Philips GC9240 User manual

ServiceManual
Philips Consumer Lifestyle
Published by Philips Consumer Lifestyle Printed in the Netherlands © Copyright reserved Subject to modification
Steam Generator
GC9240
11/10
PRODUCT INFORMATION
Fast & powerful crease removal
- Soleplate: SteamGlide
- OptimalTemp
- Continiuous steam output: 120 g/min
- Steam boost: 260 g/min
- Vertical steam
- Steam pressure: Up to 6.0 bar
- Steam tip
- Power: 2400 W
Easy to use
- Water tank capacity: 1500 ml
- Filling and emptying water: Detachable water tank
Extra large opening door
- Refill any time
- Heat-up time: 2 min
- Auto Off
- Hose storage: Hose storage compartment
- Cord storage: Cord storage compartment
- Power cord lenght: 1.8 m
- Cord freedom (swivel): 180 degree cord freedom
- Hose length: 1.7 m
- Safe for all fabrics: Even for delicates like silks
- Carry Lock
Calc management
- Suitable for tap water
- Calc clean solution: Easy De-calc
- Calc clean reminder
EMF & Service Information
- This product meets the requirements regarding interference
suppression on radio & TV.
- After the product has been repaired, it should function
properly & has to meet the safety requirements as officially
laid down at this moment.
TECHNICAL INFORMATION
Voltage : 220 - 240 V
Frequency : 50 - 60 Hz
Power - Iron : 800 W at 230 V
- Boiler : 1370 W at 230 V
Dimension (F-box) : 491 mm x 305 mm x 335 mm
(Depth x Width x Height)
Weight : Weight of iron: 1.2 kg
Weight of iron + base: 5 kg
Optimal Temp technology
- Delivers always perfect combination of steam and temperature
- 100% easy to use, no adjustment required
- 100% safe on all ironable garments
- 100% effective on all fabrics, no other iron is faster
- Tested and approved by independent textile experts
Always the perfect setting thanks to:
1 - Cylonic steam chamber
2 - Advanced Smart control processor
Easy De-calc
Easy De-calc cap allows hassle free & effective scale removal
to extend the life of the steam generator.
Carry Lock
Lock your iron securely & carry your appliance easy.
1
2

GC9240
2-12
BACKPLATE ASSY 16
SOS KNOB 13
INLAY MOLDED 17
MICRO-SWITCH ASSY 12
HOSE CORD MOUNTED
ASSY SOS 15
HOUSING & LENS
ASSY PRINTED 9
LIGHT GUIDE ASSY 10
COVER MOLDED SOS 8
DEVIATOR ASSY 3
SOLEPLATE MOUNTED
ASSY 1
Remove Screw A
Disassemble BACKPLATE SCREW PLATE 21
Remove Screws B1, B2
Disassemble BACKPLATE ASSY 16
Remove Screws C1, C2
Remove Cord clamp
Disassemble SOS KNOB COVER 18
Tip for disassembling SOS KNOB COVER 18:
Carefully insert a sharp object into the gap at the side & slowly
lift up the part
Disassemble SOS KNOB 13
Remove Screw D
Disassemble INLAY MOLDED 17
Remove Screw E
Disassemble MICRO-SWITCH ASSY 12
Remove Screw F
Disassemble HOUSING & LENS ASSY PRINTED 9
Remove Screws G1, G2
Disassemble LIGHT GUIDE ASSY 10
Remove Screws H1 - H3
Disassemble COVER MOLDED SOS 8
Remove Screws J1 - J6
Disassemble DEVIATOR ASSY 3
DISASSEMBLY ADVICE - IRON

GC9240
3-12
PARTS LIST - IRON
Pos Service code Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
4239 021 61371
4239 021 61471
4239 021 61523
4239 015 59151
4239 010 11991
4239 010 10281
4239 015 70153
4239 026 42411
4239 021 65521
4239 021 61771
4239 021 64361
4239 021 61561
4239 021 65531
4239 026 42481
4239 021 61572
4239 021 61881
4239 026 42511
4239 026 42521
4239 026 42531
4239 014 54961
4239 026 42551
Soleplate mounted assy 230 V / 800 W
Thermistor assy Iron
Deviator assy
Braided rubber hose iron
Hose clip (ID=8.7)
Hose clip-Braided rubber hose
Ryton ring
Cover molded SOS
Housing & Lens assy printed
Light Guide Assy
Deco_Plate & top Cover assy printed
Micro-switch assy
SOS knob sprayed painted
SOS lever molded
Hose cord mounted assy SOS
Backplate assy
Inlay molded
SOS knob cover
Trigger molded (Sky Blue)
Trigger spring
Backplate screw cap (Chalk White)

GC9240
4-12
EXPLODED VIEW - IRON
18
13
17
14
20
19
9
8
3
1
Rubber gasket
21
5
11
12
Micro Switch holder
Cord clamp
2
6
4
7
DE
F
H2
G1 G2
C1
B2
B1
A1
C2
H1
H3
J2
J6 J5
J4
J1
J3
15
10
16

GC9240
5-12
DISASSEMBLY ADVICE - STAND
WATER TANK PRINTED
ASSY 58
TRAY MOLDED 53
DISPLAY COVER PRINTED
ASSY 50
STAND TOP MOLDED 45
POWER CORD STORAGE
MOLDED 42
HOSE CORD STORAGE
COMPARTMENT ASSY 43
RINSE CAP ASSY 56
RINSE HOUSING
PRINTED 39
BOILER ASSY 36
BUTTON PANEL ASSY 51
POWER BOARD PCB
ASSY 60
Remove WATER TANK PRINTED ASSY 58
Remove TRAY RUBBER CAP 54
Remove Screws K1, K2
Disassemble TRAY MOLDED 53
Remove Screws L1 - L4
Remove Screw M
Remove Screws N1 - N4
Disassemble DISPLAY COVER PRINTED ASSY 50
Remove Screws P1 – P3
Disassemble STAND TOP MOLDED 45
Remove Screws Q1, Q2
Disassemble POWER CORD STORAGE MOLDED 42
Disassemble HOSE CORD STORAGE COMPARTMENT
ASSY 43
Remove RINSE CAP ASSY 56
Remove Screws R1, R2
Disassemble RINSE HOUSING PRINTED 39
Remove Screws S1, S2, S3
Disassemble BOILER SUPPORT BRACKET MOLDED 41
Disassemble BOILER ASSY 36
Remove Screws T1, T2
Disassemble BUTTON PANEL ASSY 51
Remove Screw U
Disassemble POWER BOARD PCB ASSY 60

GC9240
6-12
PARTS LIST - STAND
Pos Service code Description
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
4239 021 61591
4239 021 61601
4239 026 42081
4239 015 59201
4239 010 10261
4239 026 32181
4239 021 61611
4239 017 10902
4239 021 61812
4239 021 65541
4239 026 31641
4239 026 42581
4239 026 42591
4239 021 61621
4239 000 11371
4239 000 11721
4239 026 42621
4239 026 42631
4239 014 54982
4239 021 61751
4239 026 42651
4239 021 65761
4239 021 61801
4239 021 61661
4239 026 42741
4239 015 59221
4239 015 59231
4239 021 61671
4239 015 58201
4239 021 63771
4239 021 61721
4239 021 61652
Stand bottom assy
Pump assy
De-air valve
Braided rubber hose boiler
Inox clamp
Spacer Bottom molded
Boiler assy
Electrovalve
Thermistor assy Boiler
Rinse Housing printed
Spacer top molded
Boiler support bracket molded
Power cord storage molded
Hose cord storage compartment assy
Cord set EU
Cord set Australia
Stand top molded
Tank Catch molded
Tank Catch Spring
Inlet coupling plate welded
De-air coupling molded
Display cover printed assy
Button panel assy
Front lock assy
Tray molded
Tray rubber cap
Rinse Rubber Bush
Rinse cap assy
O-ring
Water tank printed assy
Hall sensor PCBA assy
Power Board PCB assy
= changed

GC9240
7-12
EXPLODED VIEW - STAND
58
46
35
37
49
48
45
43
31
59
30
32
52
53
42
40
36
41
39
56
57
60
38
34
33
44
55
54
47
L1
L2
L3
P2
K2
K1
P3
P1 M
Q2
Q1
S1
T2
T1
U
R2
R1
N1
N2
N4
N3
S3
S2
L4
50
51
Cord
clamp

GC9240
8-12
ELECTRICAL BLOCK DIAGRAM
Iron
LED
STAND IRON
Power Board
L
L
Stand Electronics
Hall Sensor
Board
UI Board
Thermistor
Pump Steam
E-valve Boiler Heating
Element
Thermal
Fuse
M
N
N
N
L
E
E
E
Thermistor
Trigger
Switch
Iron
Heating
Element
Thermal
Fuse

GC9240
9-12
WIRING DIAGRAM
LEGEND:
Female Push-on 4.8 x 0.8 mm L-shape Connector
Female Push-on 5.2 x 0.8 mm L-shape Connector
Male Tab Terminal 4.8 x 0.8 mm
Female Push-on L-shape Connector 6.35 x 0.8 mm
Piggy Back Push-on Connector 4.8 x 0.8 mm
Male Tab Terminal 6.35 x 0.8 mm
Female Push-on Connector 6.35 x 0.8 mm
Sleeve - Fiber Glass
Insulated Tab - Silicon Rubber
Ring Terminal M4.3
Splice 6.0 mm
Directly soldered on PCB
7-pin Board-in Connector 2 mm (horizontal)
7-pin Connector 2 mm (vertical)
POWER BOARD
HALL
SENSOR
BOARD
HOSCORD
FLEX ASSY IRON
UI
BOARD
9013 (Live)
9016 (Pump-Control)
9015 (Evalve-Control)
THERMAL
FUSE (L)
THERMISTOR TRIGGER NEUTRAL
9014 (Live)
WA1 : PCB-Pump (L)
WA2 : PCB-Pump (ctrl)
WA7 : PCB-EV (ctrl)
WA4 : PCB-EV (L)
WA5 : PCB-Fuse (L)
WA19 : HE-Fuse (L)
WA6 : PCB-Fuse (N)
9003 (Boiler-L)
3
2
1
3
2
1
2
1
9009 (Boiler-N)
9001 (Live) 9002 (Neutral)
9018 (Iron LED)
9007
9004 (Iron Live)
9006 (To UI)
PUMP
EVALVE-EARTH
7x
2x
3x
H
VsF
sFsF
F
sF mF
mF sF
sF
sF
sPB sM
sM
F
M
sF
F
F
MM#1
#1
#2
#1
#1
#2
#2
THERMAL
FUSE (N)
sFsF
#2#1
#2
F
F
F
H
V
M
M
M
WA20 : HE-Fuse (N)
WA3 : EARTH WIRE_BOILER
THERM-BOILER
sPB
9012
(3.96 mm)
9017

GC9240
10-12
REPAIR INSTRUCTIONS
- Due to the high wattage of the iron, only the specified cord set must be used.
- Should damage be observed on the HOSE CORD MOUNTED ASSY 15 or CORD SET 44, they must be replaced.
Continued usage is not allowed.
- When replacing the MICROSWITCH ASSY 12, please dress the 2 attached wires such that they are free of tension. Pulling force
on the wires may affect the steam triggering.
- To avoid damage to the sealing & components of the BOILER ASSY 36, NEVER clean the boiler assy with vinegar, descaling
agent or other corrosive chemicals.
- When replacing ELECTROVALVE 37 or PUMP ASSY 31, please be reminded to apply loctite at the joints for good sealing.
- After the product has been repaired, it should function properly and has to meet the safety requirements & legal regulations as
laid down & officially established at this moment.
- The following tests are common checks that are conducted on a repaired product before it is returned to the consumer.
1. Soleplate temperature
Check that soleplate temperature is within IEC requirement.
Measure the temperature of the soleplate after the iron has reached steady state i.e connected to the mains for at least 15 minutes.
The table below shows the temperature requirement.
Marking
Soleplate temperature (Deg C)
Material, for example
Test-
point
==
Minimum Maximum Nominal + Tolerance
•(1 dot) 70 120 95 ± 25 Acetate, elastane, polyamide, polyproylene
•• (2 dots) 100 160 130 ± 30 Cupro, polyester, silk, triacetate, viscose, wool
••• (3 dots) 140 210 175 ± 35 Cotton, linen
2. Leakage current
Check that leakage current is within IEC requirement.
Measure leakage current between LIVE/NEUTRAL & EARTH.
IEC requirement is that at 230 V supply, the EARTH leakage current must be less than 0.75 mA.
3. Water leakage / Functionality
Check that there is no water leakage from any part of the product during operation.
Check that the functionality of the product (product dependent) eg. steaming, variable steam, SOS, ASO etc is working properly.
4. Loose part
Check that there are no loose parts eg. extra screw in the product that can cause short-circuit or product malfunction.

GC9240
11-12
REPAIR INSTRUCTIONS
5. Crimping INOX CLAMP 34
When exchanging BOILER ASSY 36 or DE-AIR VALVE 32 or BRAIDED RUBBER HOSE BOILER 33, it is necessary to
replace the INOX CLAMP 34. Below instructions ensure that the inox clamp is crimped correctly.
CAUTION: When crimping on plastic part like DE-AIR VALVE, avoid over crimping which may lead to plastic part crack.
Inox clamp Crimping tool
Knipex Crimping tool
2.7 mm
(max)
1 - 2 mm
Distance from edge of
crimp to rubber hose
Fold in crimpDirect crimp form
3.5 mm
(max)

GC9240
12-12
REPAIR INSTRUCTIONS
6. Replacing ELECTROVALVE 37
To prevent damage to the electrovalve during service activity, please observe below precautions during disassembly & reassembly.
Tools required: Torque wrench (set to 6kgf)
CAUTION #1: The torque wrench engagement is allowed ONLY at the yellow box locations in below picture.
CAUTION #2: Ensure torque wrench jaw does not contact the solenoid body.
Contact area for torque
wrench to screw/unscrew
the electrovalve.
Torque wrench
Electro-valve
solenoid body
Maintain gap between
the torque wrench and
the solenoid body