Steam Generator

GC9540

Philips Consumer Lifestyle

Service Manual
PRODUCT INFORMATION EMF & Service Information
Fast & powerful crease removal - This product meets the requirements regarding interference
- Soleplate: SteamGlide suppression on radio & TV.
- OptimalTemp - After the product has been repaired, it should function
- Continiuous steam output: 120 g/min properly & has to meet the safety requirements as officially
- Steam boost: 290 g/min laid down at this moment.
- Vertical steam
TECHNICAL INFORMATION
- Steam pressure: Up to 6.0 bar
Voltage : 220 - 240 V
- Steam tip
Frequency : 50 - 60 Hz
- Power: 2400 W
Power - Iron : 800 W at 230 V
Easy to use - Boiler : 1370 W at 230 V
- Water tank capacity: 1500 ml Product Dimensions : 28.3 x 26.3 x 42.4 cm
- Filling and emptying water: Detachable water tank Weight : Weight of iron: 1.2 kg
Extra large opening door Weight of iron + base: 5.4 kg
- Refill any time
Optimal Temp technology
- Heat-up time: 2 min
- Delivers always perfect combination of steam and
- Auto Off
temperature
- Hose storage: Hose storage compartment
- 100% easy to use, no adjustment required
- Cord storage: Cord storage compartment
- 100% safe on all ironable garments
- Power cord lenght: 1.8 m
- 100% effective on all fabrics, no other iron is faster
- Cord freedom (swivel): 180 degree cord freedom
- Tested and approved by independent textile experts
- Hose length: 1.7 m
1
- Safe for all fabrics: Even for delicates like silks Always the perfect setting thanks to:
- Carry Lock 1 - Cylonic ste am chamber
2
Sustainability 2 - Advanced Smart control processor
- ECO setting: 20% energy reduction Easy De-calc
Calc management Easy De-calc cap allows hassle free & effective scale removal
to extend the life of the steam generator.
- Suitable for tap water
- Calc clean solution: Easy De-calc Carry Lock
Lock your iron securely & carry your appliance easy.

Published by Philips Consumer Lifestyle Printed in the Netherlands © Copyright reserved Subject to modification

12/01
DISASSEMBLY ADVICE - IRON
GC9540
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

2-12
PARTS LIST - IRON
GC9540
Pos Service code Description
1 4239 021 66252 Soleplate mounted assy 230 V / 800 W
2 4239 021 61471 Thermistor assy Iron
3 4239 021 61523 Deviator assy
4 4239 015 59151 Braided rubber hose iron
5 4239 010 11991 Hose clip (ID=8.7)
6 4239 010 10281 Hose clip-Braided rubber hose
7 4239 015 70153 Ryton ring
8 4239 021 67421 Cover SOS spray painted
9 4239 021 67433 Housing & Lens assy printed
10 4239 021 61772 Light Guide assy
11 4239 021 67452 Deco_Plate & Top Cover assy Printed
12 4239 021 61561 Micro-switch assy
13 4239 021 67471 SOS knob sprayed painted
14 4239 026 42481 SOS lever molded
15 4239 021 67481 Hose cord mounted assy SOS
16 4239 021 67501 Backplate assy
17 4239 021 67511 Inlay spray painted
18 4239 026 42521 SOS knob cover
19 4239 026 47631 Trigger molded
20 4239 014 54961 Trigger spring
21 4239 026 42551 Backplate screw cap

3-12
EXPLODED VIEW - IRON
GC9540

18

13
D E
Micro Switch holder

17 12
A1

11 21
20
B2
14

19 B1
C2
F C1 16

Cord clamp
9

10

G1
G2
H2
H1

H3

8 15

J2 J1
J3
5

J4
3 J5
J6 4

Rubber gasket 2

4-12
DISASSEMBLY ADVICE - STAND
GC9540
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

FLOATING PLATFORM
ASSY 61

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
Remove Screws X1 - X4
Disassemble PLASTIC CAP MOLDED 62
Disassemble FLOATING PLATFORM ASSY 61

5-12
PARTS LIST - STAND
GC9540
Pos Service code Description
30 4239 021 68322 Stand bottom assy
31 4239 021 68311 Pump assy
32 4239 026 42081 De-air valve
33 4239 015 59201 Braided rubber hose boiler
34 4239 010 10261 Inox clamp
35 4239 026 32181 Spacer Bottom molded
36 4239 021 68331 Boiler assy
37 4239 017 12802 Electrovalve
38 4239 021 61812 Thermistor assy Boiler
39 4239 021 68341 Rinse Housing Printed
40 4239 026 31641 Spacer top molded
41 4239 026 42581 Boiler support bracket molded
42 4239 026 47671 Power cord storage molded
43 4239 021 67521 Hose cord storage compartment assy
44 2422 070 98358 Cord set EU
2422 070 98381 Cord set Australia
45 4239 021 67532 Stand top printed
46 4239 026 44771 Tank Catch molded
47 4239 014 54982 Tank Catch Spring
48 4239 021 63562 Inlet coupling plate welded
49 4239 026 44801 De-air coupling molded
50 4239 021 67543 Display cover printed assy
51 4239 021 67561 Button panel assy
52 4239 021 67591 Front lock assy
53 4239 021 68442 Tray assy
54 4239 015 59221 Tray rubber cap
55 4239 015 59531 Rinse Rubber Bush
56 4239 021 67611 Rinse cap assy
57 4239 015 58201 O-ring
58 4239 021 67631 Water tank printed assy
59 4239 021 61723 Hall sensor PCBA assy
60 4239 021 68572 Power Board PCB assy
61 4239 021 68812 Floating platform assy
62 4239 026 47651 Plastic cap molded

6-12
EXPLODED VIEW - STAND
GC9540
L1
L2
52 K1
47 K2
54
58
53
46
49

L3
L4
M 50
48
P1 P2

45

P3

43 42
Q2

37 S1
Q1 T2
S2
40 T1

36
32 51
33
U
34
31
60
62 X4 35 S3
X3 59 41 38
X2 X1 Cord
clamp

55
R1 R2
61 56

39
57
30

N4 N1 44
N2
N3
7-12
ELECTRICAL BLOCK DIAGRAM
GC9540

Thermistor

Stand Electronics
L
UI Board
L Trigger
L Switch
N
N
E N
E Power Board

Iron Thermal
Hall Sensor LED Thermistor Fuse
Board

Thermal Iron
M Fuse Heating
Element

Pump Steam
Boiler Heating
E-valve
Element E

STAND IRON

8-12
WIRING DIAGRAM
GC9540

#1
THERMAL
PUMP FUSE (L)
sF sF
#2 #1

WA19 : HE-Fuse (L)

#2 M M #1

sF
F F

#2
THERM-BOILER

THERMAL
FUSE (N)

#1
sF
WA20 : HE-Fuse (N)

#2

WA3 : EARTH WIRE_BOILER

WA2 : PCB-Pump (ctrl)
WA1 : PCB-Pump (L)

WA6 : PCB-Fuse (N)

WA5 : PCB-Fuse (L)
WA7 : PCB-EV (ctrl)

WA4 : PCB-EV (L)

UI
BOARD
#1 M
F
M EVALVE-EARTH
H
#2 M
F
7x

F sF V
2 2x
9013 (Live)

9016 (Pump-Control)

9015 (Evalve-Control)

9014 (Live)

9003 (Boiler-L)

9009 (Boiler-N)

9006 (To UI)

9007
1

3 HALL
3x
9012 2 SENSOR
1 BOARD
3
POWER BOARD (3.96 mm) 2
9017
1
sM
mF
9002 (Neutral)

9018 (Iron LED)

THERMISTOR
9001 (Live)

sPB
sF
NEUTRAL
TRIGGER
sF

9004 (Iron Live)

sF sF

HOSCORD

IRON
FLEX ASSY

LEGEND:
sF

Female Push-on 4.8 x 0.8 mm L-shape Connector Sleeve - Fiber Glass

mF

Female Push-on 5.2 x 0.8 mm L-shape Connector Insulated Tab - Silicon Rubber

sM Male Tab Terminal 4.8 x 0.8 mm Ring Terminal M4.3

F

Female Push-on L-shape Connector 6.35 x 0.8 mm Splice 6.0 mm

F Female Push-on Connector 6.35 x 0.8 mm Directly soldered on PCB

M Male Tab Terminal 6.35 x 0.8 mm H 7-pin Board-in Connector 2 mm (horizontal)

sPB Piggy Back Push-on Connector 4.8 x 0.8 mm V 7-pin Connector 2 mm (vertical)

9-12
REPAIR INSTRUCTIONS
GC9540
- 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 below 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-
Minimum Maximum point

=
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.

10-12
REPAIR INSTRUCTIONS
GC9540
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.

Inox clamp Crimping tool

Knipex Crimping tool

3.5 mm 1 - 2 mm
(max)
2.7 mm
(max)

Direct crimp form Fold in crimp Distance from edge of

crimp to rubber hose

CAUTION: When crimping on plastic part like DE-AIR VALVE, avoid over crimping which may lead to plastic part crack.

11-12
REPAIR INSTRUCTIONS
GC9540
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.

Contact area for torque

wrench to screw/unscrew
the electrovalve.

CAUTION #2: Ensure torque wrench jaw does not contact the solenoid body.

Torque wrench

Maintain gap between Electro-valve

the torque wrench and solenoid body
the solenoid body

12-12