Dyson DC 23 User manual

Service manual
Issue 2 (Issued Feb 08)

Service manual
Product overview Technical info. Fitting notes Parts recognition
Cable rewind replacement - removal
Cable rewind replacement - fitting
Motor bucket assembly replacement - removal
Motor bucket assembly replacement - fitting
Main chassis replacement - dismantle
Main chassis replacement - assemble
Sub-assemblies - Bin assembly
Sub-assemblies - Power wand hose assembly
Sub-assemblies - Power floor tool - dismantle
Sub-assemblies - Power floor tool - assemble
Electrical safety testing
Electrical overview
Wiring schematic Motorhead variant
Electrical fault diagnostic - Motorhead variant
Main body
Cyclone and bin assemblies
Wand and hose assemblies
Power floor tool assembly
Contents
This manual is written specifically for Dyson trained engineers and covers the full DC23
range. The service instructions assume the engineer has the approved tools and test
equipment with them.
Features and benefits 01
63
64
65
66
06
14
22
27
32
37
40
42
45
56
02
03
04
05
Page

Service manual
Product overview
dyson stowaway
The full-sized cylinder with hygienic bin emptying
Sits on the stairs
Hygienic bin emptying
Lower profile contact head
Doesnʼt lose suction and captures
more microscopic dust
Combines Cyclone technology
with a core separator an extra
cyclonic stage between the outer and
inner cyclones to separate particles
as small as 0.5 micron from the
airflow.
TM
Product overview
01

Technical info.
Service manual
dyson stowaway
The full-sized cylinder with hygienic bin emptying
Sits on the stairs
Hygienic bin emptying
Lower profile contact head
Doesnʼt lose suction and captures
more microscopic dust
Combines Cyclone technology
with a core separator an extra
cyclonic stage between the outer and
inner cyclones to separate particles
as small as 0.5 micron from the
airflow.
TM
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.
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.
This is vital to avoid any possibility of
personal injury to the end user.
Insulation test points:
All variants
Motorhead variant
Test directly onto the motor through the
grille in the pre-filter housing.
Test the two screws in the wand cuff
cover.
Test the two screws in the stow neck
cover.
Test the front screw in the brushbar
motor cover lower.
Test the two screws highlighted in
the upper chassis.
The Seaward Primetest 200 (or equivalent) should
be used to test the electrical insulation of a Class
11 appliance; it indicates any electrical leakage.

Service manual
Technical info.
03
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.
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:
The vac motor.•
The cyclone inlet wiring loom.•
The wires underneath the brushbar motor•
cover lower.
The wires behind the stow neck cover.•
The wires behind the wand cuff cover.•
Plugging the powercord into a suitable electrical outlet and pressing the on/off actuator will always turn on
the vacuum and brushbar motor simultaneously. Pressing the brushbar actuator will turn the brushbar motor
off. Pressing the brushbar actuator whilst the brushbar motor is off will turn the brushbar motor on again.
Note: for safety purposes, if the product is unplugged from the electrical outlet without turning the product
off at the on/off actuator first, the brushbar will fail to turn upon plugging the product back into the
electrical outlet. To activate the brushbar it will be necessary to switch the product off and then on again at
the actuator.
The vacuum motor is fitted with a heat sensitive Thermal Cut-out (TCO). This will shut the motor down to up
to 60 minutes if it reaches a temperature >96 degrees. Excessive temperatures within the motor are usually
caused by machine/filter blockages.
The brushbar motor is protected by a current overload switch that turns off power to the brushbar motor if
the brushbar is obstructed (usually caused by a blockage around the brushbar or within the brush housing).
The obstruction must be cleared and the motor reset by pressing the brushbar actuator. If the cause of the
obstruction is not cleared the overload switch will continually activate.
For added protection the underside of the power floor tool assembly neck contains a stow microswitch that
is activated when the floor tool is stowed (stored) on the rear of the product. When activated the brushbar
motor will not operate.
Electrical overview

Technical info.
Service manual
04
Wiring schematic Motorhead variant
Cable reel
Vac motor
To the wand
To the main body
Socket
To the cleaner head
Cleaner Head
Power Wand Hose Assembly
1MΩ
BB
microswitch
Stow
microswitch
470KΩ
M/C
J4 5
J5
PCB
4
3
2 1
J2
J3
J1
ON / OFF
L
NN
L
LL
L
L
S
N
L
L
L
L
L
S
S
SS
N
N
N
N
14
11
12
13
18
15
16
17 20 23
24
25
21
22
26
27
28
19
3
7
8
910
6
5
4
1
2
29
30
31
32 33
34 35
36 37 BB
motor
Wire colours may vary between territories

Service manual
Technical info.
Electrical fault diagnostic - Motorhead variant
05
6. Carry out a resistance test across the brushbar microswitch (points 34-35).
7. Carry out a resistance test across the Neutral wire within the power floor tool (points 29-37).
8. Carry out a resistance test across the Live wire within the power floor tool (points 30-36).
9. Carry out a visual inspection of the brushbar motor (commutator, brushes, windings etc.).
10. Carry out a resistance test across the brushes on the brushbar motor.
If no faults are found replace the PCB assembly.
Unable to turn the brushbar motor on or off using the brushbar switch
1. Check for a loose connection onto the brushbar microswitch (points 34 & 35).
2. Check the mechanical actuation of the brushbar actuator and the brushbar switch.
If no faults are found replace the PCB assembly.
Brushbar motor operating whilst power floor tool is in stowed position
1. Check for a loose connection onto the stow microswitch (points 32 & 33).
2. Check the mechanical actuation of the stow microswitch cam and stow microswitch.
3. Carry out a resistance test from the PCB assembly to the end of the power wand/hose assembly
(points 11-27, 12-28 & 13-26).
If no faults are found replace the PCB assembly.
Note: check ‘points’ refer to the wiring schematic on page 4.
No power to either motor
1. Check for damage/electrical failure to the plug and powercord.
2. Carry out a resistance test across the fuse (UK only).
3. Check the mechanical actuation of the on/off switch.
4. Check for a loose connection at points 1-6.
5. Carry out a resistance test on the cable rewind assembly (Live pin on the plug to point 1, and neutral pin
on the plug to point 2) and across the on/off switch (points 4-6).
If no faults are found replace the PCB assembly.
No power to the vacuum motor (brushbar motor operates)
1. Check for a loose connection at points 7-10.
2. Carry out a resistance test between points 7-9 and 8-10 (the wires from the PCB assembly to the vacuum
motor).
3. Carry out a visual inspection of the vacuum motor (commutator, brushes, windings etc.).
4. Carry out a resistance test across the vacuum motor.
If no faults are found replace the PCB assembly.
No power to the brushbar motor (vacuum motor operates)
1. Check for a loose connection between points 11-37.
2. Carry out a resistance test of the Live wire from the PCB assembly to the end of the power wand/hose
assembly (11-27).
3. Carry out a resistance test of the Switch wire from the PCB assembly to the end of the power wand/hose
assembly (12-28).
4. Carry out a resistance test of the Neutral wire from the PCB assembly to the end of the power wand/hose
assembly (13-26).
5. Check the mechanical actuation of the stow microswitch and cam and the brushbar microswitch.

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.
Female terminal clips used in DC23 contain a locking
mechanism. The release pip will need to be activated
before separation from the male terminal can occur.
Protective safety goggles and gloves must be worn when
applying glue.
All screws used in DC23 are Torx T15 unless otherwise
stated.
Cable rewind replacment - removal
Recommended tools to repair DC23:
Torx T-10 and T-15 screwdrivers
Philips screwdriver
Large flat bladed screwdriver
Terminal screwdriver
Long/needle nosed pliers
06
01 Press the cyclone release catch
to remove the cyclone and bin
assemblies from the front of the
product.
Wire colours may vary between territories.

Service manual
Fitting notes
07
02 Push the hose bracket release
catch to remove the hose and
wand assemblies from the front
of the product.
03 Press the release catch on the
cyclone inlet to release the hose
and wand assemblies from the
product.
04 Lever the wheel next to the cable
rewind firmly off the product using
a large flat bladed screwdriver.
Motorhead variant only

Fitting notes
Service manual
08
05 Undo the two screws in the side of
the product.
06 Undo the five screws in the upper
chassis.
07 Lift off the upper chassis.

Service manual
Fitting notes
09
08 Slide the cyclone inlet off the
upper chassis.*
09 Disconnect the two wires from the
switch.
10 Remove the switch actuator and
spring from the switch housing.*
*Not necessary if replacing the cable rewind only.

Fitting notes
Service manual
10
11 Remove the switch from the switch
housing.*
12 Remove the screw in the switch
housing.
13 Remove the switch housing from
the product.
*Not necessary if replacing the cable rewind only.

Service manual
Fitting notes
11
16 Remove the cable rewind
assembly from the main body.
15 Slide a large flat bladed
screwdriver down the channel
between the cable rewind
assembly and the main chassis to
activate the cable rewind release
clip.
14 If the PCB assembly needs
replacing, carefully detach all
wires from it and remove it from
the product.
Motorhead variant only

Fitting notes
Service manual
12
17 Release the motor wire from the
cable rewind assembly.
18 Unclip the cable rewind actuator
from the product.
19 Slide the cable rewind actuator
and spring out of the upper
chassis.

Service manual
Fitting notes
13
20 Remove the cable guard screw.
21 Insert a Torx T15 screwdriver into
the detail at the bottom of the
cable rewind actuator housing
and lever down to release the
cable guard from the upper
chassis.
22 Release the cable from the upper
chassis.

Fitting notes
Service manual
23 Locate the cable into the cable
rewind housing.
24 Locate the cable guard onto the
detail on the rear of the upper
chassis.
25 Press the cable guard onto the
upper chassis.
Fit the screw on the underside.
14
Cable rewind replacement - fitting

Service manual
Fitting notes
15
26 Locate the cable rewind actuator
and spring into the upper chassis.
28 Dress the wires neatly within the
clips on the cable rewind holder.
27 Attach the motor wire onto the
cable rewind.

Fitting notes
Service manual
16
29 Lower the cable rewind into the
side of the product ensuring the
release mechanism locates within
the channel.
30 Ensure any wires are located
under the detail on the top of the
cable rewind holder.
31 Dress all wires neatly within the
channels provided.

Service manual
Fitting notes
17
33 Lower the switch housing onto the
detail on the side of the chassis
ensuring the wires are retained
within the detail on the front of the
housing.
Fit the screw in the front of the
switch housing.
34 If previously removed locate the
switch into the top of the switch
housing.
32 If previously removed, locate the
PCB assembly onto the product.
Carefully connect all wires.
Motorhead variant only