Philips PerfectCare Aqua GC8635 User manual

Published by Philips Consumer Lifestyle Printed in the Netherlands © Copyright reserved Subject to modification
ServiceManual
Philips Consumer Lifestyle
PerfectCare Aqua
GC8635
12/07
PRODUCT INFORMATION
Fast & powerful crease removal
• Soleplate: SteamGlide
• OptimalTemp
• Continuous steam output
• Continuous steam output: 120 g/min
• Steam boost: 220 g
• Vertical steam
• Steam pressure: Up to 5 bar
• Steam tip
• Power: 2400 W
Easy to use
• Water tank capacity: 2200 ml
• Filling and emptying water: Extra large filling hole
• Refill any time
• Heat-up time: 2 min
• Safety auto off
• Storage solution: Carry lock
• Hose storage: Hose storage compartment
• Power cord length: 1.8 m
• Hose length: 1.6 m
• Safe for all fabrics: Even for delicates like silks
• Low water alarm
Calc management
• Suitable for tap water
• Calc clean solution: Easy De-calc
• Calc clean reminder
Safety Information
• This product meets the requirements regarding
interference suppression on radio and TV.
• After the product has been repaired, it should function
properly and has to meet the safety requirements and
legal regulations as officially laid down at this moment.

GC8635
2-13
TECHNICAL INFORMATION
Voltage : 220 - 240 V
Frequency : 50 - 60 Hz
Power : 2400 W
Dimension (F-box) : 362 (D) x 270 (W) x 263 (H) mm
Weight of iron : 1 kg
Weight of iron + base : 4.5 kg
Water advice
Suitable for tap water use. Advice to mix with equal
portion of distilled water or use only distilled water if the
tap water is very hard.
Soleplate: Steam Glide
New SteamGlide soleplate is the best Philips soleplate. It
has great scratch resistancy, glides excellent and is easy to
clean.
OptimalTemp Technology
- Always deliver 1 perfect setting for all your clothes
thanks to:
1. Cylonic steam chamber
2. Advance Smart control processor
- 100% easy to use, no adjustment required.
- 100% safe on all delicate fabrics.
- 100% fast on the toughest fabrics.
Tested and approved by experts
Tested and approved by independent textile experts
institutes.
Steam pressure: Up to 5 bar
Double your ironing speed with pressurized steam.
2.2L fully visible water tank
Large water tank ensures long hours of ironing without
rell of water tank.
Lock your iron securely
Lock your iron securely and carry your steam generator
easily.
Easy De-Calc
Easy De-Calc, hassle free & effective scale removal to
extend the life of your steam generator.

GC8635
3-13
LIGHT STRIP CAP ASSY 1
INLAY AND LIGHT STRIP ASSY 2
REFLECTOR MOLDED 3
LED MICROSWITCH HOLDER ASSY 4
TRIGGER SPRING 5
TRIGGER MOLDED 6
MICA PLATE 7
PLASTIC WASHER (1x) 8 (FRONT)
DECORATION CAP PRINTED 9
Remove Screw A
Disassemble LIGHT STRIP 1
Fig 1. Using “-” screw driver to lift up the Inlay and release
the catch at the end of the handle.
Apply forces
Fig 2. Position of the catch to be applied forces
at the end of the handle.
Remove Screw B
Disassemble INLAY AND LIGHT STRIP ASSY 2
Disassemble REFLECTOR MOLDED 3
Remove Screw C
Disassemble LED MICROSWITCH HOLDER
ASSY 4
Disassemble TRIGGER SPRING 5
Disassemble TRIGGER MOLDED 6
Remove Screw D
Disassemble MICA PLATE 7
Disassemble PLASTIC WASHER (1x) 8
Remove Screw E1, E2
Remove Screw F
Disassemble DECORATION CAP PRINTED 9
RYTON RING 10
DEVIATOR HOUSING MOLDED 11
IRON THERMISTOR ASSY 12
PLSTIC WASHER (2x) 8 (REAR)
HOSE CORD MOUNTED ASSY 14
HOUSING PRINTED 15
SOLEPLATE MOUNTED ASSY 16
Remove Screw A
Disassemble LIGHT STRIP 1
Remove Screw B
Disassemble INLAY AND LIGHT STRIP ASSY 2
Disassemble REFLECTOR MOLDED 3
Remove Screw C
Remove Screw E1, E2
Remove Screw D
Disassemble MICA PLATE 7
Disassemble PLASTIC WASHER (1x) 8
Disassemble RYTON RING 10
Remove Screw G1, G2, G3, G4
Disassemble DEVIATOR HOUSING MOLDED 11
Remove Screw H
Disassemble IRON THERMISTOR ASSY 12
Remove Screw I1, I2
Disassemble PLASTIC WASHER (2x) 8
Disconnect Wires
Release Hose clip (2x)
Remove Screw J
Disconnect Wires
Disassemble HOSE CORD MOUNTED ASSY 14
Disassemble HOUSING PRINTED 15
Disassemble SOLEPLATE MOUNTED ASSY 16
DISASSEMBLY ADVICE - IRON

GC8635
4-13
PARTS LIST - IRON
Pos Service code Description
1
2
3
4
4239 021 70734
4239 021 70841
4239 026 49561
4239 021 71942
Light strip cap assy
Inlay and light strip assy
Reector molded
LED microswitch holder assy
5
6
7
8
4239 014 54961
4239 026 50372
4239 010 12911
4239 026 49501
Trigger spring
Trigger molded
Mica plate
Plastic washer
9
10
11
12
4239 021 70901
4239 015 70153
4239 026 49491
4239 021 69942
Decoration cap printed
Ryton ring
Deviator housing molded
Iron thermistor assy
14
15
16
4239 021 71992
4239 021 70692
4239 021 70651
Hose cord mounted assy
Housing printed
Soleplate mounted assy

GC8635
5-13
Rubber
bung
Rubber pad
4
9
15
14
1
2
6
3
5
8
12
8
7
10
16
8
11
B
C
A
F
I2
E1 E2
I1
G2
G1
G3
G4
H
D
EXPLODED VIEW - IRON

GC8635
6-13
FILLING DOOR MOLDED 17
REAR LOCK RUBBER 18
TRAY RUBBER CAP 19
TRAY CAP MOLDED 20
TRAY PRINTED 21
FRONT LOCK ASSY 22
WATER TANK ASSY 23
Disassemble FILLING DOOR MOLDED 17
Disassemble REAR LOCK RUBBER 18
Remove TRAY RUBBER CAP 19 (4x)
Remove Screw K1, K2, K3, K4
Remove TRAY CAP MOLDED 20 (2x)
Remove Screw L1, L2
Disassemble TRAY PRINTED 21
Remove Screw M1, M2
Disassemble FRONT LOCK ASSY 22
Remove Screw N1, N2, N3, N4, N5
Disassemble WATER TANK ASSY 23
RINSE CAP ASSY 24
SAFETY CAP 25
INOX CLAMP 26
BRAIDED RUBBER HOSE BOILER 27
ELECTROVALVE 28
SPACER TOP 29
RINSE HOUSING CAP PRINTED 30
RINSE HOUSING MOLDED 31
O-RING 32
BOILER ASSY 33
BOILER SUPPORT BRACKET 34
SPACER BOTTOM 35
BOILER THERMISTOR ASSY 36
Disassemble RINSE CAP ASSY 24
Remove Screw N1, N2, N3, N4, N5
Disassemble WATER TANK ASSY 23
Remove SAFETY CAP 25
Release INOX CLAMP 26 (2x)
Disassemble BRAIDED RUBBER HOSE BOILER 27
Release Hose clip
Disconnect Wires
Disassemble ELECTROVALVE 28
Remove Screw O1, O2
Remove Screw P
Remove SPACER TOP 29
Remove Screw Q
Disassemble RINSE HOUSING CAP PRINTED 30
Remove Screw R
Disassemble RINSE HOUSING MOLDED 31
Disassemble O-RING 32
Disassemble BOILER ASSY 33
Disassemble BOILER SUPPORT BRACKET 34
Remove SPACER BOTTOM 35
Disassemble BOILER THERMISTOR ASSY 36
DISASSEMBLY ADVICE - STAND

GC8635
7-13
POWER BUTTON PRINTED 37
BUTTON FRAME PRINTED 38
POWER BOARD PCB-PUMP
SERVICE KIT 39
POWER CORD EU 40
STAND BOTTOM MOLDED 41
Remove Screw N1, N2, N3, N4, N5
Disassemble WATER TANK ASSY 23
Remove Screw S1, S2, S3
Disassemble POWER BUTTON PRINTED 37
Disassemble BUTTON FRAME PRINTED 38
Remove Screw T
Release INOX CLAMP 26 (2x)
Disassemble BRAIDED RUBBER HOSE BOILER 27
Disconnect Wires
Disassemble POWER BOARD PCB-PUMP
SERVICE KIT 39
Remove Screw U1, U2
Disassemble Cord clamp
Disassemble POWER CORD EU 40
Disassemble STAND BOTTOM MOLDED 41
DISASSEMBLY ADVICE - STAND

GC8635
8-13
PARTS LIST - STAND
Pos Service code Description
17
18
19
20
21
4239 026 50134
4239 015 59741
4239 015 59731
4239 026 51841
4239 021 71512
Filling door molded
Rear lock rubber
Tray rubber cap
Tray cap molded
Tray printed
22
23
24
25
26
4239 021 71493
4239 021 71523
4239 021 70862
4239 015 59791
4239 010 10261
Front lock assy
Water tank assy
Rinse cap assy
Safety cap
Inox clamp
27
28
29
30
31
4239 015 59771
4239 017 12802
4239 026 51241
4239 021 72612
4239 026 49732
Braided rubber hose Boiler
Electrovalve
Spacer top
Rinse housing cap printed
Rinse housing molded
32
33
34
35
36
4239 015 59751
4239 021 69891
4239 026 42581
4239 026 32181
4239 021 69951
O-ring
Boiler assy
Boiler support bracket
Spacer bottom
Boiler thermistor assy
37
38
39
40
4239 021 70772
4239 021 70762
4239 022 67101
2422 070 98403
2422 070 98424
Power button printed
Button frame printed
Power board PCB-Pump service kit
Power Cord EU
Power Cord AU
41 4239 026 50112 Stand bottom molded

GC8635
9-13
21
19
18
17
22
20
23
L2
M1
M2
L1
K1
K2
K4
K3
EXPLODED VIEW - STAND

GC8635
10-13
39
41
27
38
37
34
30
24
31
32
40
26
36
N1
U1 U2
N2
N3
N4 N5
T
S1
S2
S3
28
29
25
35
33
O1
O2
PRQ
EXPLODED VIEW - STAND

GC8635
11-13
Pump
Boiler Heater
Earth Inter-
connection
Thermal Fuse
Thermal Fuse
PCBA
E-valve
Hosecord
(to Iron)
STAND
Flex
Boiler Earth
Point
Flex
Neutral
Iron
Live
Pump-EV-
Live
WA1 - PCB to
EV-Pump-Live
WA2 - PCB to
Pump-Ctrl
WA19 : HE (L)
- Fuse (L)
WA7 - PCB
to EV-Ctrl
WA20 : HE (N)
- Fuse (N)
WA6 : Fuse
(N) - PCB
WA5 : Fuse
(L) - PCB
Flex Live
Boiler Live
Iron
Neutral
Thermistor
Boiler
EV
Ctrl
Pump
Ctrl
Boiler
Neutral
Comms
Thermistor
WA3 : Earth
Wire_Boiler
WIRING DIAGRAM STAND

GC8635
12-13
Thermal
Fuse
Mid-air crimp
connection
Hosecord
(to Stand)
IRON
JST eSL 3-way
wite-to-wire
connector
Trigger
micro-switch
Iron Earth
Point
Iron
Thermistor
Iron Heater
LED
WIRING DIAGRAM IRON

GC8635
13-13
• Due to the high wattage of the iron, only the specified cord set must be used.
• Should damage be observed on the HOSE-CORD ASSY 14 or CORDSET 40, they must be replaced.
Continued usage is not allowed.
• When replacing the MICROSWITCH ASSY 4, 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 33, NEVER clean the boiler assy with vinegar,
descaling agent or other corrosive chemicals.
• When replacing ELECTROVALVE 28 or PUMP ASSY 39, 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.
Soleplate temperature (Deg C)
Materials, for example
Test-
point
==
Minimum Maximum
120 143 All fabric types
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.
REPAIR INSTRUCTIONS