Dyson DC24 Blueprint Limited Edition, Service Manual

Page 1: ...Service manual Issued Jan 08 ...

Page 2: ......

Page 3: ...g Duct assembly replacement dismantle Duct assembly replacement fitting Sub assemblies wand handle assembly Sub assemblies cyclone assembly Sub assemblies bin assembly Sub assemblies cleaner head assembly Electrical safety testing Electrical circuit Electrical fault diagnosis Main body Motor assembly Cyclone and bin assemblies Cleaner head assembly Wand and hose assemblies Contents This manual is ...

Page 4: ...ick to empty Just press the button at the top of the cyclone and the dust empties from the bottom Fingertip brush control Turn brushbar on and off at the touch of a button Clear binTM Made of tough polycarbonate lets you see when it needs emptying On board accessory tool Nozzle converts to a brush tool for dusting Dyson CycloneTM technology Patented technology that doesn t lose suction power as yo...

Page 5: ...e wiring behind the upright switch cover All wiring behind the switch housing If you cannot repair a product with an insulation test reading of below 2MΩ you must inform the customer that the product is unsafe to use Please inform the customer of the required actions to repair the product including the charge structure If the product is left un repaired please indicate on your paperwork hand held ...

Page 6: ...TERRITORY RESISTANCE Ω All other components TEST POINTS 10 to 11 UK Euro 230 240V 16 to 17 UK Euro 230 240V UK Euro 230 240V 23 to 24 Vac motor 2 4 Approx Cleaner head assembly Brushbar motor US Can 120V Vac motor 2 25 Approx Cleaner head assembly Brushbar motor Japan 100V 10 to 11 16 to 17 23 to 24 10 to 11 16 to 17 23 to 24 Japan 100V Japan 100V All 1 Max 725 Approx 400 Approx 420 Approx 120 App...

Page 7: ...utral wire only No power to the vac motor brushbar motor on in tilt position 1 Check connections at points 10 and 11 2 Test the resistance of the motor cable assembly and vac motor points 8 9 3 Check the vac motor brushes windings commutator etc for signs of wear No power to the brushbar motor vac motor on 1 Ensure the TCO reset button has been pressed 2 Check connections at points 3 4 12 13 14 15...

Page 8: ...s a connector behind the upright switch cover To disconnect any wires from it you will have to insert a fine bladed tool 1mm to activate the release catch All screws used in DC24 are Torx T15 unless otherwise stated Motor and yoke assembly replacement removal Recommended tools to repair DC24 Torx T 8 T 10 T 15 screwdrivers Philips screwdriver Large flat bladed screwdriver Terminal screwdriver 1mm ...

Page 9: ...Fitting notes Service manual 06 02 Remove the cleaner head assembly 03 Remove the four screws from the ball assembly 04 Remove the two halves of the ball assembly ...

Page 10: ...ice manual 07 05 Remove the post filter assembly 06 If it needs replacing the post filter button can be prised out of the post filter assembly 07 To fit align the button onto the spring and push firmly into the retainers ...

Page 11: ... filter offering arm needs replacing carefully release the spring 09 With the spring removed firmly push the post filter offering arm out of the housing on the motor bucket Fit in reverse 10 Remove the three long screws in the upright switch cover ...

Page 12: ...Fitting notes Service manual 11 Twist the upright switch cover off the side of the product 12 Separate the internal cable connector 13 Detach the wire from the lower terminal of the upright switch 9 ...

Page 13: ...Fitting notes Service manual 10 16 Remove the long screw behind the lower duct hose 15 Firmly pull the lower duct hose off the side of the product 14 Remove the long screw next to the arrow ...

Page 14: ...ing notes Service manual 11 17 Release the yoke and motor assemblies from the duct assembly 18 Release the yoke wire from the cable connector 19 Remove the yoke assembly from the motor bucket Release catch ...

Page 15: ...the swivel lock needs replacing release the catch from the yoke assembly 21 With the end released remove the swivel lock from the middle of the yoke assembly 22 To fit lower the swivel lock onto the detail on the middle of the yoke assembly ...

Page 16: ... the side of the yoke assembly that the spring locates onto the side of the peg 25 Once initially released it can then be removed by easing it away from the yoke assembly 24 If necessary the connector clip can be removed by initially inserting a screwdriver into the gap 13 ...

Page 17: ...re the yoke loom grommet is positioned in the connector clip as shown 28 Align the lugs on the connector clip with the detail on the yoke assembly Rotate the clip to lock into position 27 Ensure the yoke loom loops around the pip detail on the yoke ...

Page 18: ...Fitting notes Service manual 15 29 If replacing the motor remove the motor inlet seal 30 Remove the bearings from either end of the motor bucket 31 Remove the four screws in the motor bucket ...

Page 19: ...Fitting notes Service manual 16 34 Remove the motor from the motor bucket rear assembly 33 Remove the motor cable assembly from the motor bucket front 32 Separate the two halves of the motor bucket ...

Page 20: ... notes Service manual 17 35 Detach the motor wires from the motor cable assembly 36 Remove the fancase seal and motor mount from the motor 37 Remove the motor cable assembly from the fancase seal if necessary ...

Page 21: ...e fancase seal ensuring the lip of it covers the fancase 39 Align the arrow detail on the fancase seal with the arrow printed on the side of the motor 38 Fit the motor mount onto the top of the motor Motor and yoke assembly replacement fitting ...

Page 22: ...ancase seal is seated centrally on the base of the motor 42 If previously removed fit the wiring harness through the opening in the fancase seal Connect the motor wires to the harness 43 Dress the motor wires and harness neatly into the fancase seal ...

Page 23: ...motor Ensure the motor mount protudes through the hole in the bucket 44 Feed the wiring harness through the opening in the motor bucket front Pull the wiring harness grommet through the opening ensuring the notch detail catches 45 Locate the motor bucket front into the fancase seal ...

Page 24: ...re the motor bucket rear assembly is located within the detail on the fancase seal Fit the four screws 49 Align the tabs on the connector clip with the slots in the end of the motor bucket 48 Fit the bearings on the ends of the motor bucket ...

Page 25: ...Fitting notes Service manual 22 50 Ease the other end of the yoke assembly onto the lug on the motor bucket 52 Fit the motor inlet seal 51 Locate the yoke wire into the cable connector ...

Page 26: ...duct assembly 55 Slide the other end into the duct ensuring the three holes align Fit a long screw next to the arrow and a long screw on the other side behind the hose 53 Before fitting the yoke and motor bucket onto the duct ensure the internal cable wires are located into the channels on the duct ...

Page 27: ...onnect the red wire to the upright switch Dress all wires neatly into the channels provided 57 Fit the upright switch cover onto the side of the duct assembly Fit the three long screws 58 Fit the lower duct hose onto the side of the product ensuring the ends are seated around all edges ...

Page 28: ...n the cleaner head assembly with the plug on the yoke assembly Clip the cleaner head into position 60 Locate the c clip onto the top of the cleaner head assembly 59 Fit the post filter assembly Fit the two halves of the ball assembly Fit the four screws ...

Page 29: ...e the three long screws in the upright switch cover 64 Detach the two wires from the upright switch Undo the short screw in the upright switch housing 63 Twist the upright switch cover off the side of the product Stabiliser and pedal removal ...

Page 30: ...ing notes Service manual 27 66 If it needs replacing the upright switch can be carefully removed from the housing 65 Carefully remove the upright switch housing 67 Remove the short screw and plastic washer ...

Page 31: ... and plastic washer holding the stabiliser assembly onto the duct assembly 70 Prise the stabiliser over the large lug on the other side of the duct assembly 68 Remove the short screw and plastic washer from the other side of the duct Remove the pedal assembly ...

Page 32: ...Fitting notes Service manual 29 71 Using a pair of long nosed pliers unclip the stabiliser assembly from the spring ...

Page 33: ...tabiliser assembly over the large lug 72 Squeeze the spring firmly over the lug on the stabiliser assembly 73 Locate the small lug on the stabiliser assembly into the hole in the side of the duct Fit a plastic washer and short screw Stabiliser and pedal replacement fitting ...

Page 34: ...the upright switch and cam are positioned correctly on the upright switch housing 75 Slide the pedal axles into the channels in the stabiliser assembly 76 Locate the lugs on the pedal into the holes on either side of the duct Fit the plastic washers and short screws ...

Page 35: ...right switch housing onto the side of the duct assembly Locate the cam spring into the channel on the duct Fit the short screw Attach the two red wires to the upright switch 79 Fit the upright switch cover onto the side of the duct Fit the three long screws ...

Page 36: ...0 Remove the cyclone and bin assemblies from the product Valve wheel replacement 81 Remove the Torx T 8 screw and washer 82 Slide the centre of the valve wheel onto the lug on the end of the valve hatch and remove Fit in reverse 33 ...

Page 37: ...e duct assembly 84 Remove the rear retaining lug from the valve 85 Remove the second retaining lug Twist the hose and remove Remove the seal from the base of the hose Valve hose replacement removal Before continuing the following parts should be removed as previously shown Valve wheel Page 33 34 ...

Page 38: ...ing the hole in the seal fits over the detail on the shuttle 87 Lower the hose into the duct ensuring the pin on the shuttle locates into the channel 88 Locate the retaining lugs on either side of the shuttle into the valve Valve hose replacement fitting ...

Page 39: ...tting notes Service manual 89 Push the hose onto the duct ensuring it is adequately seated 36 After fitting the previous parts the following parts should be fittied as previously shown Valve wheel Page 33 ...

Page 40: ...lve hatch 92 Carefully prise the valve hatch off the lugs on the valve 90 Remove the screw and captive washer from the hatch Valve hatch replacement removal Before continuing the following parts should be removed as previously shown Valve wheel Page 33 Ball assembly Page 6 ...

Page 41: ...Fitting notes Service manual 38 93 The valve seal can be removed if necessary ...

Page 42: ... Locate the legs of the spring into the channels on the hatch and valve Using a screwdriver hold the spring under tension whilst sliding the axle into position Valve hatch replacement fitting 94 If previously removed fit the valve hatch seal onto the valve Ensure it is adequetly seated ...

Page 43: ...ervice manual 40 97 Hold the axle in place to stop it from turning whilst fitting the screw and captive washer After fitting the following parts should be replaced as previously shown Valve wheel Page 33 Ball assembly ...

Page 44: ... Service manual 41 100 Remove the switch cover from the front of the duct assembly 99 Undo the three screws in the rear of the duct assembly 98 Remove the wand assembly from the product Switch and powercord removal ...

Page 45: ...witch buttons from the switch cover 102 If the locking slider or switch cover need replacing carefully remove the spring 103 Prise the catch on the rear of the switch cover to remove the locking slider Fit in reverse 42 only necessary if replacing ...

Page 46: ...ing notes Service manual 105 Prise the connection insulator out of the duct assembly 106 Carefully open the connection insulator Detach the neutral wires 43 104 Carefully detach the wires from the switches ...

Page 47: ...Fitting notes Service manual 107 Remove the powercord assembly from the duct 44 ...

Page 48: ... powercord assembly through the cable protector Locate the end of the outer insulation into the channel as shown 109 Locate the cable protector into the side of the duct assembly 110 Attach the neutral wires together Switch and powercord fitting ...

Page 49: ...Fitting notes Service manual 111 Locate the connection insulator over the neutral wires 112 Route the neutral wire into the channel as shown 113 Locate the connection insulator into the duct assembly 46 ...

Page 50: ...otes Service manual 47 114 Attach a switch to the live wires from the powercord and internal powercord assemblies 115 Locate the switch into the duct assembly 116 Fit the other switch to the two remaining wires ...

Page 51: ... manual 117 Locate the second switch into the duct assembly 118 If previously dismantled ensure the brushbar button brushbar reset arm and spring are assembled as shown 48 119 Lower the brushbar button into the switch cover ...

Page 52: ...the switch cover onto the front of the duct assembly Ensure when fitting that the brushbar reset arm locates into the triangular detail on the duct Hold the switch cover in place and test the buttons The brushbar button should work independently from the On Off button Triangular detail Brushbar reset arm ...

Page 53: ...Pressing the On Off button when the brushbar button is off should also activate the brushbar button If this does not work check the position of the brushbar reset arm in the triangular detail When working satisfactory fit the three screws ...

Page 54: ...ct assembly 124 And then release it from the rear Duct assembly replacement dismantle Before continuing the following parts should be removed as previously shown Motor and yoke assembly Pages 5 11 Stabiliser and pedal assembly Pages 26 29 Valve wheel Page 33 Valve hose assembly Page 34 Valve hatch assembly Pages 37 38 Switch and powercord assembly Pages 41 44 ...

Page 55: ...es Service manual 52 126 And sliding it off the side of the duct Fit in reverse 127 Undo the two screws shown 125 The combination tool clip can also be removed at any stage by undoing the screw in the centre of it ...

Page 56: ...emoved slide the upright lock assembly off the side of the duct 130 Should it need replacing the pedal plunger can be replaced by carefully detaching the spring and removing the plunger Fit in reverse 128 Followed by the screw on the underside of the duct ...

Page 57: ...Fitting notes Service manual 54 132 Remove the valve U bend from the duct assembly 133 Remove the entry seal from the duct assembly 131 Undo the three screws in the underside of the duct assembly ...

Page 58: ...Fitting notes Service manual 55 135 Remove the internal powercord assembly from the duct assembly 134 Remove the exhaust seal from the duct assembly ...

Page 59: ...insulation of the internal powercord under the retainer in the base of the duct assembly 137 Push the end of the insulation into the channel 138 Feed the switch end of the internal powercord through the window in the duct assembly Duct assembly replacement fitting ...

Page 60: ...Fitting notes Service manual 57 139 Locate the internal powercord under all the retainers along the length of the duct assembly 140 Fit the exhaust seal 141 Fit the entry seal ...

Page 61: ...ight lock assembly onto the valve U bend Fit the three screws 143 Before fitting the upright lock assembly ensure the pedal spring is located in the orientation shown 142 Locate the valve U bend onto the base of the duct assembly Fit the three screws ...

Page 62: ...sembly After fitting the following parts should be fitted as previously shown Motor and yoke assembly Pages 23 25 Stabiliser and pedal assembly Pages 30 32 Valve hose assembly Pages 35 36 Valve hatch assembly Pages 39 40 Valve wheel Page 33 Switch and powercord assembly Pages 45 50 ...

Page 63: ...Fitting notes Service manual 60 146 Should it need replacing the wand cap can be prised off the top of the wand assembly Fit in reverse Sub assemblies Wand handle assembly ...

Page 64: ...d valve cap assembly 148 With the bleed valve cap unlocked prise it away from the cyclone cap assembly Remove all parts of the bleed valve from the cyclone cap assembly Fit in reverse 149 The cyclone cap assembly can be replaced by prising it off the cyclone assembly Fit in reverse Sub assemblies cyclone assembly ...

Page 65: ...62 150 The bin seal can be replaced When fitting a new one ensure the detail on the seal aligns with the notch on the cyclone assembly 151 If the FDC seal needs replacing ensure the new one covers all the ribs on the dust collector ...

Page 66: ...catch can be replaced by prising off from the lugs on the bin 154 The bin base assembly can be firmly prised off the base of the bin 153 To fit press firmly onto the lugs ensuring the spring locates onto the retainers Sub assemblies bin assembly ...

Page 67: ...ting notes Service manual 64 155 If replacing the bin base seal ensure the new one is fitted adequately around all edges of the bin base 156 Firmly press the new bin base assembly onto the lugs on the bin ...

Page 68: ...ng out of the soleplate To fit firmly push into place 159 With the end released slide the flicker strip out of the retainers in the soleplate 158 If the flicker strip needs replacing lift the end out of the soleplate using a thin flat bladed screwdriver Sub assemblies cleaner head assembly ...

Page 69: ...gth of the soleplate under the retainers Press the end under the last retainer 161 If the PCB need replacing remove the flicker strip and nine Torx T 10 screws eight in Japanese models 162 With the screws removed lift the brushbar motor cover off the cleaner head ...

Page 70: ...Fitting notes Service manual 67 163 Carefully detach all wires from the board 164 Release the PCB assembly from under the retaining catch ...

Page 71: ... all wires to the PCB assembly 165 To fit locate the front of the new PCB assembly under the brush housing and lower under the retaining catch 167 Lower the brushbar motor cover onto the cleaner head assembly Fit the nine screws and flicker strip ...

Page 72: ...e Wheel Cap Upright Lock Assy Pedal Plunger Lower Duct Hose Change Over Valve Spring Axle Screw Captive Washer Screw Plastic Washer Screw Change Over Valve Hatch Upright Switch Housing Upright Switch Upright Switch Spring Upright Switch Cam Screw Spring Spring Locking Slider Screw Screw Screw Hatch Seal Screw Screw Spring Stabiliser Stand Spring Valve U Bend Upright Switch Cover Duct Assy Internal...

Page 73: ...ing Spring Post Filter Assy Post Filter Offering Arm Ball Assy Motor Assy Motor Cable Assy Fancase Seal YDK Post Filter Door Assy Motor Inlet Seal Front Motor Bucket Screw Motor Mount Rear Motor Bucket Assy Swivel Lock Yoke Bracket O Ring Spring Connector Clip Yoke Assy Screw Captive Washer Screw 70 ...

Page 74: ...yclone and bin assemblies Cyclone Cap Assy Bin Base Assy Bin Base Seal Bin Assy FDC Seal Bin Seal Cyclone Assy Pre Filter Assy Bleed Valve Housing Bleed Valve Cap Bleed Valve Cap Seal Bleed Valve Housing Seal Spring Bin Catch Spring 71 ...

Page 75: ...Parts recognition Service manual Cleaner head assembly PCB Assy End Cap Assy C Clip Bumper Strip Flicker Strip Brushbar Assy Soleplate Wheel Axle Screw Cleanerhead Assy 72 ...

Page 76: ...Parts recognition Service manual Wand and hose assemblies 73 Spring Wand Assy Swivel Catch Combination Tool Assy Instruction Pack Hose Assy Wand Cap ...