Dyson DC22 Service Manual
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Dyson DC22 Service Manual

Dyson DC22 Service Manual

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Service manual
Issued Jan 08

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Summary of Contents for Dyson DC22

  • Page 1 Service manual Issued Jan 08...

  • Page 3: Table Of Contents

    Service manual This manual is written specifically for Dyson trained engineers and covers the full DC22 range. The service instructions assume the engineer has the approved tools and test equipment with them. Contents Page Features Electrical safety testing AC wiring schematic (models with finger tip controls only)

  • Page 4: Features

    Combined with Dyson’s latest innovation - the Fingertip controls core separator - it’s more efficient at removing microscopic dust than any other Operate the machine without bending down to reach cyclonic system.

  • Page 5: Electrical Safety Testing

    The Seaward Primetest 200 (or equivalent) prior to and upon completion of all should be used to test the electrical repairs to Dyson floorcare products and insulation of a Class 11 appliance; it before any functional checks. You must indicates any electrical leakage.

  • Page 6: Ac Wiring Schematic (Models With Finger Tip Controls Only)

    Service manual AC wiring schematic (models with finger tip controls only) Motor Motor/PCB Loom Assembly ON/OFF Switch Assembly Satellite Power Wand Assembly Hose Assembly 12 13 Brushbar Cable Rewind P1 P2 Jockey wheel Motorhead Brushbar Floor Tool Motor Assembly Antenna...

  • Page 7: Ac Electrical Fault Diagnostics (Models With Finger Tip Controls Only)

    Service manual AC electrical fault diagnostic (models with finger tip controls only) No power to either motor Check for damage/electrical failure to the plug and powercord. Check the resistance across the fuse (UK only). Check mechanical connection at points 1-8. Check the resistance between the live pin on the plug and point 1.

  • Page 8: Ddm Wiring Schematic

    Service manual DDM wiring schematic DDM Assembly Opto Switch/PCB Assembly Assembly Satellite Power Wand Assembly Hose Assembly 12 13 Cable Brushbar Rewind P1 P2 Jockey wheel Motorhead Brushbar Floor Tool Motor Assembly Antenna...

  • Page 9: Ddm Electrical Fault Diagnostics

    Service manual DDM electrical fault diagnostics No power to either motor (power LED off) Check for damage/electrical failure to the plug and powercord. Check the resistance across the fuse (UK only). Check mechanical connection at points 1-8. Check the resistance between the live pin on the plug and point 1. Check the resistance between the neutral pin on the plug and point 2.

  • Page 10: Ddm On-Board Diagnostics

    Service manual DDM on-board diagnostics DDM variants of DC22 also include the following on-board diagnostics: Green light: machine is healthy Red light: machine is blocked. The machine should be unplugged from the electrical outlet and checked for blockages. Once the blockage is cleared the machine should be plugged into the electrical outlet.

  • Page 11: Tuning (Finger Tip Controls Only)

    Service manual Tuning (finger tip control models only) After replacing the wand handle assembly, handle cover assembly or satellite assembly it is necessary to tune the relevant part with the corresponding part(s). Failure to tune the parts will result in the machine not turning on when using the fingertip controls on the wand handle assembly. The following sequence should be used to tune the product: 1.Plug the machine into the mains supply.

  • Page 12: General Notes

    Wire colours may vary depending on territory. All screws used in DC22 are Torx T15 unless otherwise stated. All female terminal clips used in DC22 contain a locking mechanism. The release pip will need to be activated before separation from the male terminal can occur.
  • Page 13 Service manual 02 Push the hose bracket release catch to remove the hose and wand assemblies from the front of the product. 03 Undo the screw below the cyclone release catch. 04 Slide the upper hose guide off the chassis.
  • Page 14 Service manual 05 Undo the screw in the parking yoke. 06 Remove the parking yoke from the chassis. 07 Undo the screw in front of the cable collar.
  • Page 15 Service manual 08 Pull the rear wheel and cap off the side of the product. 09 Undo the three screws in the cable rewind housing. 10 Unclip the cable rewind housing from the side of the product.
  • Page 16 Service manual 11 Remove the cable rewind housing from the side of the product. 12 Firmly press the catch to remove the cable collar from the cable rewind housing. 13 Open the cable collar and remove from the cable rewind.
  • Page 17 Service manual Models with finger tip controls only 14 Undo the short screw in the satellite assembly. Models with finger tip controls only 15 Force the cyclone inlet assembly to one side. Release the satellite assembly from the side of the product.
  • Page 18 Service manual 17 Release the cable rewind from the catch (catches on DDM products) on the side of the product. Models with finger tip controls only 18 Release the cable rewind fly leads from the retaining channels. Remove the cable rewind. Models without finger tip controls 19 Detach the live wire from the...
  • Page 19 Service manual Models without finger tip controls 20 Release the connection insulator from the side of the product. Open the insulator and detach the neutral wires. Remove the cable rewind.

  • Page 20: Cable Rewind Replacement - Fitting

    Service manual Cable rewind replacement - fitting 21 Ensure before fitting the cable rewind that the fly leads are twisted together and secured with electrical tape as shown. Models without finger tip controls 22 Ensure before fitting the cable rewind that the motor leads and ESD loom are neatly dressed within the channels as shown.
  • Page 21 Service manual Models without finger tip controls 23 Attach the neutral wire from the cable rewind to the neutral wire/ ESD loom from the motor. Enclose the connections in the connection insulator. Locate the connection insulator onto the side of the product.
  • Page 22 Service manual Models with finger tip controls only 25 Attach the cable rewind fly leads to the terminals on the PCB assembly EMC (left handside). Models with finger tip controls only 26 Dress the fly leads into the retaining channels. 27 Locate the ‘fin’...
  • Page 23 Service manual 28 Press the cable rewind down until it clips under the retaining catch/ catches. Models with finger tip controls only 29 Carefully locate the lower edge of the satellite assembly into the product. Models with finger tip controls only 30 Locate the top edge of the satellite assembly into the channel in the cyclone inlet assembly.
  • Page 24 Service manual 31 Locate the cable into the cable rewind housing. 32 Locate the cable rewind housing over the rewind and switch actuators. 33 Fit the cable rewind housing onto the side of the product. Fit the four screws.
  • Page 25 Service manual 34 Locate the top of the cable collar into the rear of the cable rewind housing. Firmly snap the bottom of the cable collar into place. 35 Place the wheel assembly onto the side of the product. Align the wheel cap lugs with the guide recesses on the product.
  • Page 26 Service manual 37 Slide the upper hose guide onto the chassis. Fit the screw. 38 Locate the hose bracket onto the front of the product. 39 Fit the cyclone and bin assembly onto the product.

  • Page 27: Switch & Ac Motor Replacement - Removal

    Service manual Switch & AC motor replacement - removal Before continuing the following parts should be removed as previosly shown: Cable rewind assembly (pages 9-16). Models with finger tip controls only 40 Carefully detach all wires from the satellite assembly. Place the satellite assembly to one side.
  • Page 28 Service manual 43 Lift the cyclone inlet assembly off the side of the product. Models with finger tip controls only 44 If the cyclone inlet assembly or PCB assembly EMC need replacing the parts should be separated by undoing the Torx T-8 screw.
  • Page 29 Service manual AC models only 46 Replace the necessary part/parts and fit in reverse order. Note: when fitted correctly the bleed valve cap should be flush with the outside of the inner cable housing assembly. 47 Release the switch actuator from the cable housing inner cover.* * Only necessary if replacing the switch.
  • Page 30 Service manual AC models only 48 Slide the switch out of the housing.* AC models with finger tip controls only 49 Carefully release the connectors from the switch terminals using a thin, flat bladed screwdriver.* DDM models only 50 Carefully detach the ribbon cable from the switch.* * Only necessary if replacing the switch.
  • Page 31 Service manual DDM models only 51 Push the switch/PCB assembly out of the housing.* 52 Carefully release the ESD loom. 53 Undo the fastener in the pre-filter door assembly. * Only necessary if replacing the switch.
  • Page 32 Service manual 54 Prise the pre-filter door assembly off the hinge points. 55 Remove the pre-filter assembly. AC models only 56 Undo the four Torx T-10 screws around the fancase seal retainer.
  • Page 33 Service manual AC models only 57 Firmly release the fancase seal retainer from the four retainers. AC models only 58 Remove the fancase seal. AC models only 59 Release the motor mount from the inner cable housing assembly.
  • Page 34 Service manual AC models only 60 Remove the motor from the chassis. AC models only 61 Remove the motor mount from the motor. AC models only 62 Release the loom grommet from the motor mount.
  • Page 35 Service manual AC models only 63 Carefully detach the loom from the motor terminals. AC models with finger tip controls only 64 Undo the two Torx T-20 screws and remove the loom from the side of the motor.

  • Page 36: Switch & Ac Motor Replacement - Fitting

    Service manual Switch & AC motor replacement - fitting 65 Attach the motor/PCB loom assembly bracket to the motor using the two Torx T-20 screws.* Attach the Live and Neutral wires to the motor. Note: the Neutral wire should sit behind the PCB.
  • Page 37 Service manual 68 Locate the motor mount onto the motor. The detail on the mount fits over the screw. 69 Feed the loom through the hole in the chassis. Force the motor past the retainers on the motor bucket. 70 The arrow on the motor mount should align with the screw boss on the chassis.
  • Page 38 Service manual 71 Locate the fancase seal under the motor bucket retainers and onto the motor. 72 Locate the fancase retainer onto the motor bucket. Fit the four Torx T-10 screws. DDM models only 73 Fit the pre-filter assembly (DDM models must be fitted with correct orientation).
  • Page 39 Service manual 74 Force the pre-filter cover hinges onto the lugs on the chassis. 75 Tighten the fastener. 76 Locate the ESD tab into the detail on the side of the chassis.
  • Page 40 Service manual Models without finger tip controls Models with finger tip controls 77 Locate the resistors into the retainers. Ensure the ESD wire is neatly dressed within the channel provided. AC models with finger tip controls only 78 Locate the Live and Neutral wires into the channels provided.
  • Page 41 Service manual AC models with finger tip controls only 79 Locate the ribbon cable into the channel provided. The ribbon cable must be folded as shown. AC models with finger tip controls only 80 Fold the end of the ribbon cable as shown.
  • Page 42 Service manual AC models with finger tip controls only 82 Dress the switch loom into the channels provided. DDM models only 83 If previously removed locate the switch/PCB assembly onto the housing (the hole in the board locates over the pip in the housing).
  • Page 43 Service manual 85 Lower the cyclone inlet assembly onto the side of the product. Ensure no wires/ribbon cables are caught under the assembly and are free to move. Models with finger tip controls only 86 Attach the motor wires to the PCB assembly EMC (right handside pins).
  • Page 44 Service manual 87 Attach all cables to the satellite assembly (models with finger tip controls only). Please note: when attaching cables to the satellite assembly it is possible to fit two of the cables incorrectly. It is essential to ensure all cables are attached to the correct connectors as shown below.

  • Page 45: Chassis, Satellite Assembly, Ddm Assembly Replacement - Dismantle

    Service manual Chassis, Satellite assembly, DDM assembly replacement - dismantle To replace the DDM assembly it is necessary to strip the product down as far as the chassis. This section therefore details how to replace a chassis on any model and ultimately how to replace the DDM assembly.
  • Page 46 Service manual 90 Remove the cable rewind actuator from the side of the chassis.* 91 Undo the two fasteners and remove the post filter soleplate assembly from the underside of the chassis. 92 Remove the post filter assembly. * Not necessary if replacing the DDM only.
  • Page 47 Service manual 93 Prise the castor wheel and axle out of the castor body.* 94 Prise the castor body off the base of the chassis.* 95 Undo the seven screws in the post filter housing. * Not necessary if replacing the DDM only.
  • Page 48 Service manual 96 Remove the post filter housing. 97 Carefully detch the antenna from the underside of the chassis. Remove the satellite assembly from the product. 98 Undo the screw in the exhaust vent.* * Not necessary if replacing the DDM only.
  • Page 49 Service manual 99 Remove the exhaust vent from the side of the chassis.* 100 Remove the 8 screws in the side of the chassis. 101 Remove the cable housing inner cover from the side of the chassis. * Not necessary if replacing the DDM only.
  • Page 50 Service manual 102 Remove the exhaust seal from the side of the chassis.* 103 Undo the five Torx T-10 screws in the side of the chassis. DDM models only 104 Release the DDM loom grommet from the side of the chassis. Remove the DDM assembly or AC motor bucket from the chassis.
  • Page 51 Service manual 105 Remove the motor bucket outer seal from the AC motor bucket or DDM assembly.

  • Page 52: Chassis, Satellite Assembly, Ddm Assembly Replacement - Assemble

    Service manual Chassis, Satellite assembly, DDM assembly replacement - assemble 106 Fit the motor bucket outer seal onto the top of the AC motor bucket or DDM assembly. AC models only 107 Ensure the cable grommet plug is fitted into the side of the chassis.
  • Page 53 Service manual AC models only 109 Lower the AC motor bucket into the chassis. The windows in the bucket should align with those in the chassis. Fit the five screws. DDM models only 110 Locate the wires from the DDM assembly through the slot in the chassis.
  • Page 54 Service manual 112 Fit the cable housing inner cover assembly onto the side of the chassis. Fit the eight screws. 113 If previously removed clip the exhaust vent onto the chassis. Fit the screw.
  • Page 55 Service manual 114 Locate the end of the satellite assembly antenna through the slot in the front of the chassis. Pull the antenna through and dress as shown above on the underside of the chassis. The antenna should be located into any retaining clips provided and held in place with electrical tape.
  • Page 56 Service manual 115 Lower the post filter housing onto the base of the chassis. Fit the seven screws. 116 If previously removed firmly press the castor body onto the base of the chassis. 117 Press the castor wheel and axle into the castor body.
  • Page 57 Service manual 118 Fit the post filter assembly into the underside of the chassis. Fit the post filter cover. Tighten the fasteners. 119 Lower the cyclone release catch and spring into the top of the chassis. Ensure the legs of the release catch are fully engaged into the hinge points of the chassis.
  • Page 58 Service manual 121 Apply several spots of glue around the manifold. Fit the manifold seal. DDM models only 122 All wires and cables should be dressed in all channels provided. Ensure the ribbon cable is neatly folded and the ends laid flat to avoid any possibility of damage from the cyclone inlet assembly.

  • Page 59: Sub-Assemblies - Bin Assembly

    Service manual Sub-assemblies - Bin assembly 123 The front bin catch can be removed from the bin assembly by gently prising off with a thin flat bladed screwdriver. 124 To fit, locate the spring onto the pip on the catch. Firmly press both parts onto the bin.
  • Page 60 Service manual 126 To fit a bin base assembly locate one of the legs on the assembly onto the hinge point on the bin. Once located firmly press the other leg into place. 127 The bin base seal and FDC/IDC seal can be replaced by firmly pulling out of the bin base assembly.

  • Page 61: Sub-Assemblies - Wand/Hose Assembly

    Service manual Sub-assemblies - Wand/Hose assembly Models with finger tip controls only 128 To replace the handle cover assembly or batteries undo the Philips screw and remove the handle. Models with finger tip controls only 129 When replacing the batteries ensure they are fitted correctly and aligned with the connections.
  • Page 62 Service manual 131 To fit, locate the spring onto the rear of the swivel catch. Firmly press the catch into the retainers on the hose or wand.

  • Page 63: Sub-Assemblies - Turbine/Motorhead Assembly

    Service manual Sub-assemblies - Turbine/Motorhead assembly 132 The soleplate wheels or axles can be removed by prising out from the brush housing. To fit press firmly into place. 133 The flicker strip can be replaced by prising the end out from the brush housing.
  • Page 64 Service manual 135 To fit, slide the flicker strip into the channel under the retaining catches. Clip the end under the retaining catch. 136 To replace the end cap or brushbar assembly, undo the endcap fastener. 137 Lift the endcap and brushbar assembly out of the brush housing.
  • Page 65 Service manual Turbine head only 138 To replace the brush housing, axial turbine assembly or belt cover assembly, prise the brush housing out with a screwdriver. Turbine head only 139 Remove the short screw from the inside of the axial turbine assembly.
  • Page 66 Service manual Turbine head only 141 Remove the axial turbine assembly from the side of the floortool. Turbine head only 142 Prise the belt cover assembly off the axial turbine assembly. Turbine head only 143 Ensure the seal is fitted adequately within the belt cover assembly before fitting onto the axial turbine assembly.
  • Page 67 Service manual Turbine head only 144 Press the belt cover assembly onto the axial turbine assembly. Locate the axial turbine assembly into the side of the floortool. Fit the two screws (short screw on the inside). Turbine head only 145 Locate the end of the brush housing assembly over the detail on the axial turbine assembly.
  • Page 68 Service manual 147 Locate the endcap assembly onto the brushbar assembly. 148 Lower the endcap assembly and brushbar assembly into the floortool. Tighten the fastener. Turbine head only 149 The hose can be replaced by firmly pulling out of the neck.
  • Page 69 Service manual Turbine head only 150 When fitting the hose note that there are locating tabs of different sizes on the hose. These must be aligned correctly with the neck.

  • Page 70: Main Body

    Service manual Main body Screw Upper Hose Wrap Cable Housing Inner Cover Assy On/Off Actuator Stow Cable Collar Cable Rewind Actuator Screw Spring Manifold Seal Spring Cyclone Release Catch On/Off Switch Spring Switch Loom Exhaust Vent Switch Loom Chassis Screw Cable Grommet Plug Cable Rewind Assy...

  • Page 71: Motor Assembly

    Service manual Motor assembly DC22 Motor (DDM) Wheel Hub Wheel Assy Pre-Filter Door Assy (DDM) Pre-Filter Door Side Cap Seal Pre-Filter Motor Base Cap Seal Pre-Filter Assy (DDM) DDM Motor Assy Motor Bucket Outer Seal (DDM) DC22 Motor (AC) Pre-Filter Door Assy (AC)

  • Page 72: Hose, Wand And Floor Tools

    Service manual Hose, wand and floor tools Handle Swivel Catch Cover Assy Battery Spring Wand Handle Assy Screw Power Wand Hose Assy Spring Screw Swivel Catch Lower Motorhead Hose Wrap Swivel Catch End Cap Spring Motorhead Lower Floor Tool Assy Hose Wrap Flicker Strip Hose Assy...

  • Page 73: Cyclone And Bin Assemblies

    Service manual Cyclone and bin assembly Spring Cyclone Assy Bin Seal Bin Catch Spring Bin Assy Bin Base Seal FDC/IDC Seal Bin Base Assy...

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