Dyson Ball DC25 User manual

Service manual
Issued Feb 08

Service manual
Product overview Technical info. Fitting notes Parts recognition
General notes
Motor and yoke assembly replacement - removal
Motor and yoke assembly replacement - fitting
Stabiliser and pedal replacement - removal
Stabiliser and pedal replacement - fitting
Valve wheel replacement
Valve hose replacement - removal
Valve hose replacement - fitting
Valve hatch replacement - removal
Valve hatch replacement - fitting
Switch and powercord - removal
Switch and powercord - fitting
Duct assembly replacement - dismantle
Duct assembly replacement - fitting
Sub assemblies - hose and wand assemblies
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 written specifically for Dyson trained engineers and covers the full DC25
range. The service instructions assume the engineer has the approved tools and test
equipment with them.
Features 01
63
64
65
66
67
05
05
18
28
30
33
34
36
37
39
40
43
48
51
54
55
57
59
02
03
04
Page

Technical info.
Service manual
Hygienic and quick to empty
Just push the button at the top of the
cyclone and the dirt empties from the
bottom.
Motorised brush bar
Powerful bristles remove dirt and pet
hair from carpets.
dyson ball
No wheels. No more awkward moves.
Dyson Ball™ technology
Because DC25 uses a ball and not fixed wheels, it turns on a sixpence.
The motor sits inside the ball so the machine has a low centre of gravity,
making it even easier to steer
Quick draw Telescope Reach™ wand
Single action wand with instant 16ft reach for stairs and high-reach
cleaning
Lightweight
Weighs only 7.2 kilos
Quick draw Telescope Reach™ wand
For cleaning awkward areas.
Product overview
01

Technical info.
Service manual
02
Electrical safety testing
Ensure that at all times during the repair and testing of products
that customers, pets, children and you are not exposed to any
Live electrical supply.
Insulation test
The following tests must be performed
prior to and upon completion of all
repairs to Dyson floorcare products and
before any functional checks. You must
ensure that a full visual inspection
of the product is completed prior to
repair.
Test results
An insulation test reading of >2 MW
is acceptable.
A reading of below 2 MWis not considered
safe and further investigation, rectification
and testing must be completed before the
product is used. The following components
must be visually inspected:
Wiring behind the upright switch cover.•
All wiring behind the switch housing.•
All wiring within the cleaner head•
assembly.
If you cannot repair a product with an
insulation test reading of below 2MW
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
device that the product is electrically
unsafe and attach a ‘WARNING:
product electrically unsafe’ sticker in
a visable location on the product.
The Seaward Primetest 200 (or equivalent)
should be used to test the electrical
insulation of a Class 11 appliance; it
indicates any electrical leakage.
Test the 2 screws highlighted in
the upright switch cover.
Test the 3 screws highlighted in
the rear of the duct assembly.
Insulation test points:
These tests are vital to avoid any
possibility of personal injury to the
end user.
Test the 3 screws highlighted in
the cleaner head assembly.

Technical info.
Service manual
03
Wiring Schematic
BB Motor
PCB Assembly
SA1
SA4
SA2
SA3
2420 22
21
18
16
12
11
10
9
8
7
123456
17
15
14
13
19
23
Vac motor
Upright
switch
COMPONENT
Vac motor 6 Approx
Cleaner head assembly
Brushbar motor
TERRITORY RESISTANCE (Ω)
All other components
TEST POINTS
9 to 10 UK/Euro/ANZ (230/240V)
17 to 18
UK/Euro/ANZ (230/240V)
UK/Euro/ANZ (230/240V)
23 to 24
Vac motor 2.4 Approx
Cleaner head assembly
Brushbar motor
US/Can (120V)
9 to 10
17 to 18
23 to 24
All 1 Max
260 Approx
70 Approx
50 Approx
20 Approx
US/Can (120V)
US/Can (120V)
Wire colours may vary between territories.

Technical info.
Service manual
04
When DC25 is switched on in the upright position, the brushbar motor is off. Tilting the machine into
normal vacuuming mode will automatically operate the upright switch, turning the brushbar motor on.
The brushbar motor can be switched off using the brushbar switch.
The vacuum motor of DC25 is fitted with a heat sensitive Thermal Cut-Out (TCO). This will shut the
motor down for up to 60 minutes if it reaches a temperature >96 degrees celcius. Excessive
temperatures within the motor are usually caused by machine/filter blockages.
The switch housing is fitted with a TCO reset switch that will shut the brushbar motor off if it is put
under an excessive load (blocked/seized brushbar etc.). The cause of the shut down should be cleared
and the TCO reset by pressing the brushbar switch button.
If the cause of the brushbar motor cut-out is not rectified the TCO will repeatedly reactivate, preventing
the brushbar from turning.
Electrical fault diaignosis
Note: all ‘connection’ numbers and ‘continuity’ checks refer to the illustration and table on page 3.
No machine power (vac motor and brushbar motor off)
1) Check for damage/electrical failure to the plug, fuse and powercord.
2) Check for a loose connection at points 1, 2 and 7.
3) Check the mechanical actuation of the on/off switch.
4) Test the resistance of the powercord, fuse (UK only), on/off switch and the neutral wire of the internal
cable (points 7 to 11).
No power to the vac motor (brushbar motor on in tilt position)
1) Check for a loose connection at points 8, 9, 10 and 11.
2) Test the resistance of the motor cable assembly (points 8 to 9 and 10 to 11) and across the vac
motor (points 9 to 10).
3) Check the vac motor brushes, windings, commutator etc. for signs of wear or damage.
No power to the brushbar motor (vac motor on)
1) Ensure the TCO reset button has been pressed.
2) Check for a loose connection at points 3, 4, 5, 6, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22,
23 and 24.
3) Check the mechanical actuation of the brushbar switch and upright switch.
4) Check the brushbar motor and PCB assembly for signs of damage/wear.
5) Test the resistance of the brushbar switch (points 3-4), the switch/TCB cable (points 4 to 5), the
internal cable (red wire only points 6-13), the upright switch (points 13-14), the yoke loom (points
12 to 16 and 14 to 15) and the cleaner head assembly (wires from the plug to the PCB only, points
17 to 19 and 18 to 20).
If no faults are found replace the cleaner head assembly.
Brushbar motor on in upright position (switches off with brushbar switch)
1) Check the mechanical actuation of the upright switch. Ensure the micro switch isn’t jamming or sticking.
Brushbar switch does not switch brushbar motor off in tilt position
1) Check for correct location of the brushbar reset arm (see item 121, page 47).
2) Check the mechanical actuation of the brushbar switch.
3) Test the resistance of the brushbar switch (points 3-4).
Electrical fault diagnosis
Wire colours may vary between territories.

Fitting notes
Service manual
General notes
Disconnect the machine from the electrical outlet at all
times during repair and test. Failure to do so could result
in electric shock or personal injury.
Some female terminal clips used in DC25 contain a locking
mechanism. The release pip will need to be activated before
separation from the male terminal can occur.
All screws used in DC25 are Torx T15 unless otherwise stated.
Motor and yoke assembly replacement - removal
Recommended tools to repair DC25:
Torx T-15 screwdriver
Philips screwdriver
Large flat bladed screwdriver
Terminal screwdriver
Long/needle nosed pliers
05
01 Slide the catch on the underside
of the cleaner head.
Remove the cleaner head from
the product.
Wire colours may vary between territories.

Fitting notes
Service manual
06
02 Remove the four screws from the
ball assembly.
03 Remove the two halves of the ball
assembly.
04 Press the release button and
remove the post filter assembly.

Fitting notes
Service manual
07
05 If it needs replacing the post filter
button can be prised out of the
post filter assembly.
06 To fit, align the button onto the
spring and push firmly into the
retainers.
07 If the motor bucket spring cap
needs replacing prise it out of the
motor bucket.

Fitting notes
Service manual
08
08 To fit, locate the spring onto the
retainer. Locate the cap onto the
spring. Push the cap down onto
the catches.
09 Remove the three screws in the
upright switch cover.
10 Remove the upright switch cover.

Fitting notes
Service manual
11 Detach the wires from the upright
switch.
12 Release the wires from the upright
switch housing.
13 Carefully release all wires and
connections from the retainers on
the yoke loom carrier.
09

Fitting notes
Service manual
10
16 Firmly pull the lower duct hose off
the side of the product.
15 Undo the screw on the side of the
duct.
14 Separate all connectors.

Fitting notes
Service manual
11
17 Remove the long screw behind the
lower duct hose.
18 Remove the yoke spigot from the
side of the product.
19 Release the yoke and motor
assemblies from the duct
assembly.

Fitting notes
Service manual
12
20 Remove the yoke loom carrier
from the yoke assembly.
21 Force the yoke assembly away
from the motor bucket.
22 If necessary the swivel arm can
be replaced by removing the
screw from the side of the yoke
assembly.

Fitting notes
Service manual
23 Remove the swivel arm pin.
25 If the yoke loom assembly needs
replacing remove the three screws.
24 Firmly release the swivel arm from
the side of the yoke and twist
away from the centre.
Fit in reverse ensuring the spring is
located correctly.
13

Fitting notes
Service manual
14
26 With the screws removed release
the yoke loom assembly from the
yoke assembly.
28 To fit the new one locate the
wires through the side of the yoke
assembly.
27 If fitting a new yoke loom
assembly ensure the wires are
neatly dressed within the channels.

Fitting notes
Service manual
15
30 Remove the four screws in the
motor bucket.
31 Separate the two halves of the
motor bucket.
29 Locate the yoke loom onto the
centre of the yoke assembly.
Fit the three screws.

Fitting notes
Service manual
16
34 Remove the motor bucket front
and inlet bucket seal from the
motor.
33 Detach the motor bucket wiring
assembly from the motor.
32 Remove the motor mount from
the motor.

Fitting notes
Service manual
17
35 Remove the inlet bucket seal from
the motor bucket front. Detach the
motor bucket wiring assembly.
36 Remove the motor bucket duct
seal from the motor bucket front.