasing DC04 brushroll bearings, or the main ball bearing on a DC25

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Onto the other ball shell. This glamour cap twists 1/4 turn to release, a pair of thin nosed pliers will do it, or a firm whack with a small screwdriver if you don't mind dinking the plastic

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With a large flatblade screwdriver, unscrew the black threaded nut

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And on this side, the clear washer holds everything in from the inside

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The black nut then pushes out of the bearing

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Back to normal things that normal* people would be doing, unscrew the 2 screws underneath the top outer shell cover

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Then recline the machine fully flat and push the cover down and pull it off as you go, it rides in 2 channels

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As you can see, it rides smoothly...

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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 #3 on: August 25, 2018, 10:05:57 PM »
The HORRIBLE yolk loom can come off now, pop out the retaining clip that carries the wire up and down as the machine reclines and stands up, the clip pulls off and splits in 2

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And is held at the top by this rubber bung which pushes inwards with a screwdriver

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With the wiring released, the socket for the powerhead can be lifted out of where it lives

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Next, flip the machine over so the exhaust side is visible, and remove the 3 screws that hold it on

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On the other side, unscrew the white securing shell

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And lift it off

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Over to the other side again, and with the rear wheels in the correct position, 3 screws will be visible. Have those out

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With that off, the yolk assembly can be lifted off, although the internal hose will hold onto it yet

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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 #4 on: August 25, 2018, 10:14:21 PM »
Simply pop the locking tab out to release the hose. Next, the clear cog that moves the rear wheels in time with the reclining action can be unscrewed

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Then the plastic tab that locks into the brushroll housing and stops the machine falling sideways when upright pops out, along with its spring

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Under the yolk assembly, usually hidden by the ball shells  are 2 metal wheels that aid the shells to always rotate smoothly, these pop out

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The thread for the post motor filter shell has 2 washers, the same as the other side, but to stop these falling off when the ball shell is removed, they are held in with a plastic stopper, which unscrews

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And with that, the yolk assembly is stripped! The white part to the left seems pressed on, and will be damaged if removed, so I leave it alone.

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We can move back to the main machine

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And remove the screws that hold the PCB cover on

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The PCB sits in the exhaust air flow, so it was a little bit surprising to see all the fluff built up around it!

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We can start unplugging things now, starting with the yolk loom itself

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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 #5 on: August 25, 2018, 10:35:51 PM »
Just switched to a thinkpad with a thinklight as it's getting dark and I cant be bothered to get up and put the light on!

Anyway, whilst we hold the yolk socket in our hands, we can take note of the wiring orientation

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Open the flap that locks the terminals into place

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And remove the wires! Next to be unplugged are the wires leading to the switch that shuts the brushroll off when the machine is upright

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Then remove the other wires which provide the power, and the wires that run to the motor! The PCB should unscrew, but I got a quarter of a turn in and the threaded standoff snapped right off... We'll glue that on later!

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Because next, we need to remove the main suction channel that goes from the motor. There are screws here

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and one this side

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and 2 here

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Then the whole assembly lifts off!

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Signs of water where it shouldn't be in the past...

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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 #6 on: August 25, 2018, 10:43:07 PM »
The bin seal is removed from the suction inlet and outlet

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The release valve can be removed now by rotating the cap slightly and pulling it off, and removing all the bits inside

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On the motor housing, we can see the cam that activates the brushroll cutoff switch

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It and its spring lifts off

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Then the switch itself can be removed

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Now we can start on the rear wheels. This spring is what helps the wheels flip up and down as needed

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Remove the screw with the big washer that fixes it to the motor housing, then the wheels can be removed from the chassis

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The flap to enable the user to check the tiny air paths for blockages pops off

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Then the screw partially hidden by it can be removed

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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 #7 on: August 25, 2018, 10:48:51 PM »
Tucked under the spinal wire on the side is another screw

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and one last screw sits at the back underneath the lower cord hook, which just lifts out to reveal. Then the spine can come off the lower chassis

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Down to the motor!

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The changeover valve needs to come out next, and it starts with this little bracket that holds the hose in place on one end

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Then remove the screw that sits the other side

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Then, remove this spring from the machine, or undo the 2 screws holding the plate the spring clips to and leave the plastic attached

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Then pull the securing cage out of the machine

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The hose and top pivot can be withdrawn now

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the other end of the internal hose lifts out of its locating slot

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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 #8 on: August 25, 2018, 10:57:16 PM »
Now we can remove the 2 screws and release the 2 clips that hold the motor cover in place

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To remove the motor, first remove the carbon brush that you can see, take this screw out

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Then pull the carbon brush assembly off. The motor will then twist enough to come out of the housing, pull the wires through the housing as you go

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This black box of tricks contains the locking mechanism for the rear wheels, it's this you hear making the crack sound as it lets go when you push the machine down to flip the rear wheels up!

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The cover comes off

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Then the spring and inner part lift out. This white cam is all thats left!

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And the motor housing is stripped! Talking of the motor, it bloody stunk, the fan was full of all sorts of crap, so I knocked the case off

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And stripped the top end down, including the white bit and washed them!

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Now we can move onto the brushroll housing!

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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 #9 on: August 25, 2018, 11:40:14 PM »
Which is utterly disgusting

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So we open the baseplate and undo the screws holding it onto the main housing

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And it separates from the brushroll housing

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TBH this bit is, apart from the motor the ONLY difference between a Mk1 and a Mk2 I think, the ERP bit of the brushroll housing. The red slider knob lifts off

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Then the blue sealing strip lifts out of it's 3 securing latches

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This black bar is what moves the blue squegee up and down as the red slider is slid, it does come out, although is a bit fiddly. Worth it though so you can flush all the grit out that causes this mechanism to jam up

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The stupid EU rules bodge velour strips are looking pretty knackered

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And the floating head isn't floating very well due to all the crap built up inside the rubber part (as usual)

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I scraped it all out, and moved onto unscrewing the brushroll

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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 #10 on: August 25, 2018, 11:47:25 PM »
Delightful

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The centre screw comes out, and this allows the end caps to be removed from the brushrolls

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Which were nice and clean... Next the brushroll cogs need to be removed to allow a step later to happen more smoothly

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More red hair! This stuff is everywhere

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Removing the screws from inside the housing, the suction channel lifts out, once you break it free from the crust that sticks it down

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Now, flip it over and undo all the screws that hold the motor cover on

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And lift out the motor! (the brushroll cogs need to be removed already to do this!)

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I wonder what the failure rate of these will be as they get older and are run in this state...

Next the wiring loom lifts out of the clear head

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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 #11 on: August 25, 2018, 11:53:14 PM »
The plug simply pops out of the housing

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Which leaves the brushroll housing chassis looking vomit-tastic, and ready to be lobbed in a heavy G101 solution to soak for a few hours!

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But not after sorting more of the blasted hair out, this rear wheel was jammed ruddy solid

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Picking at it did nothing

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So with a small centre punch and a hammer I knocked the pin through and cleared it properly

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The motor comes off the securing part

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I removed the lid from the belt guard

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separated the 2 parts

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Which uncovered yet more bloody red hair jamming the centre wheel!

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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 #12 on: August 25, 2018, 11:57:35 PM »
Much nicer!

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I removed the brushroll drive cog from the centre housing

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And removed the bit that holds the belt guard assembly onto the motor from the motor itself

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Onto the cyclone now, and we all know this isn't going to be pretty don't we...

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It is empty, that's just a tidemark... Flap open...

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I'd stopped feeling  :sick0012: by this stage and was mostly  :biglaugh: :biglaugh:. Probably the fumes...

Flap off and seals removed

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I had to scrape most of this off for my own sanity and plumbing

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Bin flap release rod off

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And onto the cyclone itself

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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 #13 on: August 26, 2018, 12:01:07 AM »
Top handle off

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Red lever and filter cap popped off

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Top bin seal off

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Shroud and bottom cones popped off

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Shroud removed from the inner assembly

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It was stuck well! I'd stopped thinking if this was poo or sick by now, it smelt like both!

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Infact I was actually pleased to see our old friend plaster dust! Always know where you stand with safe boring old plaster dust!

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Cyclone cone tip seal now, it's under here somewhere...

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Here it comes

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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 #14 on: August 26, 2018, 12:02:59 AM »
And once off, I could get to the screws holding the top part together, so apart it fell!

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And that was that! Quite alot of this had a night and day soaking in G101, agitated every now and again when I walked past and saw it had settled, then it was all washed, some bits washed again, dried, polished and laid out ready for reassembly!

Which you will see another day, when we put this machine back together!
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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