Daewoo DWF-204AY Service Manual

Service Manual

Auto Washer

Model: DWF-204AY

S/M No. :

Feb. 2013

✔ Caution

: In this Manual, some parts can be changed for improving,

their performance without notice in the parts list. So, if you need the latest parts information, please refer to PPL(Parts Price List) in Service Information Center (http://svc.dwe.co.kr).

DWF204AY01

AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER AUTO WASHER

WASHING MACHINE

Contents

1. SPECIFICATIONS ....................................................................................................................................2

2. STRUCTURE OF THE WASHING MACHINE .......................................................................................3

3. DIRECTIONS FOR INSTALLATION AND USE ....................................................................................4

INSTALLATION OF THE COVER UNDER ...................................................................................4

HOW TO INSTALL ON AN INCLINED PLACE .............................................................................4

HOW TO CONNECT THE INLET HOSE .......................................................................................5

HOW TO CLEAN THE FILTER ......................................................................................................6

4. FEATURE AND TECHNICAL EXPLANATION .....................................................................................7

FEATURE OF THE WASHING MACHINE ....................................................................................7

WATER CURRENT TO ADJUST THE UNBALANCED LOAD ...................................................7

AUTOMATIC WATER SUPPLY SYSTEM FOR BLANKET WASH ............................................7

FUNCTIONAL PRINCIPLE OF BUBBLE WASHING MACHINE .................................................8

AUTOMATIC DRAINING TIME ADJUSTMENT ............................................................................8

AUTOMATIC UNBALANCE ADJUSTMENT .................................................................................9

CIRCULATING-WATER COURSE AND LINT FILTER ................................................................9

LINT FILTER ..................................................................................................................................10

RESIDUAL TIME DISPLAY ..........................................................................................................10

DRAIN MOTOR .............................................................................................................................10

GEAR MECHANISM ASS’Y .........................................................................................................11

5. DIRECTIONS FOR DISASSEMBLY AND ADJUSTMENT ................................................................12

GEAR MECHANISM ASS’Y REPLACEMENT ...........................................................................12

MOTOR SYNCHRONOUS AND VALVE REPLACEMENT .......................................................14

6. THE REPAIR METHOD OF GEAR MECHANISM FOR CLUTCH SPRING PROBLEM ................15

THE STRUCTURE OF GEAR MECHANISM ..............................................................................15

HOW TO CHECK THE CLUTCH SPRING .................................................................................16

THE PROCESS OF DISASSEMBLING .......................................................................................17

THE PROCESS OF ASSEMBLING .............................................................................................19

7. TROUBLE SHOOTING GUIDE .............................................................................................................22

CONCERNING WATER SUPPLY ...............................................................................................22

CONCERNING WASHING ...........................................................................................................23

CONCERNING DRAINING ...........................................................................................................24

CONCERNING SPINNING ...........................................................................................................25

CONCERNING OPERATING .......................................................................................................26

8. PRESENTATION OF THE P.C.B ASS’Y .............................................................................................27

CONCERNING ERROR MESSAGE ..........................................................................................27

APPENDIX

WIRING DIAGRAM .......................................................................................................................28

PARTS DIAGRAM .........................................................................................................................29

PARTS LIST ...................................................................................................................................33

SPECIFICATIONS

1 POWER SOURCE AL AC VOLTAGE AND CYCLE

2 POWER CONSUMPTION 550W

3 MACHINE WEIGHT 45Kg

4 DIMENSION (WXHXD) 630 X 1,055 X 670

5 WASHING COURSE

6 WATER CONSUMPTION 232 L

7 WATER LEVEL SELECTOR

OPERATING WATER PRESSURE

0.3kgf/cm2~8kgf/cm2(2.94 N/cm2~78.4N/cm2)

9 REVOLUTION PER MINUTE WASH 140~150 RPM, SPIN 675~710RPM

10 PULSATOR

11 WATER LEVEL CONTROL ELECTRONICAL SENSOR

12 GEAR MECHANISM ASS’Y HELICAL GEAR

13 MAGIC FILTER O

14 SOFTENER INLET O

15 FUNCTION FOR SOAK WASH O

16 ALARM SIGNAL O

17 RESIDUAL TIME DISPLAY O

18 AUTO. WATER SUPPLY O

FUNCTION FOR BUBBLE AND RADICAL

20 AUTO RE-FEED WATER O

21 AUTO POWER OFF O

no. item DWF-204AY

1. SPECIFICATIONS

In case of moving Washing Machine, please follow the following picture.

NOTES

FULL AUTOMATIC 8 COURSES

(SMART CLEAN(FUZZY), JEANS, ECONOMIC, EXTRA DIRTY,

HEAVY LOAD, TUB WASH(CLEANING), COLOR, WOOL)

HIGH

MEDIUM

LOW

E.LOW

88 L

73 L

58 L

45 L

6 WINGS (ø 406mm) TBM(ø 406mm)

COVER UNDER (OPTION) WATER TAP ADAPTER INLET HOSE

HOSE DRAIN (FOR PUMP) HOSE DRAIN CLAMP HOSE DRAIN (FOR NON-PUMP)

2. STRUCTURE OF THE WASHING MACHINE

STRUCTURE

ACCESSORIES (FULL OPTION)

The parts and features of your washer are illustrated on this page. Become familiar with all parts and features before using your washer.

NOTE

• The drawings in this book may vary from your washer model. They are designed to show the different features of all models covered by this book, Your model may not include all features.

• COLD WATER TAP

After using the washing machine, close the water tap.

• HOT WATER TAP

After using the washing machine, close the water tap. In case of the single valve model, there is no hot water valve.

• CONTROL PANEL

• POWER CORD

•

GROUND WIRE(OPTION)

In case of 3-wire power cord ground wire will not be provided.

• HOSE DRAIN

• ADJUSTABLE LEG

• CASE DETERGENT AND SOFTENER

3. DIRECTIONS FOR INSTALLATION AND USE

DIRECTIONS

The openings must not be obstructed by carpeting when the washing machine is installed on a carpeted floor.

⏿⏿

Installation Of the COVER UNDER (Noise Insulation Plate)

⏿⏿

How To Install On An Inclined Place

ᵄ The place where it would be exposed to

direct sunlight.

ᵄ The place nearby a heater or heat

appliance.

ᵄ The place where it would be supposed

to be frozen in winter.

ᵄ The kitchen with coal gas and a damp

place like a bathroom.

NOTES

Install the washer on a horizontal solid floor. If the washer is installed on an unsuitable floor, it could make considerable noise and vibration.

INSTALLING PLACE

Never install in these places

Push the COVER UNDER to the end. This reduces the noise from washing machine.

In the packing box or the tub of the washer, there is the COVER UNDER. Put the COVER UNDER at the bottom of the back.

Check the Horizon Status

Check the position of tub above the center of the washer.

Horizon Setting

After controlling the height by turning the adjustable leg, let the washer put down to the ground.

Keep the machine body more than 25cm apart from the wall surface. It will make easy cleaning the drain filter which is equipped at the back side of it. And if it comes into contract vibration may occur.

* The drawing of the COVER UNDER is variant from your model

25cm

10Cm

CONNECTION

FOR ORDINARY TAP

Connect the inlet hose adapter to the water inlet of the washer by turning it clockwise to be fixed tightly.

• Please check the rubber packing inside the inlet hose adapter.

Pull down the collar of the inlet hose to separate it from the water tap adapter.

Loosen the four screws at the water tap adapter, but don’t loosen the screws until they are separated from the water tap adapter.

Remove the tape, and screw connector B into connector A tightly.

Connect the inlet hose to the water tap adapter by pulling down the collar of the hose end.

Connect the water tap adapter to the water tap and tighten the four screws evenly with pushing up the adapter so that the rubber packing can stick to the water tap tightly.

⏿⏿

How to Connect the Inlet Hose

Be careful not to mistake in supplying between the hot(maximum : 50˚C) and cold water. In using only one water tap or in case of attached one water inlet valve, connect the inlet hose to the cold water inlet valve. Do not over tighten : this could cause damage to couplings.

FOR SCREW-SHAPED TAP

Insert the inlet hose adapter into the water inlet of a washer and turn it to be fixed.

• Check the packing in the inlet

Connect the inlet hose to the water tap by screwing the connector D tightly.

Connect the connector-inlet supplied if necessary.

Inlet Hose

Connector D

Rubber Packing

Connector C

Connector

Inlet



Rubber

Packing

Connector D

Connector C

Hose

TAPE

Connector B

Connector A

CONVENIENCE

⏿

HOW TO CLEAN THE FILTER

Remove the dirt from the inlet filter with a brush.

Pull the power plug out before cleaning it.

Turn off the water supply to the washer and sperate the inlet hose.

Pull the inlet filter out.

CLEANING THE LINT FILTER

CLEANING THE WATER INLET FILTER

• Clean the filter when water leaks from, the water inlet.

CLEANING THE DRAIN FILTER

• In case “U” shape drain hose, this filter’s equipped at the back side of washer.

• This drain filter is to screen the foreign stuffs such as threads, coins, pins, buttons etc ...

• If the drain filter is not cleaned at proper time (every 10 times of use), Drain problem could be caused.

Put down the remained water in the hose. And put a container under the filter to collect water.

Turn the cap counter clockwise.

Pull out the filter assembly off the case of the main body.

Turn the cap clockwise tightly.

Clean the drain filter removing the foreign stuffs.

Put in the filter along the guiding prominence of the case. Please note the left position of the filter adjusting the groove to the guide rib.

FILTER

CAP

SLIT

CASE

CONTAINER

FILTER

CAP

CASE

SUIT

GUIDE RIB

While pressing the handle of filter, remove the filter from the guide.

Remove the dirt inside the filter and clean the filter.

Insert the filter into guide.

FEATURE

4. FEATURE AND TECHNICAL EXPLANATION

WASH DRAIN SPIN FILL RINSE 1 DRAIN SPIN FILL RINSE 2 DRAIN •••

MOTOR C.W

SIGNAL C.C.W

TIME(SEC.) 0.3 0.3 0.3 0.3 0.3 0.3 •••••••

60 SEC.(About 50 Times)WASH

RINCE 30 SEC.(About 25 Times)

Feature of the Washing Machine

1 First applying the Radical Technology in the world ... go beyond washing, sterilize your clothes and deodorize a

bad smell. 2 The first air bubble washing system in the world. 3 Quiet washing through the innovational low-noise design. 4 Improving washing performance by more than 35%, while reducing power consumption by 40%. 5 The laundry detergent dissolves well in water because of the air bubble washing system. 6 The adoption of the water currents to adjust the unbalanced load. 7 One-touch operation system.

Water Current to Adjust the Unbalanced Load

It is a function to prevent eccentricity of the clothes after wash by rotating pulsator C.W and C.C.W for 60 seconds.(But, the SUIT course have no operation of the water currents to adjust the unbalanced load.)

EFFECT

It reduces vibration and noise effectively while spinning.

WATER FLOW

Automatic Water Supply System for Blanket Wash

The water level would be lowered because the blanket absorbs water at the beginning of washing. Therefore, after 2 minutes, the operation is interrupted to check the water level, and then the water is supplied again until the selected water level is reached.

FEATURE

FUNCTIONAL PRINCIPLE

1 The micom can remember the time from the begining of drain to reset point when the pressure switch reaches to

“OFF” point

2 In case of continuous draining, residual drain time is determined by micom.

Draining time as a whole = D + 90

Residual drain time. The time remembered by micom.

FUNCTIONAL PRINCIPLE

Bubble Motor supplies the air from the bottom of outer tub to the inner space of pulsator, the air is dispersed by the rotation of pulsator. Air-bubble is created by the centrifugal force, and rises up.

Draining

Good draining The washer begins spin process after drainage.

condition

Bad draining Draininig time is prolonged.

No draining Program is stopped and gives the alarm.

Drain Time Movement of the Program

Less than

Continue draining

15 minutes

More than

Program stops and gives the alarm with blinked on display lamp.

15 minutes

Functional Principle of Bubble Washing Machine

ACROSS SECTION

Automatic Drainning time Adjustment

This system adjusts the draining time automatically according to the draining condition.

Air bubble

Tub

Outer tub

Pulsator

FEATURE

Contact of safety switch

Contact lever A

Normal (ON)

Position of unbalanced load (OFF)

Automatic Unbalance Adjustment

Circulating-Water Course and Lint Filter

The alarm finished when you close the lid after opening it. Check the unbalance of the wash load and the installation condition.

NOTES

Filter

Tub

Outer tub

Water channel

Pulsator

This system is to prevent abnormal vibration during intermittent spin and spin process.

CIRCULATING-WATER

The washing and rinsing effects have been improved by adopting the water system in which water in the tub is circulated in a designed pattern. When the pulsator rotates during the washing or rinsing process, the water below the pulsator fans creates a water currents as shown in figure. The water is then discharged from the upper part of the tub through the water channel. About 40 L/min. water is circulated at the ‘high’ water level, standard wash load and standard water currents.

FUNCTIONAL PRINCIPLE

1. When the lid is closed, the micro switch contact is "ON' position.

2. In case that wash loads get uneven during

spin, the outer tub hits the safety switch due to the serious vibration, and the spin process is interrupted.

3. In case that P.C.B. ASS’Y gets “OFF” signal

from the safety switch, spin process is stopped and rinse process is started automatically.

4. If the safety switch is operated due to the

unbalance of the tub, the program is stopped and the alarm is given.

Contact of micro switch

Lid closing

('ON' position)

Lid closing

('OFF' position)

FEATURE

When the START/HOLD button is pressed, the residual time (min.) is displayed on the time indicator, and it will be counted down according to process. When operation is finished, the TIME INDICATOR will light up .

1 When the DRAIN MOTOR connected to the power source, the DRAIN MOTOR rotates with 900 r.p.m and revolves

the pulley by gear assembly for reducing. 2 When the pulley is rotated, the pulley winds the wire to open the drain valve. 3 Therefore, rotation of pulley changed to the linear moving of wire. 4 The wire pulls the brake lever of Gear Mechanism Ass’y within 5 seconds. 5 After the wire pulled, gear assembly is separated from motor and condition of pulling is held by operation of the

lever. 6 When the power is turned off, the drain valve is closed because the wire returns to original position.

STRUCTURE

Much lint may be obtained according to the kind of clothes to be washed and some of the lint may also stick to the clothes. To minimize this possibility a lint filter is provided on the upper part of the tub to filter the wash water as it is discharged from the water channel. It is good to use the lint filter during washing.

HOW TO REPLACE LINT FILTER

1 Pull the filter frame upward. 2 Turn the lint filter inside out, and wash the lint off with water. 3 Return the filter as it was, and fix the filter frame to the slot.

Pull Loosen

Pulley

Lever

Inductive ring Magnet

Coil of motor Magnet of motor

Lint Filter

Residual Time Display

Drain Motor

Filter

FEATURE

The proper water currents is made by the rotation of pulsator at a low speed to prevent the damage to the small sized clothes.

Planetary gear

Sun gear

Internal gear

Pulsator

1 revolution

5 revolutions

Gear pulley

V-belt

Gear unit as

Motor

Motor 1800 r.p.m (60Hz) 1500 r.p.m (50Hz)

Gear Unit as

Directly

V-Belt

Tub

710-740r.p.m(60Hz) 640-675r.p.m(50Hz)

Pulsator

125-140r.p.m(60Hz) 130-150r.p.m(50Hz)

Spinner Pulley

710-740r.p.m(60Hz) 640-675r.p.m(50Hz)

Gear Mechanism Ass’y

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