Smell of Burning Carbon (Models WITH Brush Control)

This is the symptom of an overheating motor. The motor can be overheating due to either a blockage, usually in the cleaner head or hose, dirty filters or most likely a worn motor.

1. Firstly check that the filters are clean.

2. Check for blockages in the cleaner head and hose.

If, after doing both of the steps above, you can find no obvious reason for the cleaner to overheat then inspect the motor for damage by following the steps detailed below.

PLEASE NOTE: If your are in anyway unsure of any of the steps listed below. Please consult a qualified electrician and always disconnect the Dyson from the mains before commencing work.

 

1. Lay your Dyson onto it's back and, using a two pence piece or a large flat screwdriver, turn each of the three soleplate fasteners a quarter of a turn in an anti-clockwise direction.

 

2. Remove the soleplate by twisting either side of the centre plastic screw.

 

3. Place the Brush Roll Removal Tool (Designed by and sold exclusively through www.sparesaver.com) over the brush roll at the belt end and then Using the belt hook, pull the belt onto the bottom holding pin of the Brush Roll Removal Tool.

 

4. Then hook the belt onto the top pin.

 

5. Carefully pull the brush roll out of the brush holder. Then unhook the belt from the Brush Removal Tool and remove the tool.

 

6. Remove the internal hose by firstly pulling it from the main body.

 

7. Then by unwinding the other end from the brush holder.

 

8. Remove the brush holder by grasping the end firmly and rocking it backwards and forwards whilst pulling it away from the cleaner head.

 

9. Then remove the brush holder from the other end using the same method.

 

10. Remove the U-bend.

 

11. Using a Torx T15 screwdriver remove the 3 screws holding the clutch cover in place.

 

12. Remove the clutch cover.

 

13. Use a large flat screwdriver and gently prise the belt off the motor shaft.

 

(The photographs below show a DC07 without Brush Control. The procedure for removing the motor from this point onwards is identical for all DC07's)

14. Using a large flat screwdriver. Gently remove the two large plastic circlips holding the cleaner head in place. One on each side.

 

15. Hold the cleaner head firmly in both hands and gently open the sides to clear the cleaner head from the main body.

 

16. Carefully remove the bearing clip from the left side of the Dyson.

 

17. Then remove the bearing clip from the right side.

 

18. Remove the cyclone/bin assembly.

 

19. Remove the post motor filter lid by prising it free with a screwdriver and then remove the post motor filter. Which lies beneath the lid.

 

20. Using a Torx T15 screwdriver. Remove the 4 screws holding the upper motor cover onto the main body.

 

21. Gently pull the upper motor cover and motor housing free of the main body.

 

22. Remove the Upper motor cover by holding each side and gently spreading the sides to clear the motor housing.

 

23. Using a large flat screwdriver gently prise off the motor retaining ring.

24. Grasp the black fancase seal and pull the motor free of the motor housing. (This may require a considerable force)

 

25. When you have removed the motor from it's housing. Take careful note of the correct connection of the wires. Red to Brown (live wires), Black to Blue (neutral wires).

26. Remove the offset motor bearing mount and the rubber fancase seal from the old motor and fit them to the new motor.

27. When the motor is fully out of the main cleaner body examine the motor for wear or damage. Pay particular attention to the commutator (The copper segments where the carbon brushes contact the motor - red arrow). If the commutator is blackened and heavily scored the motor must be replaced. Also pay attention to the bearings on the motor. The armature shaft should turn easily with the fingers with very little resistance other than the resistance of the carbon brushes touching the commutator ring. If the bearings are stiff or make a grinding noise the motor must be replaced.

REASSEMBLY

28. Before refitting the motor to the motor housing. Lubricate the rubber seal with a very slight smear of vaseline to allow the motor to be manouvered into place.

 

29. When refitting the motor ensure that the offset motor bearing mount is correctly alligned so that the large protusion lines up with the large cut out of the motor housing.

Reassembly is a simple reversal of the steps listed above.