7 Kg Washing Machine (UK production 2004)

Transcription

1 7 Kg Washing Machine (UK production 004) GB 04--8/0-6

2 Index SAFETY NOTES AND GENERAL SERVICING ADVICE MANUFACTURING DATE CODE CHART 5 SPECIFICATIONS 6 4 CONTROL PANEL DISPLAY, CONTROLS AND PROGRAMMES 7 4. Controls 7 4. Automatic Features 0 5 WASHCODES 5. Dispenser Drawer 6 WIRING DIAGRAM, LEGEND AND CONNECTION DETAILS 7 AUTO TEST SETUP 9 7. Test setup and Indications 9 7. Test sequence 0 8 ERROR CODES AND POSSIBLE CAUSES 9 THREE PHASE MOTOR 0 DISMANTLING INSTRUCTIONS 4 GB 04--8/0-6

3 SAFETY NOTES AND GENERAL SERVICING ADVICE. This manual is NOT intended as a comprehensive repair/maintenance guide to the appliance.. It should ONLY be used by suitably qualified persons having technical competence applicable product knowledge and suitable tools and test equipment.. Servicing of electrical appliances must be undertaken with the appliance disconnected (unplugged) from the electrical supply. 4. Servicing must be preceded by Earth Continuity and Insulation Resistance checks. 5. Personal safety precautions must be taken to protect against accidents caused by sharp edges on metal and plastic parts. 6. After servicing the appliance must be rechecked for Electrical Safety. In the case of appliances which are connected to a water supply (i.e.: Washing Machines, Dishwashers and Food Centres, etc.) checks must be made for leaks from seals gaskets and pipe work and rectification carried out where necessary. 7. It can be dangerous to attempt DIY repairs / maintenance on complex equipment and the Company recommends that any problem with the appliance is referred to its own Service Organisation. 8. Whilst the Company has endeavoured to ensure the accuracy of the data within this publication they cannot hold themselves responsible for any inconvenience or loss occasioned by any error within. 9. The appliances equipped with phase motor uses a different type of power module. This power board is fitted with a large aluminium heat sink which remains live after the power is disconnected. Under no circumstances should the board be removed under the time shown below in Fig.. Alternative quick methods of discharging the board SHOULD NOT be used or attempted! GB 04--8/0-6

4 IMPORTANT NOTE Risk of Electric Shock The metal heatsink fitted on the Power Module may hold an electrical charge for a short period after switching off the machine. Allow 5 minutes after disconnecting the machine from the electrical supply before commencing ANY work. GB 04--8/0 4-6

5 MANUFACTURING DATE CODE CHART Jan Feb March April May June July Aug Sept Oct Nov Dec First digits of the serial number indicate production date This example shows that the machine was manufactured in SEPTEMBER 004: Date Code 0054 GB 04--8/0 5-6

6 SPECIFICATIONS Dimensions Height mm Width mm Depth mm Weight - 66 kg. Packed approx. 69 kg. Electrical Supply 0/40 Volts AC at 50 Hz Fuse amp Energy Energy Class: A at 7 kg Washing Performance Class: A Wash Load 7 kg Cottons Water Supply Cold Valve - Coil Resistance.8 Ω Wash Heater 800 Watts at 0 volts Resistance 0 Ω approx. Thermistor NTC Resistance: 0 Ω at 0 C Pump Pole Synchronous 0 / 40 Volt 5 Watt, Resistance = 65 Ω. Maximum Head.4 metres Door Lock P.T.C. Bimetallic - GB 04--8/0 6-6

7 4 CONTROL PANEL DISPLAY, CONTROLS AND PROGRAMMES 4. Controls Fig. PROGRAMMES KEY FUNCTION Buttons FUNCTION LEDs ON-OFF/DOOR LOCK LED PROGRESS INDICATOR LEDs START/RESET Button ON/OFF LED DETERGENT DISPENSER SPIN SPEED Knob Programme Knob TEMPERATURE Knob ON/OFF Button On-Off / Selecting a programme The machine is switched on by pressing the On/Off button for seconds. All the indicator lights will light up for a few seconds and the Door Locked indicator light will flash once. Turn the programme selector dial to the desired programme. Load the laundry and detergent. Select the options you require. Press the Start/Cancel button for seconds to start the programme. To stop or change a programme Press the Start/Cancel button for seconds. Select Pump Out on the programme selector dial. When the machine has finished emptying, turn the programme selector dial to the new programme. Press the Start/Cancel button to start the programme. If you cancel a hot wash programme, take care when removing the laundry, it might still be very hot. Progress indicator lights These will light up when you choose a programme, to indicate the progress of the selected programme. When started, the first light in the cycle will stay lit and as the programme progresses, successive lights will come on until the programme finishes. GB 04--8/0 7-6

8 Door Locked indicator light The Door Locked indicator light will come on two seconds after you press the Start/Cancel button and will stay lit throughout the programme. A short time after the programme has finished the indicator light will go out and you can then open the door. The selected programme will not start if the door is not closed properly, the Door Locked indicator light will flash to show this. Push the door shut until you hear the catch click. Button Selection: To select an option, press the button and you will see a light come on alongside the button. Press again to cancel, and the light will go out. Easy Iron Reduces wash action and spin speed, meaning less ironing for delicate clothes. This does not apply to Cotton, Wool or Handwash programmes, except Super Wash and 60 C Fast Wash. Mini Load For washing a smaller load. In addition to reducing actual washing time, this option will reduce water and energy consumption by up to 50%. Note: You can reduce the amount of detergent you use with this wash. Extra Rinse For large wash loads and items for young children or people with sensitive skin. This option adds a rinse. This is not available with Pre-Wash, Wool, Handwash, Silks, Fast Wash or Spin only programmes. Variable Spin Speed Use this control to reduce the programme spin speed only. If you leave this dial in the maximum position, the spin speed will be the maximum which is appropriate for whatever wash programme you have chosen. When the programme has finished, return the dial to the original setting. Rapid Wash Saves up to a third on the programme time. Available on programmes, 4, 7 and 8 only. Rinse Hold Clothes will be held in the final rinse water, keeping them fresh until you are ready to complete the programme. Complete the final spin by pressing the Rinse Hold button when the light is flashing. This is not available with Pre-Wash, Wool, Handwash or Spin only programmes. GB 04--8/0 8-6

9 Variable Temperature Use this control to reduce the wash temperature only. If you leave this dial in the maximum position (95), the actual wash temperature will be the maximum which is appropriate for the wash programme you have chosen. When the programme has finished return the dial to the original setting. GB 04--8/0 9-6

10 4. Automatic Features Auto half load Auto half load saves you time and money when washing smaller loads. Water levels are automatically adjusted to cater for the different loads. Unbalanced load The machine has an inbuilt feature to prevent it spinning with an unbalanced load. This will minimise excessive vibration and prolong the life of the machine. Before each spin the machine senses the load within the drum and if the machine considers the load to be unbalanced, it will not automatically spin. Instead the machine will try to redistribute the load to achieve balance by tumbling backwards and forwards. Out of Balance Protection The machine has an inbuilt feature to prevent spinning with an unbalanced load. A calculation via the motor tacho and control board detects the current drawn by the motor during distribution. These calculations are done very quickly and are unlikely to be detected by the user. Before each spin, the controls senses the load within the drum. If the load is calculated to be out of balance the machine will not automatically spin to the full speed. There are two levels of out of balance, level at 480 grams and level at 00 grams. If the out of balance is below level the machine will spin at full speed. If the out of balance is between level and level the machine will spin at the reduced speed of 800 rpm and above level, spin at a reduced speed of 400 rpm. There are 5 attempts at level, 9 attempts at level with 54 attempts in total, this being the same for both cotton and synthetic spins. The spin programme will always be completed at a spin speed depending on the balance condition. The wool spin has one level of out of balance at.8 kg. The controls will make three attempts to achieve a balance, if after three attempts a balance is not achieved, the spin is reduced to a speed of 90 rpm. GB 04--8/0 0-6

11 5 WASHCODES Type of fabric and degree of soil Programmes Wash Temperature Detergent Wash Fabric softener Cycle length (minutes) Description of washing cycle Cotton Prewash 0 0 Pre-wash only. Extremely soiled whites (sheets, tablecloths, etc.) Extremely soiled whites (sheets, tablecloths, etc.) Heavily soiled whites and fast colours Lightly soiled whites and fast colours (shirts, jumpers, etc.) Heavily soiled whites and non-fast colours Synthetics Heavily soiled fast colours (baby linen, etc.) Fast colours (all types of slightly soiled garments) Delicate Wool Very delicate fabrics (silk, viscose, etc.) Slightly soiled whites and delicate colours (shirts, jumpers, etc.) Handwash (handwash label) PARTIAL PROGRAMMES Wash cycle, rinse cycles, intermediate and final spin cycles. Wash cycle, rinse cycles, intermediate and final spin cycles. Wash cycle, rinse cycles, intermediate and final spin cycles. Wash cycle, rinse cycles, intermediate and final spin cycles. Wash cycle, rinse cycles, intermediate and final spin cycles. Wash cycle, rinse cycles, anti-crease or delicate spin cycle. Wash cycle, rinse cycles, anti-crease or delicate spin cycle. Wash cycle, rinse cycles and delicate spin cycles. Wash cycle, rinse cycles and delicate spin cycles. Wash cycle, rinse cycles, intermediate and final spin cycles. Wash cycle, rinse cycles, intermediate and final spin cycles. Rinse 0 Rinse cycles and spin cycle. Spin cycle 5 Draining and heavy duty spin cycle. Delicate spin cycle Draining and delicate spin cycle. Draining Draining GB 04--8/0-6

12 5. Dispenser Drawer Fig. GB 04--8/0-6

13 L L Merloni Elettrodomestici 6 WIRING DIAGRAM, LEGEND AND CONNECTION DETAILS Fig. Wiring Connection Chart phase Earth Lead Kimmel 0.75mm Green/Yellow - length 400mm 0.5mm Red - length 50mm J J4 J J5 J9 J8 J Door Interlock Harness Heater Heater Pressure Switch Harness -phase Mains FIlter Pump Harness Motor Harness Solenoid Valve and Heater Harness NTC (Cold Fill) Serial Link (5-way for Export Machines) L L 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Light Blue - length 80mm 0.5mm Light Blue - length 80mm 0.5mm Light Blue - length 0mm 0.5mm Light Blue - length 0mm 0.5mm White - length 0mm 0.5mm White - length 0mm 0.5mm Black - length 60mm 0.5mm Black - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.5mm Black- length 760mm 0.5mm Black - length 760mm.0mm Blue - length 950mm.0mm Brown - length 950mm.0mm Red/Green - length 900mm.0mm Red/Green - length 900mm 0.5mm Black - length 900mm 0.5mm Black - length 900mm 0.5mm Black - length 900mm 0.5mm Black - length 480mm.0mm Red/Green - length 480mm.0mm Red/Green - length 480mm.0mm Red/Green - length 480mm.0mm Brown/Green - length 560mm.0mm Blue/Green - length 50mm L L L L L C F.0mm Black - length 60mm 4 L Res N E wcc.pdf GB 04--8/0-6

14 Fig. 4 Wiring Diagram phase N L GND Vcc Test T j 5 4 SDA SCL j j7 M M M Í Í Í OVERFLOW COMMON FULL EMPTY TG R R R SEN.COND TF P A 0A 0A 8A * R R 0A 0A A A 4 5 A 0w EVL 0w EVP Lav GND RX j5 j NC j j8 j9 j5 EMI 5 0A RTN_PORTA RTN_IP j j0 j j4 5 j4 D C 5 4 SDA Vcc GND SCL VNR j5 5 4 j Connector TAB Tacho Black Pressure Switch Mains Input Filter Motor Frame 00 Kohms to Earth via Input Filter Wash Motor Thermal Protector Water Valves Wash Thermistor -phase Wash Motor Pump Cold Fabric OVERFLOW COMMON FULL EMPTY wd.pdf A A PCB with LED lights Easy Door Interlock GB 04--8/0 4-6

15 Wiring Diagram Legend phase AQS Aquastop solenoid valve N Neutral or Terminal board B Buzzer or Door lock NC No spin BF Terminal board contacts, dryer heating element and P Pressure switch BP Door lock P Pressure switch st level C Condenser P Pressure switch nd level AC Condenser PA High speed potentiometer DV Switch PB Low speed potentiometer EF/CL Cold water/bleach solenoid valve PL Pure wool EF/L Cold water/wash solenoid valve PM Motor thermoprotector EF/P Cold water/prewash solenoid valve PR Timer programmer or Pressure switch ER Cut-out heater PS Drain pump ET Cut-out thermostat R Heating element EV Solenoid valve Ras/RA Drying heater EVA Drying solenoid valve RE Relay EVC Hot water solenoid valve RR Heating element EVF Cold water solenoid valve RV Speed regulator EVL Wash solenoid valve S Indicator light EVP Prewash solenoid valve SL Line indicator light FA Noise filter SO Door indicator light FD Delicate drying thermostat SR Heating indicator light FE Intense drying thermostat ST Temperature selector or Stop with water FRT Thermofuse resistance SV Spin speed selector I Reverser T Timer contacts I..I... Switches/deviators TA Drying timer contacts IA On/Off switch TB Low temperature thermostat IC Switch NC / / load TC Crosspiece earth ID No spin switch TFL Flange earth IE Water-economizer or NC Switch TG Main earth IF Spin decrease switch TH Thermostat IP Door switch TH Thermostat st temperature IR Line switch TH Thermostat nd temperature IS Water-stop TH Thermostat rd temperature L Line or Lamp THF Work thermostat LB Low level THR Adjustable thermostat LN Normal level TM Motor earth LS Indicator light TMB Base cabinet earth M Earth symbol or Dryer motor TMP Motor thermoprotector MC Spin motor or Spin winding TMS Thermostop MI Induction motor TP Thermoprotector or Pump earth ML Wash motor or Wash winding TPS Drain pump earth MO Terminal board TR Heating element earth MP Door microswitch TS Safety thermostat or Support earth MR Microdelay device TT Timer earth MT Timer motor TTH Thermostat earth MV Fan TV Tub earth MV - Ras Dryer fan (RA) ZBN Timer Mzbn/M Mzbn/M zbn timer motor GB 04--8/0 5-6

16 L L L 4 L L Merloni Elettrodomestici Fig. 5 Wiring Connection Chart (not phase) 0.75mm Green/Yellow - length 40mm J9 J8 J J J4 J J5 Door Interlock Harness Heater Heater Pressure Switch Harness Mains FIlter Harness Pump Harness Motor Harness Solenoid Valve and Heater Harness NTC (Cold Fill) Serial Link Earth Lead (5-way for Export Machines) mm Green/Yellow - length 400mm 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Red - length 50mm 0.5mm Light Blue - length 80mm 0.5mm Light Blue - length 80mm 0.5mm Light Blue - length 0mm 0.5mm Light Blue - length 0mm 0.5mm White - length 0mm 0.5mm White - length 0mm 0.5mm Black - length 60mm 0.5mm Black - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.75mm White - length 60mm 0.5mm Black- length 760mm 0.5mm Black - length 760mm.0mm Blue - length 950mm.0mm Brown - length 950mm.0mm Red/Green - length 900mm.0mm Red/Green - length 900mm 0.5mm Black - length 900mm 0.5mm Black - length 900mm 0.5mm Black - length 900mm 0.5mm Black - length 480mm.0mm Red/Green - length 480mm.0mm Red/Green - length 480mm.0mm Red/Green - length 480mm.0mm Brown/Green - length 560mm.0mm Blue/Green - length 50mm L L L L C F L N E wcciss.pdf GB 04--8/0 6-6

17 Fig. 6 Wiring Diagram (not phase) j7 SDA SCL GND Vcc Test j 0A j M M M TACHO 5 4 M T j9 4 5 j j4 5 4 C P L 5 0w EVP 0w EVL A 9 8 Í Í Í TEST CONNECTOR Connector TAB MOTOR ARMATURE SDA Vcc GND SCL VNR j5 j7 PCB with LED lights 5 6 WATER VALVES COLD FABRIC PUMP 6 4 j5 RTN_PORTA RTN_IP j N L 6 Pressure Switch 4 MAINS INPUT FILTER WASH THERMISTOR 4 R R R TF A OVERFLOW 0A 0A 8A Lav. * OVERFLOW COMMON COMMON FULL FULL EMPTY EMPTY R R 0A 0A A A j5 j NC j j8 GND RX j j4 C D wdmono.pdf A A Easy Door Interlock GB 04--8/0 7-6

18 Wiring Diagram Legend (not phase) AQS Aquastop solenoid valve N Neutral or Terminal board B Buzzer or Door lock NC No spin BF Terminal board contacts, dryer heating element and P Pressure switch BP Door lock P Pressure switch st level C Condenser P Pressure switch nd level AC Condenser PA High speed potentiometer DV Switch PB Low speed potentiometer EF/CL Cold water/bleach solenoid valve PL Pure wool EF/L Cold water/wash solenoid valve PM Motor thermoprotector EF/P Cold water/prewash solenoid valve PR Timer programmer or Pressure switch ER Cut-out heater PS Drain pump ET Cut-out thermostat R Heating element EV Solenoid valve Ras/RA Drying heater EVA Drying solenoid valve RE Relay EVC Hot water solenoid valve RR Heating element EVF Cold water solenoid valve RV Speed regulator EVL Wash solenoid valve S Indicator light EVP Prewash solenoid valve SL Line indicator light FA Noise filter SO Door indicator light FD Delicate drying thermostat SR Heating indicator light FE Intense drying thermostat ST Temperature selector or Stop with water FRT Thermofuse resistance SV Spin speed selector I Reverser T Timer contacts I..I... Switches/deviators TA Drying timer contacts IA On/Off switch TB Low temperature thermostat IC Switch NC / / load TC Crosspiece earth ID No spin switch TFL Flange earth IE Water-economizer or NC Switch TG Main earth IF Spin decrease switch TH Thermostat IP Door switch TH Thermostat st temperature IR Line switch TH Thermostat nd temperature IS Water-stop TH Thermostat rd temperature L Line or Lamp THF Work thermostat LB Low level THR Adjustable thermostat LN Normal level TM Motor earth LS Indicator light TMB Base cabinet earth M Earth symbol or Dryer motor TMP Motor thermoprotector MC Spin motor or Spin winding TMS Thermostop MI Induction motor TP Thermoprotector or Pump earth ML Wash motor or Wash winding TPS Drain pump earth MO Terminal board TR Heating element earth MP Door microswitch TS Safety thermostat or Support earth MR Microdelay device TT Timer earth MT Timer motor TTH Thermostat earth MV Fan TV Tub earth MV - Ras Dryer fan (RA) ZBN Timer Mzbn/M Mzbn/M zbn timer motor GB 04--8/0 8-6

19 7 AUTO TEST SETUP An error test programme can be carried out using Hardware SAT code C which is inserted into the socket at the rear of appliance and connects to the Power Module. 7. Test setup and Indications. Ensure the machine is switched off and remove the serial port cap.. Insert Hardware Key into socket at the rear of the machine with the plastic pin protection tab fully extended. If it has been removed it should be refitted before use. Refit Tab with latch uppermost. See Fig. 8. Switch the machine on and verify model type by observing the LED colour displayed on the key as indicated below: Flashing Red = Indicating good connection of Hardware Key to the module. If this isn't displayed it will not work. Constant Green = EVO models. Constant Blue = EVO model.. The selector can be in any position. 4. Press the AUTO TEST button on the Hardware Key. Auto Test will scroll across the key LCD display and a beep is heard from the key. If the Programme Selector is motorised it will advance to another position after a 0 second pause (this is normal). 5. The Test Programme will now commence. 6. If there is a fault on the machine it will be indicated by a fault code in the Hardware Key LCD display. Refer to Fault Codes section. Fig. 7 Hardware Key shown fitted Fig. Fig. 8 Pin protection Tab shown fully extended 7. The fault must be cleared before the appliance or self test will run again correctly. (See Notes below) TAB LATCH GB 04--8/0 9-6

20 7. Test sequence a) Fills through main wash valve - approx. 0 seconds. b) Fills through pre - wash valve - approx. 0 seconds. c) Fills through hot valve (if fitted) - approx. 0 seconds. d) Fills through main wash and pre - wash valves together (fabric conditioner function) to pressure switch level. e) Tumbles and heats to 0 C f) Drain and spin. g) Machine now resets and a beep is heard from the Hardware Key. h) Switch off machine and remove the Hardware Key. Fig. 9 AUTO TEST BUTTON i) Replace the serial port cap and secure with screw if fitted. LCD DISPLAY Notes: Error codes and possible causes can be found in this Service Manual on the following page. On EVO LCD models the fault code will be shown on the display. When first starting a test, a fault code could immediately appear since the Hardware Key will detect the last fault the machine had in the past. In this situation it will be necessary to proceed as follows: Switch off and unplug from the power supply for 0 seconds and re-start test. Faults Without Error Codes If the motor is open circuit the machine will not fill or operate. GB 04--8/0 0-6

21 8 ERROR CODES AND POSSIBLE CAUSES Fig. 0 4 Function LEDs Door Lock LED Phase advance LED 4 GB 04--8/0-6

22 When an error occurs, the Door Lock LED flashes rapidly and one or more of the Option LEDs will flash once per second. Refer to the chart below for error code definitions. LCD Display Code Function LEDs LED LED LED LED 4 Phase advance LED 4 F0 OFF OFF OFF Flash OFF F0 OFF OFF Flash OFF OFF F0 OFF OFF Flash Flash OFF F04 OFF Flash OFF OFF OFF Possible Causes and Actions Motor triac short circuit: check motor and module connections. Motor jammed / tacho detached: check motor and module connections. NTC short/open circuit: check thermistor and module connections. Pressure switch jammed on empty: check switch and module. F05 OFF Flash OFF Flash OFF Pressure switch jammed on full or pump blocked: check pump and switch. F06 OFF Flash Flash OFF OFF N/A F07 OFF Flash Flash Flash OFF Heater relay stuck: check heater and module connections. F08 Flash OFF OFF OFF OFF Heater relay stuck: check pressure switch, heater and module connections. F09 Flash OFF OFF Flash OFF Setup error: check eeprom. F0 Flash OFF Flash OFF OFF F Flash OFF Flash Flash OFF Pressure switch not sensing: check switch and module connections. Pump cannot be activated: check pump, connections and wiring. F Flash Flash OFF OFF OFF No communication between cards: check module connections. F Flash Flash OFF Flash OFF N/A F4 Flash Flash Flash OFF OFF N/A F5 Flash Flash Flash Flash OFF N/A F6 OFF OFF OFF OFF Flash N/A F7 OFF OFF OFF Flash Flash F8 OFF OFF OFF OFF Flash Door lock error: check door, door lock and module connections. Communications error ( phase motor); replace power board. Note: LCD display codes shown above are found on the Auto Hardware Key Display - not on the machine. GB 04--8/0-6

23 9 THREE PHASE MOTOR These washing machines are equipped with three-phase motor. Compared with the commutator motor there are no brushes and the stator is delta connected internally (see diagram). The three-phase motor has a thermoprotector that cuts in turning off the supply to the power part of the electronic card and therefore to the motor. The photo and diagram below give the connection diagram of the windings. Red Grey White Blue Red Blue Protector Tacho Red Motor Connector Tacho Tacho Winding Winding Winding Thermoprotector Thermoprotector GB 04--8/0-6

24 0 DISMANTLING INSTRUCTIONS SAFETY NOTES. Ensure that the appliance is disconnected from the electrical supply before dismantling.. Beware of sharp edges on metal panels, plastic mouldings, and pressed parts. A. Table Top. Remove the two screws at the top rear of cabinet.. Slide the table top backwards to disengage the location fixings at the rear and lift off. B. Lower Rear Access Panel. Remove three screws from the lower rear access panel.. Pull the top edge of the panel out and disengage it from its location fixings along the bottom. C. Dispenser Drawer. Open the dispenser drawer fully.. Press release latch in centre of drawer and pull drawer body and pull drawer away from control panel. D. Control panel. Remove the table top (A) and dispenser drawer (C).. Remove two top screws securing control panel to cabinet and two screws securing control panel to dispenser.. Unplug wiring from control panel PCB - taking note of position. 4. Slide dispenser back. 5. Unclip two plastic lugs securing control panel to front panel and lift clear. 6. Avoid unclipping and handling the control board unless absolutely necessary, as the control board is susceptible to static electricity. GB 04--8/0 4-6

25 E. Control panel PCB and Button Assemblies. Remove the control panel (D).. Remove wiring plug - taking note of position.. Remove three securing clips and lift away from the control panel. F(a) Pressure Switch. Remove the table top (A).. Disconnect the wiring connection block and pressure hose.. Carefully unclip bracket from cabinet side and then unclip switch from bracket. F(b) Front Panel. Remove the table top (A), dispenser drawer (C) and control panel.. Remove the door seal restraint (G) and door interlock (H).. Grip the appliance kickstrip at both ends and pull it off in a forward direction. 4. Remove 4 front panel fixing screws ( bottom, top). 5. Slide the dispenser housing backwards so that it clears the control panel backplate opening. 6. Lift the front panel upwards to disengage the four cabinet fixing pegs and lift off. GB 04--8/0 5-6

26 G. Door Seal and Restraint:. Door Seal to Front Panel Fixing The door seal is fixed to the cabinet front panel by a wire clamp and a small spring. The spring is normally at the bottom of the door. Carefully place a small screwdriver into one of the lugs of the spring and by stretching the spring the wire band can be removed.. Drum Fixing The door seal is fixed to the drum with a rack type retainer. After removing the front panel (Fb) remove the rack as shown in Fig. below. On refitting place the strap around the door seal and tighten as shown in Fig.. Observe correct seal and rack fixing positions as shown in Fig. and Fig. 4. Fig. Fig. Seal to Drum fixing position Fig. Fig. 4 Correct Rack and Seal position at Drum Front Plastic Support (observe position) Rack GB 04--8/0 6-6

27 H. Door Interlock. Remove the door seal restraint (G).. Peel the door seal off the front panel, and fold it back into the inner drum.. Remove two screws from the interlock. 4. The interlock can now be eased out, allowing access to the wiring connection block. 5. Care must be taken to ensure the correct orientation of the wiring connection plug to prevent seriously damaging the interlock and / or control board. I. Door Assembly. Open the door through 80 and remove four screws securing the hinges to the front panel. Ease the hinges from the panel.. The door trims can now be split. Lay the door assembly face down on a suitably protected surface and remove 6 screws securing the two halves of the door.. Unclip the two halves at the hinge end and separate a sufficient distance to slide out the door glass. 4. When removing the hinges, note the orientation. To remove, fold hinges inward, slide towards each other to release other end. See photo. Reassemble in reverse order. Top Hinge removal (shown below) - Slide towards lower hinge, twist to the left and slide up to release. Lower Hinge removal - Slide upwards, twist to the right and slide down to release. 5. To fully separate the halves, slide the front away from the handle. 6. To remove the handle or latch, slide securing pin out noting the position of the spring and latch. GB 04--8/0 7-6

28 J. Front Panel. Remove the table top (A), dispenser drawer (C) and control panel (D).. Remove the door seal restraint (G) and door interlock (H).. Grip the appliance kickstrip at both ends tilt forwards, and pull it off in a forward direction. 4. Remove 4 front panel fixing screws ( bottom and top). 5. Slide the dispenser housing backwards so that it clears the control panel backplate opening. 6. Lift the front panel upwards to disengage the four cabinet fixing pegs, and lift off. K. Door Seal. Remove the table top (A), dispenser drawer (C) and control panel (D).. Remove the door seal restraint (G), door Interlock (H) and front panel (Fb).. Remove the drum door seal restraint (G) and lift clear. L. Drive Belt. Remove the table top (A).. Remove the lower rear access panel (B).. Carefully peel the belt off the motor pulley taking care not to trap fingers and using suitable protection against sharp edges. 4. To refit the belt, place it round the motor pulley first, tie-wrap the belt onto the drum pulley, and rotate the drum from the door aperture to move the belt into position. 5. Ensure any remaining tie-wraps are removed. It is essential for continued safety that only a genuine spare is fitted. The belt is electrically conductive and provides an electrical earth to prevent static built up on the inner drum assembly. GB 04--8/0 8-6

29 M. Motor. Remove the lower rear access panel (B) and drive belt (L).. Disconnect the motor wiring connection plug and earth wire.. Using a mm socket or ratchet ring spanner, remove both motor mount fixing screws. 4. Ease the motor off the drum mountings. 5. Prior to refitting the motor, ensure that the drip shield and mounting-bush are not worn or damaged. N(a) Lower Balance Weight. Remove the table top (A), dispenser drawer (C) and control panel (D).. Remove the door seal restraint (G), door Interlock (H) and front panel (Fb).. Using a mm socket or spanner, remove three balance weight fixing screws. 4. Pull the weight forward off its mounting lugs. 5. When refitting the balance weight it is essential to ensure that the thread forming screws are tightened to 4 Nm (using a suitable torque-wrench) and that the screws find their original threads, otherwise the thread can be stripped from the plastic drum lug. N(b)Top Balance Weight. Remove the table top (A).. Using a mm socket or spanner, remove three balance weight fixings screws.. Lift the weight off the drum mountings. 4. When refitting the balance weight it is essential to ensure that the thread forming screws are tightened to 8 Nm (using a suitable torque-wrench) and that the screws find their original threads, otherwise the thread can be stripped from the plastic drum lug. O. Heater / Thermistor. Remove the rear lower access panel (B).. Remove the heater wiring and detach the thermistor plug.. Slacken off the 0 mm heater fixing nut and withdraw the heater from the drum. GB 04--8/0 9-6

30 P. Drum Pulley. Remove the rear lower access panel (B).. Carefully peel the belt off the motor pulley taking care not to trap fingers.. Using a mm socket or spanner, remove the fixing bolt in the centre of the pulley. 4. Pull the pulley off the drum shaft. 5. To ensure adequate pulley security always fit the correct pulley bolt (high tensile with dog-point). If refitting the original bolt apply an engineering Nutlock (Part No ) to the bolt threads. Q(a) Suspension Damper. Remove two suspension clamp fixing screws and unclip the clamp from the chassis.. Remove the table top (A), dispenser drawer (C) and control panel (D).. Remove the door seal restraint (G), door interlock (H) and front panel (Fb). 4. Remove the lower balance weight (Na) if access is required to the left-hand damper. 5. Unclip any wiring retained within the integral clip on the bottom damper moulding. 6. Remove the plastic peg securing the damper to the outer drum using special tool Part No Withdraw the suspension damper. The unit should not be split and is not serviceable. 8. When reassembling, fit a new plastic peg if the locking-tab on it shows signs of damage. Q(b) Suspension Spring. Remove the table top (A).. Unclip any wiring retained within the integral clip on the spring bearing keeper plate.. Gently lever out the bearing keeper plate with a small flat bladed screwdriver. 4. Unhook the spring from the cabinet top rail bearing. GB 04--8/0 0-6

31 R. Dispenser. Remove the table top (A) and dispenser drawer (C).. Remove two screws around the dispenser recess and two screws from valve support panel.. Ease the dispenser backwards to unclip it from the cabinet top rail. 4. Remove the dispenser outlet hose, and any harness retention ties. S. Drain Pump. Remove the lower rear access panel (B).. Detach the sump hose from the pump using a suitable container to catch any water.. Disconnect the drain hose from the pump and unplug the wiring connection block. 4. Lift plastic the locking tab and slide the pump inwards and lift clear. T. Inner Drum Lifter rd hole from the front. Insert a small screwdriver onto the rd lifter hole from the front of the drum. This will depress the drum flap securing the lifter.. Slide the lifter to the front of the drum and remove.. Before refitting, lift the drum locking tab mm above the drum surface. 4. Offer the lifter to the holes in the drum, slide lifter to the back of the drum until a click is heard as the lifter is locked into place. GB 04--8/0-6

32 U(a) Drum Assembly. Remove the table top (A).. Remove the top balance weight (Nb).. Remove the dispenser drawer (C). 4. Remove the control panel (D). 5. Remove the dispenser (S). 6. Remove the front panel (Fb). 7. Remove the lower balance weight (Na). 8. Remove the lower rear access panel (B). 9. Remove the motor (M). 0. Detach the drum from the damper units by removing the two plastic pegs using special tool Part No Remove the sump hose fixing clip and detach the sump hose from the sump chamber.. Disconnect heater / thermistor wiring and release the wiring harness from the drum clips.. Unclip any wiring retained within the integral clip on the spring bearing keeper plates. 4. Gently lever out the spring bearing keeper plates with a small flat bladed screwdriver. 5. Unhook springs from the cabinet top rail bearings. 6. Carefully lift the drum assembly out of the cabinet. GB 04--8/0-6

33 U(b) Inner Drum and Support Assembly / Drum Seal / Outer Drum Halves. Remove the drum assembly (Va).. Remove the drum pulley (Q).. Loosen the inner drum assembly by tapping the drum shaft with a soft copper hammer or by inserting a pin punch into the shaft hole and tapping with a copper hammer. 4. Remove sixteen T0 Torx head drum fixing screws and detach the drum front. 5. Lift out the inner drum and support assembly. 6. The inner drum and support are not designed to be separated, and must be replaced as an assembly if required. 7. Always fit a replacement drum seal if the drum has been split and ensure that the seal joint is at the top. When reassembling the drum halves it is essential to ensure that the thread forming screws find their original threads, otherwise the thread can be stripped from the plastic drum lugs. Retighten the drum joint fixing screws to 8 Nm (using a suitable torque-wrench). V. Cabinet. Remove the table top (A).. Remove the dispenser drawer (C) and control panel (D).. Remove the front panel (Fb). 4. Remove the lower balance weight (Na). 5. Remove the lower rear access panel (B). 6. Remove the motor (M). 7. Remove the top balance weight (Nb). 8. Remove the drum assembly (Va). 9. Remove the drain pump (T). 0. Unscrew feet, remove the wheels, and remove hose clips from the rear of the cabinet. GB 04--8/0-6

34 X. Power Module! IMPORTANT NOTE Appliances equipped with a phase motor use a different type of power module. This power board is fitted with a large aluminium heat sink which remains live after the power is disconnected. Under no circumstances should the board be removed under the time shown below in Fig. Alternative quick methods of discharging the board SHOULD NOT be used or attempted.. Remove back panel (B). Ensure the module has electrically discharged for 5 minutes before moving to Step. Refer to Important note above.. Remove screw or screws securing module support to the cabinet.. Disconnect the wiring - it may be necessary to remove one of the plugs to extract the module from its location. IMPORTANT NOTE - AVOIDING ELECTRICAL DAMAGE TO THE MODULE. Before disconnecting any plugs it is advisable to note their locations. When reconnecting the plugs to the module it is essential that the large WHITE multiway edge connector plug is fitted with the wires from the plug oriented as shown below. Applying power to the machine with the plug fitted in the wrong position WILL CAUSE PERMANENT DAMAGE to the module. White Multiway Connector Plug Ensure correct orientation when refitting Wires must exit the plug as shown here GB 04--8/0 4-6

35 4. Lift module clear. 5. When replacing the board an EEProm will also be required. Service modules are not normally supplied with a programmed EEProm. Note: To remove and fit the EEProm use Insulated Tweezers Part No. COOO669 as shown below. On the original control board, the EEProm may be soldered to the board and cannot be removed. Fig. 5 IC Removal Tool Fig. 6 EEPROM Removal from PCB GB 04--8/0 5-6

36 Merloni Elettrodomestici S.p.A. viale Aristide Merloni, Fabriano - Italy tel. 07/66 - telex fax 07/ GB 04--8/0 6-6