Smell of Burning Carbon

The most likely cause of a smell of burning, such as an accrid burnt carbon smell, is a worn out motor. A good indication of this is the post motor filter, the filter located below the bin, being blackened and having an accrid smell. To inspect/replace the motor please follow the detailed instructions 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. Start by removing the cyclone/bin assembly from the main body.

 

2. Remove the post motor filter cover by using a two pence piece to twist the cover off.

 

3. lay your Dyson onto it's back and, using a two pence piece, turn each of the three soleplate fasteners a quarter of a turn in an anti-clockwise direction.

 

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

 

5. Place the DC04 Brush Roll Removal Tool (Designed by and sold exclusively through www.sparesaver.com) over the brush roll at the belt end.

 

6. Using the belt hook, pull the belt onto the bottom holding pin of the DC04 Brush Roll Removal Tool. Then hook the belt onto the top pin.

 

7. Carefully pull the brush roll out of the brush holder. (You may find it easier to remove the brush roll's black end cap before pulling it through the belt opening.)

 

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

 

9. Then pull the other end off the brush holder.

 

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

 

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

 

12. Remove the U-bend.

 

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

 

14. Using a large flat screwdriver remove the belt from the motor shaft.

 

15. Remove the first cleaner head circlip.

 

16. Then remove the second circlip from the other side.

 

17. Remove the cleaner head by holding both sides firmly and pulling one end outwards to free it from the main body. Then do the same to free the otherside.

 

18. Remove the bearing clip by very carefully, unhooking it and gently prising it free.

 

19. Then remove the bearing clip from the other side.

 

20. Using a Torx T15 screwdriver. Remove the 8 screws that hold the upper motor cover onto the main body.

21. Carefully pull the upper motor cover and motor housing away from the main body.

 

22. Carefully spread the sides of the upper motor cover and pull it away from the motor housing.

 

23. Remove the fancase pipe.

 

24. Gently prise the motor retaining ring away from the motor housing.

 

25. Remove the motor retaining ring completely

 

26. Grasp the fancase mount firmly and pull the motor out of the motor housing.

 

27. Remove the motor completely out of the motor housing and note the correct connections of the wires. (Red to Brown (live) & Black to Blue(neutral))

 

28. Before fitting the new motor ensure that the rubber motor bearing mount and rubber fancase seal from the old motor are correctly fitted to the new one. Ensure that the holes in the motor bearing mount (red arrows). Line up with the pegs in the motor housing (blue arrows).

 

29. 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 is a simple reversal of the steps listed above.